SAT-T Parallel Triple Screw Extruder
The SAT-T series is a co-rotating parallel triple screw extruder for high-filler compounding, dispersion-sensitive masterbatches and demanding devolatilization. Compared with a standard twin screw extruder it is better suited where volumetric feeding becomes a bottleneck, powder loading is high or the processing window is narrow.
- CaCO₃ loading on delivered high-filler lines
- 84–85%
- Output, SAT-T35 to SAT-T95
- 50–3,600kg/h
- Main motor, five sizes
- 30–400kW
Twin or triple screw
For conventional compounding tasks, twin screw extruders usually remain the more economical choice. The third screw pays off in specific cases.
Twin screw
The standard for compounding. Usually the more economical choice.
- Sizes
- SAT, U+, EC, TDY, Lab
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Triple screw
When feeding volume limits the output: light powders, very high filler loading.
- Sizes
- SAT-T35 to SAT-T95
Tandem: twin + single
Mixing in the twin screw, cooling and pressure build-up in a slow single screw.
- Sizes
- SAT52-TDD150 to SAT95-TDD240
Single screw
Melt extrusion with venting, force-fed lumps, or the second stage of a tandem.
- Sizes
- TDD20 to TDD500
Stay with a twin screw
Conventional compounding, medium filler levels
For most conventional compounding tasks and medium filler levels, a twin screw line remains the more economical and sufficient solution.
Twin screw extrudersChoose the SAT-T
When output is limited by feeding volume
Low-bulk-density material feeding, ultra-high filler loading, tighter dispersion requirements or heavier devolatilization loads.
Technical advantages
High-filler and low-bulk-density materials
Stronger volumetric intake than a standard twin screw extruder of the same size class, for stable feeding of lightweight, low-bulk-density powders. Calcium carbonate formulations run at 84–85% filler loading.
Improved dispersion efficiency
The third screw introduces additional meshing and mixing opportunities. The target dispersion level is reached within a relatively compact process length, with better control over the thermal history of heat-sensitive materials.
Devolatilization and stable continuous operation
More frequent material surface renewal and melt exposure for intensified devolatilization. In high-filler systems the feed zone is more stable and feeding fluctuations interrupt production less.
Triple screw gearbox
3D drawing of the gearbox with its three output shafts.
Three parallel screws
The three co-rotating screws of the SAT-T.
Applications and reference lines
| Line | Material | Model | Pelletizing | Output |
|---|---|---|---|---|
| High-filler compounding | PE / PP + 84% CaCO₃ | SAT-T75 | Water ring | 1,800–2,200 kg/h |
| High-filler masterbatch, Middle East | PE / PP + 82% CaCO₃ | SAT-T75L/D 52 · 250 kW · 600 rpm | Water ring | — |
| Filler masterbatch and bioplastic | PE / PP + CaCO₃ + additives | SAT-T75 | Air cooling strand | 1,500 kg/h |
| Premium colour masterbatch | PP + high-concentration TiO₂ | SAT-T52 | Water cooling strand | 250–350 kg/h |
Data from delivered USEON projects or representative process references. Final equipment selection depends on formulation rheology, filler particle size and shape, bulk density, feeding method, screw configuration and the downstream pelletizing route.
Line layout
A typical layout of one of our SAT-T75 lines: feeding system, SAT-T triple screw extruder, pelletizing system and packaging system.
- 01FeedingVolumetric or loss-in-weight
- 02ExtruderTwin, triple, tandem or single screw
- 03Melt filtrationScreen changer, melt pump
- 04PelletizingSix methods
- 05Dewatering and classifyingDryer, vibrating classifier
- 06Conveying and storageBlower, silo
- 07PackingBags or jumbo bags
Control system: one recipe and one start and stop sequence for all stationsControl system
SAT-T series specifications
| Model | Motor Power (kW) | Output (kg/h) |
|---|---|---|
| SAT-T35 | 30 | 50–200 |
| SAT-T52 | 110 | 300–900 |
| SAT-T65 | 160 | 1200–1500 |
| SAT-T75 | 250 | 1800–2200 |
| SAT-T95 | 400 | 2500–3600 |
Capacity data is based on typical validated process results. Actual output varies depending on raw materials, formulation and operating conditions.
FAQ
When is a twin screw extruder still the better choice?
For most conventional compounding tasks and medium filler levels, a twin screw line remains the more economical and sufficient solution. A triple screw solution is typically considered when output is limited by feeding volume, dispersion intensity, or available space.
What is the maximum filler loading achievable with a SAT-T solution?
In high-filler compounding projects such as calcium carbonate applications, USEON has successfully delivered triple screw extrusion systems capable of stable, high-output production at 84%–85% CaCO3 loading.
What does the added free volume of a triple screw configuration mean in actual production?
The increased free volume allows lightweight, high-volume powders to be fed more efficiently. This helps maintain a higher screw fill level at lower screw speeds, which improves process stability and also helps control material temperature rise.
What information is required for a technical recommendation?
To provide an accurate feasibility assessment, we need your base resin type, filler ratio/type, material bulk density, and target hourly throughput.
Can USEON provide a complete turnkey line?
Yes. We specialize in complete compounding lines, including the feeding system, SAT-T extruder, vacuum degassing unit, and customized downstream pelletizing systems.
Send the resin, the filler and its loading, and the bulk density. We check whether a twin screw is sufficient or the SAT-T is the better fit, and size the line.
- 01Base resin, filler type and ratio
- 02Bulk density and target hourly throughput
- 03Twin or triple, size, pelletizing route, quotation
Souder Chen
Head of Compounding Division
With USEON since 2008. Twin screw compounding, devolatilization and recycling lines.