The Extruder Power Calculator is designed to estimate the energy requirements of an extrusion system, particularly useful in plastics, food processing, and polymer industries. It helps determine how much power is needed to operate an extruder based on torque, rotational speed, pressure drop, and output volume. This tool supports engineers, plant operators, and equipment designers in optimizing motor sizing, energy efficiency, and throughput performance.
By knowing the power input, industries can ensure that the extruder is neither underpowered—leading to jams or poor output—nor overpowered, which wastes energy and increases operational costs.
Formula of Extruder Power Calculator
Extruder Power (P) = (Torque × 2π × N) / 60
Where:
P = Extruder power in watts
Torque = Rotational torque applied to the screw in newton-meters (N·m)
N = Screw speed in revolutions per minute (RPM)
2π / 60 = Factor to convert angular velocity to seconds
Alternate Formula Using Flow and Pressure:
P = (Q × ΔP) / η
Where:
P = Power input in watts
Q = Volumetric flow rate in cubic meters per second (m³/s)
ΔP = Pressure drop across the extruder in pascals (Pa)
η = Motor efficiency factor, typically 0.7 to 0.9
Conversion to Horsepower (HP):
P (HP) = P (watts) / 745.7
This formula is commonly used when sizing motors or checking if current motor capacity is adequate.
Reference Table for Estimations and Conversions
| Parameter | Typical Range | Notes |
|---|---|---|
| Torque | 50–2000 N·m | Depends on screw size and material resistance |
| Screw Speed (N) | 20–200 RPM | Affects material movement and power draw |
| Flow Rate (Q) | 0.0001–0.01 m³/s | Depends on extruder size and throughput |
| Pressure Drop (ΔP) | 1–10 MPa | Influenced by die design, material, and back pressure |
| Motor Efficiency (η) | 0.7–0.9 | Reflects energy losses in the motor |
| 1 HP | 745.7 watts | Common conversion for comparing motor sizes |
This table offers a useful guide for quick approximations or manual checks.
Example of Extruder Power Calculator
Imagine a polymer extruder operating with the following values:
- Torque = 400 N·m
- Screw Speed (N) = 100 RPM
Using the formula:
P = (400 × 2π × 100) / 60
P ≈ (400 × 6.2832 × 100) / 60
P ≈ 25132.74 / 60
P ≈ 418.88 watts
If you want the power in horsepower:
P (HP) = 418.88 / 745.7 ≈ 0.56 HP
Now using the alternate method:
- Q = 0.001 m³/s
- ΔP = 5,000,000 Pa (5 MPa)
- η = 0.85
P = (0.001 × 5,000,000) / 0.85 = 5,000 / 0.85 ≈ 5882.35 watts
P (HP) ≈ 7.89 HP
This comparison shows how both mechanical and flow-based methods can help assess the power needs depending on available data.
Most Common FAQs
This calculator is part of the mechanical and process engineering category, often used in polymer extrusion and machinery design.
The torque-speed formula focuses on mechanical drive power, while the flow-pressure version targets hydraulic or material-specific power needs. Both are valid depending on what measurements are available.
Motor efficiency accounts for energy lost as heat or friction. A higher efficiency means less energy is wasted, and the motor operates closer to its rated performance.