2. INDRODUCTION www.kaivanyaextrusion.com
Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists.
We manufacture feed screws of the highest quality, and provide service and a product that is second to none.
We service the plastics and rubber industries to processors and OEMs worldwide, countries such as USA , UK ,EUROPE, RUSSIA,MIDDLE EAST,AFRICA,ASIAN Countries etc…..
Our Technical and Engineering Department offers more than 15 years of experience in the field of plastic machinery and screw design.
We have developed our own line of screw designs which can be tailored to suit your application.
We stand behind the parts we produce and provide long term support for our products.
Ever since it & we believe in the quality first, honesty to customers, prompt services to customer’s satisfaction.

3. Complete Production Facilities
Our comprehensive production facilities enable us to perform the entire manufacturing process in-house. As for new screw or old rebuild screw , we utilize traditional methods to achieve the highest international standards.
Feed screw cutting machines over 6m (20 ft.) long x 20 cm (8 in.) diameter
Milling and turning
Welding of hard facings
Heat treatments (Ion & Gas nitriding, Vaccum hardening)
Chrome plating max. length 6 m (20 ft.)
Deep hole boring/trepanning
Honing
200 ton press

4. KAIVANYA SERVICES www.kaivanyaextrusion.com
To assist in ameliorating the designs off different Screws & Barrels for running different plastics polymers.
To assist in increasing your extruder’s out put as well as prolonging its service life.
To assist in increasing your extruders according to your specific melt quality.
Better processing of film and reduce scrap and also cost saving of resins.
Speedy returns on your initial high investments by our products.
Kaivanya extrusion use strong R&D skill work closely with our customers to ensure quality products that produce high end output at a very economical price.

5. Equipments www.kaivanyaextrusion.com Plasma Nitriding furnace
Microscopic Structure
Hardness Teter
Quality Control
Thread Milling

6. KAIVANYA EXTRUSTION TECHNIK
PRESENTATION ON EXTRUSION Single & Twin Screw & BARREL(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)
KAIVANYA EXTRUSTION TECHNIK

9. Extrusion Process www.kaivanyaextrusion.com
Extrusion moulding is a manufacturing process used to make pipes,filim,hoses,drinking straws, curtain tracks, rod and fiber,yarn,cable & wire,sheet,rope,sutli,&other product.
The machine used to extrude materials is very similar to injection molding machine. A motor turns a screw which feeds granules of plastic through a heater. The granules melt into a liquid which is forced through a die , forming a long 'tube like' shape. The shape of the die determines the shape of the tube. The extrusion is then cooled and forms a solid shape. The tube may be printed upon, and cut at equal intervals.

10. Extrusion Molding Screw
Screws are made from nitro alloy steel like 34CrAlNi7, 41CrAlMo7 etc. toughening, tempering, stress relieving, gas nitriding & additional bimetallic coatings can be incorporated on flights depending on the process application. We also do special surface treatment like hard nickel plating, chrome plating & titanium coating depending on the material to be proceed.
Our ability to design and manufacture some of the industry’s most advanced and efficient feed screws is one reason we have been an extrusion leader for more than 15 years. With our R&D facilities and team of experienced polymer process engineers, we offer customers world class screw design and technical capabilities.

11. Explanation For Extrusion single Screw
KAIVANYA EXTRUSION Engineering is the largest and by far the oldest manufacturer of extrusion screws in India.
Our designs cover all facets of the extrusion industry from thermoplastics to natural and synthetic rubber.
We have a 13 year plus record in this industry from which we have built up significant data, soundly based on experience and results.
Screw construction is hard faced, nitrided or hardened & nitrided, for highly abrasive materials we can supply screws with Tungsten carbide coatings on the flight flanks and core diameters, or in the case of highly corrosive polymers such as Fluoro polymer a Duranickle based screw is offered.
Designs are available for single flight metering screws, single barrier screws, double barrier screws, variable pitch flights, multi start flights and slotted flights.
Two stage screws for vented extruders are also offered.
Mixing sections, the more common of which, include Maddock (spiral or straight), Hoechst, dulmage, pinned, pineapple or combinations of these designs are available. Our capacity ranges from 25mm up to 200mm depending on L/D ratio.

