Predictive Maintenance for Extrusion Lines: Monitoring Screw Wear, Barrel Temps, and Die Pressure
An extrusion line failure doesn't announce itself politely. A seized screw doesn't send a warning email. A catastrophic barrel rupture from a plugged screen pack doesn't wait for a convenient maintenance window. When an extrusion line goes down hard, it takes production, material, and potentially operator safety with it — plus 8 to 72 hours of unplanned downtime while maintenance tears into a machine that's full of 400°F polymer.
The physics of extrusion, however, are generous with early warnings. Screw wear changes the relationship between screw speed and output rate. Barrel zone heater degradation shifts the melt temperature profile. Die pressure creep signals screen pack loading or die land buildup. Melt pressure instability predicts surging before it shows up in the product.