Extruders — Designed for any application
With proven results in several markets, from catalyst, mastics and ceramics to food, plastics and consumer products, Diamond America manufactures extrusion equipment designed to work and built to last.
Not every application, processing condition and end product is created the same. Our first step in the development a customer’s extruder is thorough research. This includes testing your materials in our lab to determine the ideal extrusion process for producing the high quality structured products our customers demand.
Table Top Extruders
Diamond America’s Table Top Extruders are perfect for running small batches or testing applications in a laboratory setting.
We offer Table Top Extruders in 1” and 2” models. Customized features and options — dies, feeders, cutters, etc. — are available and are designed and built per customer specification.
Twin Feed Extruders
Diamond America’s Twin Feed Extruders feature our counter-rotating feed screw design. It provides our customers with the ability to process the most challenging materials while maintaining a positive feed to the extrusion screw. Our completely original design changes the geometry of the screws, barrel liners and feeders used in the extrusion process. As a result, we are able to reduce unwanted friction and eliminate stagnation while operating at peak energy efficiency.
Built to handle the hard stuff — Petrochemical Catalysts, DeNox Catalysts, Carbon, Rubber (EPDM and Recyclable), Silicone, Clay, and Ceramics — as well as Food Manufacturing (Confectionary, Pet Food, Pasta).
Twin Feed Extruders are available in 2”, 4” or 6” base models, and can be customized to include various die assemblies (profile or pellet processing), temperature control options, and rotary or guillotine cutters.
Bulk Feed Extruders
Diamond America’s Bulk Feed Extruders are designed and built to handle large batch material straight from the mixer to eliminate the cost of handling. Dual drives offer maximum process flexibility.
The standard large capacity feeder and temperature controls make this an ideal extruder for processing mastics and butyl sealants. As with all Diamond America equipment, our Bulk Feed Extruders can be customized to meet your specific needs.
Dies — Innovative Profiles, Detailed Finishes
Custom Extrusion Dies
Diamond America offers custom designed extrusion dies for any application. Our engineers assess a customer’s process and production requirements, yield requirements, polymer rheology, and flow rate data using computer flow analysis. This thorough approach provides us with the critical information we need to create a die that will meet all of a customer’s specifications.
In addition to our custom designed and built extrusion dies, Diamond America carries multi-channel flow control dies, coating and laminating dies, sheet and film dies, and rotating blown film dies. Our experienced engineering and manufacturing team enable us to provide fast turnaround times for both new and reworked extrusion dies.
Flow Control Die
The unique design of this multi-strand die provides identical shear history for each strand regardless of location across the die. Distribution is made by directing, not restricting flow. Because shear history and residence time are identical across the die, flow rate and swell are identical for each strand. This design is of particular value for shear sensitive or low viscosity materials. The technology has been applied to strand/strip dies and can also be used in rounds, pipe/tubing, sheet, film, and striping or co-extrusion dies.
Forming dies include profiles as complex as a multi-cell monolith or as simple as a solid slug. Regardless of need, every die is designed to produce an extrusion that meets specific requirements at the highest rate, and of the utmost quality.
Sheet and Film Dies
Extrusion Dies for sheet and film applications are a specialty. An internal “ coat hanger” cross section is generated from your viscosity curves and optimized for demanding output requirements and elimination of hot spots. Exclusive choker bar, thickness and width designs allow for easy adjustment on the fly. Rotating blown film dies feature a streamlined “ spider” design to keep residence time to a minimum while maintaining superb output rates. Computer flow analysis is available as a virtual test of performance.
Rotating Blown Film Extrusion Dies
We design and manufacture rotating blown film (RBF) dies and offer components for monolayer film production. In addition to our tooling products, Diamond America assists our customers to solve sticky production problems. Whether manufacturing a 16" blown film assembly or consulting to solve process difficulties, our team of engineers will find a solution.
