Melting mechanism of a starved‐fed single‐screw extruder for calcium carbonate filled polyethylene

Abstract A study of starved‐fed single screw extrusion was initiated to understand the relation between its distinctive melting mechanism and the improved mixing capabilities attained during compounding of a calcium carbonate filler into HDPE. Experiments were carried out in a 63.5 mm single screw extruder, examining the effect of degree of starvation on a conventional and barrier feed screw. Interest was focused on the mixing/melting mechanism of starved‐fed solids‐conveying as it affects the size and number of filler agglomerates observed in the extrudate. The melting performance of both feed screws was examined using pressure and temperature measurements down the screw length as well as direct inspection of the polymer in the screw channel via rapid screw cooling. Both screws showed improved mixing quality with increased starvation.