Wayne Machine & Die Company
Contact: Joseph Scuralli
100 Furler Street
Totowa, NJ 07512
U.S.
Phone: 973 256 7374
Fax: 973 2561778
Custom Extruder Screws & Barrels
For all makes and models of Extruders, Blow Molders, Injection Molders and other Plastic Machinery
New Screws and Barrels for all makes/models of Extruders, Injection molding and blow molding machines are manufactured by Wayne with expert engineering assistance to solve all your screw and barrel problems. We REBUILD worn screws and RELINE worn barrels. Why not let us handle them for you?
Precision custom manufacturing of new screws and barrels for extruders, injection molding machines, blow molding machines and food extruders has been a major part of the company mission at Wayne Machine and Die Company since 1958.
Wayne custom builds new screws and rebuilds worn screws for all makes and models of machines, foreign or domestic. In fact, that is the first product that the company offered to the plastics industry! The primary reasons you might consider buying replacement screws from Wayne instead of the original equipment manufacturer include higher quality, lower price and custom design engineering assistance that OEMs (Original Equipment Manufacturer) usually do not offer. Also, the OEM may be out of business. The Wayne advantage is that Wayne is also a manufacturer of high quality extrusion machinery , so we have the benefit of hundreds of installed extruders running virtually every thermoplastic available. We also have hundreds of screw and barrel drawings from many manufacturers. Other Screw and barrel manufacturers that are only machine shops cannot hope to match our decades and generations of extrusion machine building experience! Wayne can duplicate your existing screws and barrels exactly to your existing specifications, or we can offer a wide variety of different materials, designs and processing information to help solve your problems or achieve your particular objectives. We can help you convert your existing equipment to run highly corrosive polymers like flouropolymers, highly abrasive glass filled resins, solve mixing problems when you need to run colors or eliminate burning when you need to run heat sensitive resins like PVC. To meet the industry's demand for quality, CAD is utilized to achieve cost effective and optimum performance designs. Finally, we are a family owned and operated company that has been under the same management since 1958 with a long proud history of service to our customers. With our decades of experience we can give you sound advice about the best way to deal with your problems. We are at your service, just give us a call.
SIZES:
Any screw or barrel can be manufactured by Wayne from the smallest 1/4" diameter screws used in research to the 8" diameter production size screws. Any L/D can also be accommodated.
MATERIALS:
Wayne will recommend the best material or combination of materials to solve your particular problem and optimize your process. We often recommend -
For standard thermoplastics like virgin PE,PS,PP:
* 4140 Flame Hardened
* Chrome plating
For abrasive plastic compounds with fillers like glass and minerals:
* 4140 Flame Hardened
* Nitrided NITRALLOY®
* CPM 9V and CPM 10V®
* Tool Steels D-2,S-7,A-11,H-13 and others.
Hard-surfacing of flights with:
* STELLITE® 6 &12
* COLMONOY ®56
* Screw Coatings:
* ARMOLOY®
* Titanium Nitride
* UCAR®
* BOROFUSE®
* CARBORIDE®
For mildly corrosive polymers like PVC or flame retardant compound:
* Stainless Steels 17-4PH® and 15-5PH®
* Chrome plating
* POLYOND®
For highly corrosive polymers like FEP, PFA, ETFE, ECTFE :
* HASTELLOY® C-276 in standard, cold reduced and pre-stressed modes.
* INCONEL®625 and hardened 718
* MONEL K-500®
* DURANICKEL®
* Electroless Nickel Plating
DESIGN OPTIONS:
* Single or multi stage
* Mixing sections including Maddock UCC, Spiral Maddock, Pins, Diamond, Blister , Dulmage, Knobby sections, gas injection mixers, foam designs and others
* Barrier flights
* Variable Lead or Pitch
* Lead Changes
* Flights with single, double or triple leads
* Keyways -single or double
* Splines - American or DIN/ISO,
* Lead - right or left hand
* Noses - fixed or removable and offset
* Cored holes to any depth
BARRELS:
* Abrasive resistant
* Corrosion resistant
* INCONEL® faced flange
* Bi-metallic
* Nitrided
* Tungsten Carbide
* Feed throats
* Vents added/deleted
* Injection Ports
* Grooved/Smooth feed sections
Accessories and Extrusion or Injection Related Products:
* CHECK VALVES
* BREAKER PLATES are available for all types of extruders in standard and special designs and materials
* BARREL END CAPS
* INJECTION VALVES
* DIE NIPPLES to fit all types of extruders and made to custom fit any configuration
Wayne Machine & Die Company presents:
The Yellow Jacket Line of Plastic, Silicone, and Rubber Extrusion Machinery
Wayne Yellow Jacket Single Screw & Twin Screw Extruders, Dies and Downstream Equipment, Complete Turnkey Lines, Replacement and New Design Extruder Screws and Barrels are custom built for your extrusion process.
