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Updated: May 20, 2025

Twin-Screw Extrusion Process to Produce Renewable Fiberboards

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Published on: January 27, 2021

Modeling Shear-Thinning Flow in Twin-Screw Extrusion Processes.

Vincent Kimmel^1,2, Lorena Gräfe¹, Luca Grieser¹

¹Laboratory of Solids Process Engineering, Department of Biochemical and Chemical Engineering, Technical University Dortmund, Emil-Figge-Str. 68, 44227 Dortmund, Germany.

|March 27, 2025

Summary

This study models screw element behavior in hot-melt extrusion for pharmaceutical formulations. It quantifies parameters for both Newtonian and shear-thinning fluids, aiding screw configuration optimization.

Keywords:

A and B parameters mechanistic modeling one-dimensional modeling screw characteristics shear thinning twin-screw extruder

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Area of Science:

Pharmaceutical Technology
Chemical Engineering
Materials Science

Background:

Hot-melt extrusion (HME) is a key pharmaceutical formulation technique.
Optimizing screw configuration for HME is challenging, especially for complex fluid behaviors.
Existing models often lack detailed screw parameter data for shear-thinning formulations.

Purpose of the Study:

To experimentally characterize the behavior of various screw elements in hot-melt extrusion.
To develop a model for predicting screw element performance with Newtonian and shear-thinning fluids.
To provide specific geometrical screw parameters for enhanced formulation design.

Main Methods:

Utilized a custom-made test rig to measure pressure and power.
Tested conveying and kneading elements with Newtonian silicon oil and shear-thinning silicon rubber.
Developed a six-parameter model (A1-A3, B1-B3) and an evaluation framework with two additional parameters.

Main Results:

Experimental data for Newtonian fluids aligned with existing literature and the Pawlowski approach.
Quantified the impact of screw speed on pressure and power for shear-thinning fluids.
Determined confidence intervals for screw parameters, differentiating element types effectively.

Conclusions:

Successfully modeled geometrical screw parameters for both Newtonian and shear-thinning flow conditions.
Characterized three conveying and three kneading elements, providing valuable data for HME process optimization.
The developed model and parameters offer a framework for improved screw configuration in pharmaceutical HME.