Welded Extruder Screen Packs
Welded Extruder Screen Packs | Spot Welded Packs
Welded extruder screen packs (also called welded screen packs or spot-welded packs) are multi-layer filter assemblies used in plastic extrusion and polymer filtration processes. They consist of 2–6 (sometimes more) layers of wire mesh screens that are permanently joined together by spot welding or resistance welding around the outer rim and often at several points across the mesh surface.
Welded Extruder Screen Packs are multi-layer filtration screens that are spot-welded along the perimeter or at strategic points to form a rigid, unified structure. These packs are engineered to offer high-strength, stable, and reliable filtration during polymer and plastic extrusion processes. Each pack typically consists of multiple layers of woven wire mesh arranged in various configurations—such as single-layer, double-layer, or multi-layer combinations—to achieve precise filtration efficiency and enhanced mechanical durability.
Designed for polymer melt filtration, blown film extrusion, sheet extrusion, masterbatch production, and compounding, welded extruder screen packs help ensure uniform material flow, improved product purity, and extended equipment life.
Advantages of Welded Extruder Screen Packs
- High Structural Strength
Spot welding firmly locks all layers in place, preventing mesh shifting or deformation under high pressure and high-temperature extrusion environments. - Stable and Uniform Filtration
Multi-layer mesh construction provides consistent filtration accuracy, effectively removing contaminants, gels, and impurities from polymer melts. - Improved Pressure Resistance
Welding enhances resistance to sudden pressure changes, ensuring stable filtration performance without rupture or distortion. - Extended Service Life
The reinforced structure reduces wear and mesh displacement, minimizing replacement frequency and lowering long-term operating costs. - Customizable Layer Combinations
Support for various mesh counts, layer structures (single → multi-layer), and custom shapes to match diverse extrusion equipment. - Improved Product Quality
Helps maintain uniform melt flow, ensuring better film surfaces, consistent sheet thickness, and improved overall product quality.
Specification of Welded Extruder Screen Packs
▪ Materials Available
- Stainless Steel (304, 316, 316L)
- Carbon Steel
- Nickel Alloys (Inconel, Monel, Hastelloy)
- Brass or Copper Mesh
- Extra Fine Dutch Weave Mesh for precision filtration
Wide selection of metals to meet different filtration requirements and processing environments. Options include stainless steel, carbon steel, copper alloys, and high-performance nickel alloys for high-temperature or corrosive polymer melts.
▪ Mesh Options
- Plain Weave Mesh
- Twill Weave Mesh
- Dutch Weave Mesh
- Multi-layer Combinations (2–12 layers)
Multiple weave types allow precise control of filtration accuracy, flow rate, and mechanical strength. Plain, twill, and Dutch weaves can be combined into multi-layer packs for enhanced performance.
▪ Welding Methods
- Spot Welding
- Perimeter Welding
- Tack Welding
- Custom Weld Patterns
Various welding styles ensure structural stability under high pressure. Spot welding, perimeter welding, and custom weld patterns prevent mesh shifting and improve durability during continuous extrusion.
▪ Common Shapes
- Circular (most common)
- Rectangular
- Oval
- Kidney-shaped
- Customized geometries per drawing
Welded extruder screen packs are typically round or kidney-shaped. Round screens are used individually and require stopping the extrusion process for replacement. Kidney-shaped screens are arranged on an automatic screen-changing wheel that advances when clogging or pressure rise is detected, enabling continuous operation while operators replace used screens without interrupting melt flow.
▪ Mesh Count Range
- 4 mesh to 400 mesh
- Multi-layer stacks such as 20/40/80 mesh, 10/20/40/80 mesh, 40/100/325 mesh, etc.
A broad mesh range—from coarse 4 mesh to ultra-fine 400 mesh—supports filtration levels from basic contaminant removal to precision melt purification. Multi-layer stacks can be configured for progressive filtration.
▪ Diameter and Size Range
- 10 mm to 1,200 mm (custom options available)
Standard sizes from 10 mm to 1,200 mm, with full support for custom diameters and tolerances. Suitable for both manual screen replacement and automated screen-changer systems.
▪ Filtration Ratings
- 5 microns to 500 microns depending on mesh configuration
Filtration levels from 5 to 500 microns, depending on mesh type and layer configuration. Ideal for removing gels, unmelted pellets, metal fragments, and fine contaminants from polymer melts.
Applications of Welded Extruder Screen Packs
Welded Extruder Screen Packs are widely used across multiple extrusion and polymer-processing industries, especially where precise melt filtration and stable flow performance are required.
▪ Polymer & Plastic Extrusion
- Blown Film Extrusion
- Casting Film Extrusion
- Sheet Extrusion
- Pipe & Profile Extrusion
- Injection Molding Pre-Filtration
▪ Masterbatch & Compounding
- Color masterbatch filtration
- Filler masterbatch production
- Additive dispersion processes
▪ Rubber & Silicone Processing
- Silicone extrusion
- Rubber sheet production
▪ Chemical & Petrochemical Industries
- High-viscosity fluid filtration
- Resin and chemical melt filtration
▪ Food & Pharmaceutical Processing
- Precision filtration of viscous materials
- Contaminant removal during thermal processes
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