Turbo-Screws®                         WELCOME

                                    HEAT UP PROFITS. COOL DOWN COSTS.   

Frequently Asked Questions ~ Technical

1. What are Turbo-Scews®?
2. What makes Turbo-Screws® revolutionary? 
3. Who developed Turbo-Screws®?
4. Can I really expect significant savings in power and water costs?
5. What polymers does Turbo-Screws® work well with?
6. How long does it take to manufacture Turbo-Screws®?
7. What kind of output rate increase might we expect when using the Turbo-Screws® system?
8. Is our rate increase guaranteed?
9. Why shouldn't I just buy a new extruder, gear pump, etc. to get my rate up?
10. Do I need to change my existing system in order to use Turbo-Screws®?
11. What blowing agents do Turbo-Screws® work with?

What are Turbo-Screws®?

Turbo-Screws® technology is a patented hardware system of both a primary and secondary extruder screw, which each employ special mechanical geometry to enhance tandem foam extrusion output. Turbo-Screws® may be supplied for most commercial sizes of tandem foam extrusion systems, regardless of machine brand, age or style of construction.

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What makes Turbo-Screws® revolutionary?

Turbo-Screws® utilize unique patented flow channel geometries, which are computationally designed to effectively redistribute the extruded polymer such that foam extrusion output rates and quality are greatly improved.

The patented primary extruder screw (Turbo-Pump™ ) is designed to provide higher melting capacity and greater gas concentration potential than traditional screws. Lower densities are typically possible along with exceptionally stable output rates and melt pressure & temperature profiles.

The patented secondary screw (Turbo-Cool™) is designed to promote greatly improved polymer melt redistribution, through the use of unique flow channel geometry. Dramatic cooling improvement, enhanced melt homogeneity and reduced energy consumption are the result of using this unique screw, thus manufacturing costs are diminished.

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Who developed Turbo-Screws®?

Jim Fogarty, our firm’s chairman and founder has invented, developed and refined the Turbo-Screws®  designs over the last several years. Jim is a chemical engineer with nearly forty years of foam extrusion research and development efforts.

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Can I really expect significant savings in power and water costs?

Most likely yes.  Many users have reported both power and water savings from the use of the Turbo-Screws®  technology. In XPS sheet applications, an average of 10% to 21% for power savings have   been reported to us for a range of foam densities.

The actual savings numbers that you might see will of course be largely related to both your local   power costs, and the polymer, product density, and type of foam end product mix that you run. With your specific circumstances, we can make an estimate of what you might expect to enjoy in power   and water savings. Your specific application may vary somewhat from our past experiences. 

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What polymers does Turbo-Screws® work well with?

Turbo-Screws®  technology has been successfully applied to both styrenic and polyolefin polymers, the two largest markets for extruded foamed end products.  

The appeal of the Turbo-Screws®  technology is that it is not polymer specific. The operative injection, distributive and cooling mechanisms are useful for most all polymers. We have development programs planned for a number of alternative raw materials, and would like to discuss your specific application’s suitability.  

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How long does it take to manufacture Turbo-Screws®?

You can have a pair of Turbo-Screws®  in as short a time frame as 4 to 6 weeks.  Typically though, delivery time for Turbo-Screws®  hardware is approximately 8 to 10 weeks. 

Also, our extensive design experience includes an inventory of both conventional and Turbo-Screws®  designs for most commercial machines, all of which allows us to respond quickly. We employ modern computer based engineering, design and manufacturing technologies in the manufacture of our Turbo-Screws® products.

Call us with your specific circumstances (polymer, end product, hardware configuration, etc) and we can discuss what you might expect to see for rate and quality improvements.

One good example is that of XPS production. We have users who have experienced from 10% to as much as 75% as a sustained extrusion rate increase, all at lower unit costs of power and water. These rates did not include the use of drastic measures such as added gear pumps, static heat exchangers or major extruder up-sizings. 

Your results may or may not be typical. Call or e-mail us to discuss your situation further. 

It can be, if you want to pay a premium, but our process guarantee is available only under narrowly defined operating parameters.

Your  best guarantee may be the comfort of knowing that you are not licensing a development project but a production proven process. Your output rate increase will be more related to your existing extrusion die tooling capacity rather than that of what Turbo-Screws®  technology can theoretically deliver.

Thus far, none of our licensees have felt the need to pay a premium for a “guarantee”. You may  however opt to purchase a guarantee if that is required for your specific circumstances. Please  Call or e-mail us to discuss your  needs further.

Turbo-Screws®  technology is one of the most productive and lowest unit cost ways to increase your company’s sales capacity. With Turbo-Screws® , you enjoy a lower initial outlay of financial capital and enhanced  capital productivity of your existing equipment.

Unlike the outright purchase of new extrusion capital hardware, with Turbo-Screws®  technology you pay as you go and only buy the capacity increase you need, when you need it. By improving your existing installed extrusion hardware productivity, Turbo-Screws®  technology adds to the bottom line quickly all without great burden on the organization.  

With typical new foam extrusion capital equipment purchases, you must make a large capital investment and thus inherit the need to sell large quantities of end product quickly.  Turbo-Screws®   technology lets you grow rationally at a calm and affordable pace.

Do I need to change my existing system in order to use Turbo-Screws®?

It depends upon your goals. Before we do anything, we ask our clients what they want to achieve. Then, we listen. Only with your approval would we implement system modifications. If higher throughput rate is your goal, for example, it's a good idea to find out if your downstream equipment can handle the higher Turbo-Screws® throughput rates. Then,  we recommend some options for you.  Remember, you are always in control of the decision making process. We'll work hard to meet your goals. That's why we ask that you contact us so that we can discuss your unique situation, in confidence. No one will work harder than us to meet your goals.

  What blowing agents do Turbo-Screws® work with?

Turbo-Screws®  users are employing a variety of blowing agents with our technology. For a list of blowing agents Turbo-Screws® works with, click here.

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