Extrusion Die Repair Service
In addition to designing and building customized extrusion dies, Diamond America also offers extrusion die repair services. Our proven system of die rebuilding begins even before the die is delivered to our door.
The steps in re-manufacturing your extrusion die include:
- Extrusion Die problems are discussed with the customer to better understand the scope of the rework. (leakage, dielines, gauging problems)
- The Die assembly is digitally recorded.
- A complete inspection of the outer die body is performed, noting the condition of the guards, electrical wiring and heaters, along with recording of the die gap.
- A detailed recommendation is made to the customer on required repairs.
- (i.e. heaters, adjustment bolts, and wiring)
- The die is then disassembled and digital photos are taken of the flow cavity.
- A complete inspection of the internal flow surfaces is recorded, noting feed channel depths, manifold dimensions, and surface blemishes.
- The chrome is stripped from the die.
- The die seal areas are ground and the flow cavities polished. The lip area is polished to 1-3 Ra and 4-6 Ra in the flow cavity. The lip area is ground flat within .0001 per 3 inches of width. The extrusion die is chromed .001 - .0015 on all flow surfaces and flash chromed on the outer body for corrosion protection.
- The chrome is polished and any chrome build-up is removed.
- The die is reassembled in “like new” condition and returned to the customer.
Feeders — Maintaining Consistent Flows
Bulk Feeder is designed to process sticky, difficult to feed batch material from mixer to profile, basically eliminating handling. Its compact size and large feed hopper combine optimum capability with minimal space requirement. Extensive jacketing and hollow shaft screws ensure optimum temperature control.
Twin Shaft Feeder
Diamond America’s Twin Shaft Feeder performs as a simple surge bin for sticky to free flowing materials, taking a batch load and providing steady, even flow to the extruder or next process. It can be provided with drive feedback loop to control feed rate.
Twin Shaft Feeders are available in standard models TSF200 (2”), TSF400 (4”), TSF600 (6”), TSF800 (8”).
Mixers — Uniform, Continuous Feeds
Twin Shaft Mixer
Diamond America’s Twin Shaft Mixer is designed to handle large amounts of material that require intense mixing. A large discharge chute ensures free flow of material to the next process. Intermeshing knives with individual pitch adjustment are mounted in opposing fashion and incorporate counter-rotating action for optimal mixing flexibility. Individual knife-pitch adjustment allows for fine tuning. Options are available for adding shear.
The mixer can be fitted with a shredding die assembly for maximum surface exposure to enhance de‐airing. Dies can be modified to intensify shear to meet product demands. Mixer can also be set up as a surge feeder for holding and dispensing batch mixes.
Standard Twin Shaft Mixer models are TSM200, TSM400, TSM600 and TSM800.
Cutters — Accuracy, Precision, Speed
Diamond America offers a number of high-speed rotary cutting options. With multiple blade and wire cutting selections, our rotary cutters are easily adjustable, operate with air or water induction, and can be mounted to your die or hinge mounted. Our Dynaforce Rotary Cutter is fitted with a spring-loaded swivel head to ensure even, full contact to the die face.
A Rotary Cutter can be built to your specification or you can choose from one of our standard models: RC200 (2”), RC400 (4”), or RC700 (6-8”).
Diamond America offers a variety of guillotine cutters for large diameter cutting requirements. The Guillotine Cutter can be outfitted with optic sensors to trigger the cutter per length of cut or with a set timer. Designed for use in conveyor systems and with an unlimited range of profiles, customers can expect even, measured cuts.
A Guillotine Cutter can be built to your specification or you can choose our standard model in two sizes, the GC200 (designed for the Diamond America TF200 Extruder) or GC400.
Fly Knife Cutter
When in need for a fast and clean cut, the Diamond America Fly Knife Cutter delivers the blade velocity and weight in motion to deliver a precise cut regardless the application.
Fly Knife Cutters can be built to your specification or you can choose our standard model, the FK100 (designed for the Diamond America TT100 Extruder).