China Nanjing Zhitian Mechanical And Electrical Co., Ltd. Company Cases

Case Background: How to Deal with Extruder Barrel End Surface Damage? A customer recently commissioned ZHITIAN to repair a 177 twin screw extruder barrel with end surface damage due to operational mishandling. The goal was to restore dimensional accuracy and sealing performance without replacing the entire unit. Repair Procedure and Inspection Protocol ZHITIAN carried out the following repair procedures in compliance with European standards: Weld repair to restore the damaged sealing surface. Leak testing to ensure no internal leakage. Penetrant Testing (PT) to detect surface cracks or welding flaws. 3D CMM inspection to verify dimensional accuracy before and after repair. Surface roughness measurement to ensure post-repair Ra ≤ 0.2 μm. Post-Repair Inspection Results Summary Item Inspection Method Post-Repair Result Acceptance Criteria Flatness CMM Measurement ≤ 0.02 mm ≤ 0.03 mm Parallelism CMM Measurement ≤ 0.02 mm ≤ 0.03 mm Overall Length CMM Measurement Within design tolerance As per drawing Pin Hole Perpendicularity CMM ≤ 0.02 mm ≤ 0.03 mm Weld Seam Quality PT + Leak Testing No cracks or leakage No visible flaws Surface Roughness Roughness Tester Ra ≤ 0.2 μm Ra ≤ 0.4 μm FAQ: Common Questions from European Buyers What is the final precision after barrel repair?We guarantee that flatness, parallelism, and hole positioning will be controlled within 0.02 mm. Surface finish is controlled at Ra ≤ 0.2 μm, suitable for critical sealing and alignment. Why choose repair instead of replacement?Repairing saves both time and cost while maintaining comparable performance. ZHITIAN verifies all key dimensions before and after to ensure full restoration. Which brands can ZHITIAN service?We support repair services for brands like Coperion, Leistritz, JSW, USEON, and other common European extruder systems. Conclusion: Why Partner with ZHITIAN? This case highlights ZHITIAN’s technical strength in restoring twin screw barrel integrity with complete dimensional and quality testing. By using German-equivalent materials and precision CNC finishing, we ensure your equipment continues to perform like new. Keywords: twin screw barrel repair extruder barrel maintenance ZHITIAN Ra roughness welding NDT PT test CMM measurement flatness correction OEM repair end-face restoration

For high-performance twin-screw extrusion systems, the barrel and screw elements are critical components that directly affect process stability, throughput, and product quality. In this case, we provided a customized solution for a European client requiring replacement parts for a ZSK250 twin-screw extruder—successfully delivering barrels and screw elements made from nitrided steel, fully compatible with the original manufacturer’s specifications. Client Background A European manufacturer using a ZSK250 twin-screw extruder approached us for a reliable alternative to OEM replacement parts. Their main concerns were long lead times and high costs associated with sourcing original components. Our Solution: Precision-Made ZSK250 Barrel and Screw Elements After analyzing the technical requirements and machine parameters, our engineering team designed and manufactured a complete set of ZSK250 barrels and screw elements, ensuring full interchangeability with the original equipment. Key Highlights: Premium Material Selection:All components were produced using nitrided steel, offering excellent wear and corrosion resistance to support long-term operation under demanding extrusion conditions. High-Precision Manufacturing:Every part is machined with CNC equipment and undergoes multiple quality control steps. Advanced heat treatment techniques are applied to ensure uniform strength and dimensional stability. OEM Compatibility with Better Value:The components are 100% interchangeable with OEM parts, offering equivalent or better performance. The client was able to significantly reduce replacement costs and delivery time without compromising quality. Performance and Feedback The components have been operating reliably since installation, maintaining consistent performance throughout. The customer has reported stable machine operation, high compatibility, and reduced maintenance frequency. They have since expanded cooperation with us for additional spare parts and technical services. Why Choose Us? With extensive experience in twin-screw extruder components, we specialize in manufacturing barrels, screw elements, shafts, and gearboxes compatible with major brands including Coperion, Leistritz, and others. Whether you need OEM replacements or custom-engineered solutions, our team delivers precision, reliability, and value. Keywords: ZSK250 twin screw extruder barrel Screw elements replacement NNitrided steel barrel OEM compatible extruder parts Twin screw barrel manufacturer Extruder screw components Europe Twin screw parts supplier

​ZSK320 Barrel Upgrade: Laser-Clad Nickel-Tungsten Carbide Boosts Wear Resistance by 6x at Minimal Cost ​The ZSK320 extruder barrel, constructed from 45# carbon steel, features a ​1-2mm laser-clad nickel-tungsten carbide (Ni-WC)​​ coating on its inner walls, replacing traditional nitrided steel barrels. This innovation delivers: ​6x higher wear resistance​ ​10-30% cost increase​ vs. conventional upgrades ​Proven reliability: Zhitian’s proprietary laser cladding technology is standard on ZSK320 barrels. ​Core Challenges & Solutions​ ​1. High-Precision Machining for Large Barrels​ ​Challenges: Structural rigidity issues in long-span machining. Thermal sensitivity causing micro-deformations. ​Solutions: Heavy-duty CNC machines with vibration-damping systems. Precision machining in 20±1°C temperature-controlled environments. ​2. Laser Cladding Thermal Deformation Control​ ​Challenges: Thermal gradients and stress imbalances. Risk of warping or coating cracking. ​Solutions: Preheating (200-300°C) + zone-based cladding + gradual cooling. CTE-matched Ni-WC alloy and post-cladding stress-relief annealing. ​3. Industry Barriers for Small Manufacturers​ ​Challenges: High costs of ultra-large CNC machines and specialized expertise. ​Zhitian’s Answer: ​Cost-effective upgrades: Laser-clad 45# steel reduces material costs. ​Open-access services: OEM solutions for ZSK320 and larger models. ​Keywords: Laser cladding screw barrel Twin-screw extruder barrel Screw barrel wear-resistant coating ZSK320 screw barrel upgrade