The Extruder Output Calculator is a valuable tool for professionals in plastics processing, food extrusion, and manufacturing. It estimates the volumetric output or throughput of an extrusion machine based on key design and operating parameters. By inputting factors like screw diameter, channel depth, screw speed, and efficiency, this calculator predicts how much material can be processed over time. This helps engineers optimize production rates, forecast material needs, and adjust machine settings for better performance.
Whether you’re scaling up production or troubleshooting inconsistencies in output, having an accurate estimate of extruder output can lead to more efficient operations and better resource planning.
Formula of Extruder Output Calculator
Where:
Q = Extruder output (in volume per time, like cm³/min or converted to kg/h using material density)
D = Screw diameter (in cm or mm)
H = Channel depth of the screw (in cm or mm)
N = Screw speed (in revolutions per minute, RPM)
η = Flow efficiency factor (unitless, typically between 0.6 and 0.9)
π × D² / 4 = Cross-sectional area of the screw channel
This formula approximates how much material the screw conveys per revolution, adjusted by the efficiency factor and the channel geometry.
Reference Table for Estimations and Conversions
| Parameter | Typical Range | Notes |
|---|---|---|
| Screw Diameter (D) | 25–150 mm | Larger screws process more volume |
| Channel Depth (H) | 2–10 mm | Depends on design and application |
| Screw Speed (N) | 20–200 RPM | Faster speeds increase throughput |
| Efficiency Factor (η) | 0.6 – 0.9 | Depends on friction, pressure, and material |
| Density (Plastic) | 0.9 – 1.4 g/cm³ | Needed for converting volume to mass output |
This table helps estimate or cross-reference values without needing to do detailed calculations every time.
Example of Extruder Output Calculator
Suppose you are using an extruder with the following settings:
- Screw Diameter (D): 50 mm (5 cm)
- Channel Depth (H): 5 mm (0.5 cm)
- Screw Speed (N): 100 RPM
- Efficiency (η): 0.8
Plugging into the formula:
Q = (π × 5² × 0.5 × 100 × 0.8) / 4
Q ≈ (3.1416 × 1000) / 4 ≈ 785.4 cm³/min
So, the extruder processes about 785.4 cm³ per minute. If the material density is 1 g/cm³, that equals 785.4 grams per minute, or about 47.1 kg/hour.
Most Common FAQs
This is a manufacturing and process engineering calculator. It is specifically used in extrusion-related calculations for plastics, rubber, food, and similar industries.
This formula mainly applies to single-screw extruders. Twin-screw systems are more complex, and their output depends on intermeshing geometry and material properties. However, this formula can provide a rough approximation.
The efficiency factor accounts for real-world losses like backflow, slip, and imperfect material feed. It usually ranges from 0.6 to 0.9, based on material behavior and extruder design.