The ZJL‑200 series torque rheometer is a modular polymer laboratory‑scale processing simulator. One main control unit can rapidly switch between internal mixer unit, single‑screw extruder unit (200A), and building‑block co‑rotating parallel twin‑screw extruder unit (200B). It reproduces actual compounding and extrusion production conditions and outputs rheological data such as torque‑time, torque‑temperature, and viscosity‑shear‑rate curves. It supports polymer factories in incoming‑material inspection, formula R&D, process optimization, failure root‑cause analysis and quality documentation. It applies to manufacturers of modified plastics, PVC, masterbatches, rubber, thermoset composites, recycled plastics and more.

I. Incoming‑Raw‑Material Inspection & Batch‑Variation Control

1. Perform rheological tests on incoming resins, powders, additives and recycled materials to evaluate material plasticating performance, thermal stability and shear sensitivity. Even materials of the same grade show differences in molecular‑chain structure and additive ratios across batches. Rheological‑curve comparison identifies abnormal incoming lots, blocks non‑conforming materials and prevents mass rejects caused by feeding defective material directly into production machines.
2. Quantify degradation of recycled materials: compare torque and viscosity between virgin and recycled feeds to guide recycling‑ratio formulation and stabilize final‑product quality.
3. Detect mis‑feeding or material mixing errors and assist grade verification of raw materials.

II. Formula R&D and New‑Material Development to Cut Pilot‑Production Costs

1. Internal‑mixing mode (mixer unit): Small‑volume chambers (60 mL / 200 mL) enable tests including PVC fusion, cross‑linking‑curing of thermosetting resins, elastomer vulcanization and multi‑component blending. Only small sample quantities are consumed. Rapidly compare plasticating, thermal‑stability, cross‑linking and vulcanization behaviours under different filler‑additive formulations to screen optimal recipes. Reduce repeated trials on large‑scale production lines and save raw‑material, energy and time costs.

Interchangeable rotors (Roller, Banbury, Cam, Delta, etc.) support R&D for thermoplastics, elastomers and thermosets.

2. Extrusion mode  ‑ ZJL‑200A: Single‑screw unit simulates single‑screw pelletizing and extrusion processes and measures apparent viscosity and shear‑dependent properties.  ‑ ZJL‑200B: Building‑block twin‑screw unit with reconfigurable screw elements replicates the full production‑scale twin‑screw workflow: feeding‑melting‑compounding‑venting. At lab scale it validates feasibility for modification, blending and alloy formulations, predicts processing behaviours and assesses recipe compatibility with production extruders.
3. Optional auxiliary units such as cooling water trough and pelletizer enable complete lab‑scale pelletizing and produce specimens for subsequent mechanical, weathering and other performance tests.

III. Production‑Condition Simulation and Processing‑Parameter Optimization

1. Adjustable temperature, rotational speed, feeding rate and vacuum venting replicate temperature, shear‑rate and pressure fields of factory mixers and extruders. Measured torque, melt‑pressure and viscosity data guide setup of production‑machine parameters: screw configuration, processing temperature, screw speed, feed rate, vacuum level, etc. Shorten commissioning cycles and reduce trial‑run waste.
2. Investigate influences of rotational speed and shear intensity to define safe processing windows, and avoid manufacturing risks such as shear‑induced thermal degradation, excessive cross‑linking and insufficient plasticization.
3. The building‑block screw of ZJL‑200B simulates alternative screw layouts and assists optimization of screw configurations for large‑scale production extruders.

IV. Reverse Analysis of Production Defects and Rapid Troubleshooting

1. When defects occur such as yellowing‑degradation, poor plasticization, inconsistent product strength, abnormal cross‑linking or surface blooming, run comparative rheological tests on qualified and defective samples. Torque‑time and torque‑temperature curves help locate root causes: raw‑material batch drift, additive failure, material degradation or improper process settings.
2. For materials like PVC and XLPE cross‑linked compounds, measure thermal‑stability time and cross‑linking characteristics. Reproduce processing defects in laboratory to cut production‑line downtime for fault investigation.

V. Quality‑Record Archiving and Technical Accumulation for Customer Audits

1. Build an in‑house material‑rheology database: archive torque, viscosity and processing‑window data for different grades and formulations. Retrieve historical datasets for fast production change‑overs upon grade or recipe modification.
2. Software generates complete test reports and superimposed comparison curves for internal quality records and customer technical audits & technical briefings.
3. Factories obtain independent measured rheological data instead of relying entirely on raw‑material‑supplier datasheets and achieve self‑control over processing technologies.

VI. Summary of Cost‑Reduction & Efficiency‑Improvement Benefits

1. Lower material cost: Lab‑scale trials validate formulas and processes without occupying large‑size production equipment and minimize pilot‑run scrap.
2. Shorter R&D cycles: Formulas and processes are validated in laboratory before full‑scale production launch.
3. Mitigate production risks: Detect raw‑material hazards and formula flaws in advance to prevent mass‑product scrap.
4. High cost‑performance through multi‑functionality: One main control unit connects to mixer, single‑screw and twin‑screw modules, covering both internal mixing and extrusion simulation.

Applicable factories: modified‑plastic manufacturers, PVC‑product plants, color‑/functional‑masterbatch producers, rubber‑goods enterprises, polymer‑composite factories, thermoset‑material plants, recycled‑plastic processors.

E-mail :
zhinengchina@znyq.com

Phone/Wechat：
+86 13069007290