12. Rubber Extrusion Screw

13. Extrusion Feed Bush/Grooved Sleeve

14. Extrusion Static Mixer

15. Single Screw Extruder www.kaivanyaextrusion.com Model (Screw Dia) mm
L/D
(Driving Motor) kw
(Capacity) Kg/h
Ket-32
-32
26-28
5.5
20-25
Ket-35
-35
7.5
30-35
Ket-40
-40
11.20
40-45
Ket-45
-45 15
50-55
Ket-50
-50
28-30
18.75
65-70
Ket-55
-55
22.4
75-80
Ket-65A
-65A
28-32 30
Ket-65B
-65B
37.5
ket-75
-75 45
Ket-90
-90 75
Ket-100
-100
75-90
Ket-120
-120
90-110

16. Explanation For Extrusion Twin Screw
KAIVANYA EXTRUSION Engineering is the largest and by far the oldest manufacturer of extrusion twin screws in India.
Based on this fact, kaivanya Factory machined the best plasticization satus & blending quality are achieved.
New configured screws, which can be application to process PVC pipes & profiles are developed by kaivanya Factory.
Also anticorrosion & wear resistant material are developed .
Polymer material can be sheared & compressed more softly in screw.
Extruders with twin-screw and short distance between screws are better than other types, because of their high capacity and good thermal and mechanical stress.
The powder mixing with chemical additives and melting with thermal and mechanical energy in three zones (feed, compression and metering zone) and because of gear pump and screw's pressure, converting to final product in latest plate.

18. Twin Screw Barrel www.kaivanyaextrusion.com
This has enabled production of Twin Barrel with approximately twice to thrice the service life of nitrided barrels at just 20% to 25 % addition cost. This renders the economic efficiency factor irrelevant in purchasing decisions. An additional benefit is the extended service like of twin screw extruders with wear resistant barrels can be operated at normal output for a longer period, without incurring through put losses due to wear. Thus production costs are reduced while competitiveness is improved.

19. KAIVANYA EXTRUSTION TECHNIK
PRESENTATION ON INJECTION MOLDING SCREW & BARREL (Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)
KAIVANYA EXTRUSTION TECHNIK

20. INJECTION MOLDING www.kaivanyaextrusion.com
We manufacture screws for both thermoplastic and thermosets, standard metering design or QLT for improved melt homogeneity and mixing.
These can be hard faced, nitrided or hardened and nitrided with optional hard chrome plating.
Whether you are manufacturing containers for packaging, duct joints for air conditioning or automotive components, we have a screw design available to suit your process for LDPE, HDPE, PP, PVC and more.

21. Injection Molding Screw
The feed section establishes solids convey in the same way as a conventional screw.
At the beginning of the transition zone , a second flight is started.
This flight separates the solids channel from the melt channel.
As material progress down the transaction .
melting continues as the solids are pressed and sheared against the barrel, forming a melt film.
The barrier flight moves under the melt film and the melt is collected in the solid pellets and melted polymer are separated and different function are performed on each.
The melt channel is deep , giving low shear and reducing the possibility of overheating the melted polymer.
the solids channel becomes shallower, forcing the unmelted pellets against the barrel for efficient frictional melting.
breakup of solids bed does not occur to stop this frictional melting . the solids bed continues to get shallower and finally disappears into the back side of the primary flight.

23. Injection Molding Barrels

24. Injection Head & Components

25. Injection Ring Plunger Sets

26. Tie Bars

27. KAIVANYA EXTRUSTION TECHNIK
PRESENTATION ON BLOW MOLDING PROCESS(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)
KAIVANYA EXTRUSTION TECHNIK

28. Blow Molding Process www.kaivanyaextrusion.com
Blow molding is a manufacturing process by which hollow plastic  parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or preform. The parison is a tube-like piece of plastic with a hole in one end in which compressed air can pass through.
The parison is then clamped into a mold and air is pumped into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected.

29. Blow Molding Screw

30. Blow Molding Barrel

31. Blow Molding Retrofit Spares

32. How does the Barrier Screw Works?
The feed section establishes solids convey in the same ways as a conventional screw.
At the beginning of the transition (compression) zone, a second flight is started. This flight separates the solids channel from the melt channel.
As material progress down the transition, melting continues as the solids are pressed and sheared against the barrel, forming a melt film, the barrier flight moves under the melt film and the melt is collected in the solid pellets and melted polymer are separated and different function are performed on each.
The melt channel is deep, giving low shear and reduction the possibility of overheating the melted pellets against the barrel for efficient frictional melting, breakup of solids bed does not occur to stop this frictional melting.
The solids bed continues to get shall over and finally disappears into the back side of the primary flight.
Decompression zone. In this zone, about two-thirds down the screw, the channel suddenly gets deeper, which relieves the pressure and allows any trapped gases (usually moisture or air) to be drawn out by vacuum.
Second metering zone. This zone is like the first metering zone, but with greater channel depth, and repressurizes the melt to get it through the resistance of the screens and the die.

33. PRESENTATION ON BIMETALLIC SCREW & BARREL (Screw & Barrel from Dia
PRESENTATION ON BIMETALLIC SCREW & BARREL (Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)
KAIVANYA EXTRUSTION TECHNIK

34. BI METALIC BARREL - HVOF THERMAL SPRAY TUNGSTON CARBIDE COATING
1 SURFACE-PREPARATION
2 THERMAL SPARY
3 MIXING ROTORS
4 Rolls
5 As sprayed screw

35. www.kaivanyaextrusion.com 6 Diamond Polish 8 Final Quality
7 SMALL SCREW

36. BIMETALIC BARRELS

37. How does tungsten carbide protect from abrasion wear?

38. Abrasion Resistance Test Data

39. PTA WELD OVERLAY BORON CARBIDE COATING

40. Bimetallic Screw Material
Base Material
Nitro alloy
AISI 4140
AISI 4340
Stainless Steels,17-4PH,316
Special alloy steel
Hard Facing Layer
KET183 (Ni/Cr/Boron/WC-35%)
KET 156 (Nickel- Cr/Boron)
KET163 (Nickel- Cr/Boron)
KET188 (Ni/Cr/Boron/WC-19%)
KET 900 (HOVF) TUGSTEN Wc/12 % Co
Root Treatment
Nitriding
Chrome plating
Vapor Deposition
HVOF Thermal Spray
Tool Steels D2
H11,H13
V4,V9
CPM9V,CPM-S90V

41. www.kaivanyaextrusion.com SKD61(1.2344) SCM440(1.7225)
Hot Work Tool Steel
Full Hardening (52 HRc)
Good Abrasive Resistance
High Temp. Hardness
Nitride
Stainless 17-4PH
Full Hardening(48HRc)
High Toughness
High Temp.
Excellent Corrosive Resistance
Hard face
SCM440(1.7225)
High Tensile Strength
Full hardening (56 HRc)
High Toughness
Flame Hardening
Chrome Plate
Nitride
Hard Face
SKD11(1.2379)
Full Hardening (60 HRc)
Multi Purpose Screw
Good Abrasive Resistance
Good Corrosive Resistance (11% Chromium)
Glass Fill 20%

42. www.kaivanyaextrusion.com Special Alloy Hard Face
High Chemical Resistance
Inconel 625 Nickel Base (21% Chromium9%molybdenum)
Hastelloy C276 Nickel Base (15% chromium ,16% molybdenum
Hard Face
Plasma Transfer ARC(PTA)
Screw Flight Built up
Cobalt (stlelite 12,48 HRc)
Nickel(colmonoy56,52 HRc,KET63)
Tungsten Carbine KET86,88 70,75 HRc

43. Alloy Hard Face Chromium Boride Hardness Tungsten Carbide Hardness
Nickel Based Material
Hardness 49-56HRc
Anti-Abrasive /Corrosive
Nickel Based Material
Hardness 48-59HRc
Anti-Abrasive /Corrosive

44. Powder Metallurgical Tool Steel
Element are Atomization to tiny droplets, mixed to a certain percentage.
Hot Isostatic pressing .
Fine & Uniform Micro Structure.
Good Toughness.
Stainless Steel Grade.
Nitride Process can enhance the PM tool Steel hardness but it is not common practice.
Companies Provided – Bohler,Germany

45. NITRIDE www.kaivanyaextrusion.com Nitride Surface Base Material
Case Depth : mm
Hardness : 1000HV
Base Material
Hardness HRC
Iron Nitride

46. Bimetallic Barrel/Backing Steel
High Tensile strength Steel
Chromium /Vanadium
950MPa Tensile Strength
630 Mpa Yield Strength
High temp. operating Condition
Alloy liner
Anti –abrasive
Anti-Corrosive
Base Material
High Tensile Strength

47. www.kaivanyaextrusion.com Chromium Boride/Carbide
KET63
KET 83
KET 56
Chromium Boride/Carbide
Iron Base Material
Hardness: HRc
Anti- abrasive
Glass Filled Application
Chromium Boride/Carbide
Iron Base Material
Hardness: HRc
Anti- abrasive
Glass Filled Application
Tungsten Carbide
Nickel Base Material
Hardness HRc
Anti-abrasive /Corrosive
High Wear application
KET 88
Premium Grade Tungsten Carbide
Hardness HRc
Excellent Anti-abrasive/corrosive

48. KAIVANYA EXTRUSTION TECHNIK
PRESENTATION ON REBUILDING OF Screw & Barrel(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)
KAIVANYA EXTRUSTION TECHNIK

49. Rebuilding of Screw & Barrel
We hard-surface, straighten, machine, grind, and polish to precision tolerances. Special hard-surfacing alloys are made with Nickel, Tungsten-Carbide and Molybdenum.
Screw Modification -- Engineering designed to your specifications. Our expert consultation assures exact results.
Twin Screw Rebuilding -- Straight or Conical Twin Screws.
Barrel Manufacturing -- Extrusion and Injection molding barrel with bimetallic inlays.
Barrel Resleeving and Honing -- Partial resleeves up to 24 inches or honing to an even oversize dimension.
Components Building and Repair -- All replaceable components.
Chrome-Plating -- On site by our sister company Central Florida Plating.
Inspection Certificate -- All incoming and outgoing screws, barrels and components are inspected and Rockwell tested for hardness and print accuracy.  

51. Barrel Rebuild/Repair
Screw Rebuild/Repair
Barrel Rebuild/Repair
Rebuild the top of the flight with hard facing (Satellite & Colmonoy)
Repair the internal thread
Repair the shank (drive section)
Repair the NPT thread
Repair the removable nose
Re-sleeve the stroke section or full length of the barrel with standard bimetallic, carbide or corrosion resistant liner
Repair the grooves within the barrel and on the feed housing section
Reline and repair the water jacket for a rubber processing barrels
Pressure testing and acid flushing for rubber processing barrels
Press-out broken screw from barrel

52. Rebuilding Process www.kaivanyaextrusion.com Screw Re Joint
Key Way Spline Repair
O.D. Rebuilding
Special Coating
Crack Root
Flight Renovation

53. www.kaivanyaextrusion.com Crack Fights Root Rebuilding Nose Resisted
Straightening
Nose Rethreading
Flight Rebuilding

54. THANK YOU
VISIT US