Need New & Rebuilt Low Cost "In-Stock" Extrusion Equipment FAST? Click for pictures and list of in stock equipment
Wayne Yellow Jacket Extruders are known worldwide for Quality, Durability and consistently reliable Performance in the wide range of extrusion processes. Recently, the United States Department of Commerce recognized Wayne Machine as a leading Exporter, and awarded Wayne Machine with the coveted Export Achievement Certificate presented by Congressman Bill Pascrell. Since 1958, Wayne has been a family owned and operated business and has been serving customers throughout the plastics, silicone, rubber and related industries by providing custom built extrusion machinery and custom built extruder screws. Our family tradition means you can rely on our generations of machine building experience, hundreds of machine installations worldwide and the fact that our family's livelihood depends on your satisfaction.Our plastic, silicone and rubber machinery works in many industries and we proudly present the Yellow Jacket line as a tailor made solution to your extrusion needs. Our Yellow Jackets commonly process plastic, silicone and rubber into the following end products:
* Blown Film
* Cast Film
* Compounding
* Co-extrusion
* Food and Feed
* Fiber
* Fiber Optic Sheathing
* Wire Insulation
* Laboratory & Research Samples
* Monofilament
* Pelletizing
* Profile
* Rod
* Shoe Last Repair
* Sheet
* Tubing
* Extrusion Pressure Testing
* Extrusion Molding System for Plastic Specimens
Click on the hypertext to see specific data sheets on our world-famous product line:
* Bantam Desktop Extruders 1/4" to 5/8"
* Table Top Extruders 3/4" to 1 1/4"
* Small Floor Model Extruders 1/4" to 1 1/2"
* Co-rotating Twin Screw Extruders 19mm to 50mm
* Conical Twin Screw Extruder 38mm/24mm
* Large Floor Model Extruders 2" to 6"
* Vertical & Satellite Co-Extruders 1/4" to 2 1/2"
* Crosshead Style Extruders for wire insulation, tubing, fiber optic sheathing, yarn and cord coating and any other crosshead application, 1/4" to 6"
* Hive Co-Extruders 1/4" to 6"
* Silicone / Rubber Extruders 5/8"to 4-1/2"
Our Extruders come with a wide range of Standard and Optional Equipment!
* Bantam Blown Film Equipment Lab desktop sized for up to 4" layflats
* Blown Film Towers 12" to 20" layflats
* Bantam Cast Film Equipment Lab desktop sized for up to 6" wide
* Cast Film Take-Offs up to 36" wide
* Crosshead dies - for tubing, wire insulation, fiber optic sheathing, yarn and cord coating
* Extrusion Molding System for Plastic Specimens
* Fiber Monofilament Spinning System
* Flat Dies and Feedblocks
* Bantam Sheet Equipment Lab desktop sized for up to 6" wide
* Sheet Take-Offs from 8" to 36" wide
* Bantam Compounding / Pelletizing Equipment Lab desktop sized
* Pelletizers 2" & 3" Throat Width
* 2 Roll Pullers Bantam 4" wide and floor model 12" wide
* Belt Pullers and Cutters
* Tubing Air Systems for medical grade and industrial grade tubing
* Vacuum Tanks For Tubing and Profiles
* Bantam Water Troughs Lab desktop sized water troughs
* Water Troughs for laboratory and production
* Bantam Universal Winders for all desktop extrusion applications
* Winders for tubing, wire, profiles, yarn and cord coating
* Payoffs for use in coating and sheathing applications
* Custom Extruder Screws & Barrels For all makes and models
Spare Parts and Technical Service - Our spare parts and technical service departments help keep your equipment running.
We PAY CASH for your Used Extrusion Equipment We BUY-SELL-TRADE your Used Extruder, Takeoff or Other Extrusion Equipment! Wayne is now buying used extrusion equipment and accepting trade-ins!
Rebuilding, Upgrading and Modernization of Extruders and downstream equipment is available for all makes and models of extruders and extrusion equipment.
The Wayne Extrusion Equipment Laboratory houses all types of extrusion equipment for your trials, small batch production, equipment justification, process parameter development, extruder screw design tests. Try it before you buy it!
Extrusion Equipment Seminars are held on a free of charge basis that explain new developments in extrusion equipment, the technology that is available and how these products can benefit you!
Sales Representatives Wanted we are currently looking for a sales representatives (USA and worldwide) with plastic extrusion experience.
Extruder and Extrusion Equipment Rebuilding
Wayne Machine's Rebuilding Services can be a profitable alternative to buying new equipment.
* All makes and models of extrusion equipment can be rebuilt by Wayne
* Upgrades for control systems, electrical panels, mechanical transmission, process sections
* Safety equipment upgrades include panel lockouts, emergency stop systems, rupture disks and more
* Wayne's customized evaluation and approach means you only upgrade the items you need and continue to benefit from existing parts of the equipment that are still in useable condition!
Many extrusion equipment users cannot immediately fund or justify new equipment purchases. These people are stuck with older equipment that may be partially useable but does not meet today's requirements for performance. Others find themselves with equipment manufactured by a company that is no longer in business. Wayne Machine's Rebuilding services can help. We can take this older and worn out equipment, and make it perform to today's demanding requirements. Equipment can be modified to process today's corrosive, abrasive, engineering and other difficult to process materials. These upgrades include:
* Safety - A key issue regarding older extruders is their lack of safety equipment.. Many older machines do not have the emergency stop system, panel lockout/tagout provisions, safety labeling, safety switches on guards, rupture disks for over pressure and other optional systems such as melt pressure shutdown, heater break alarms and other safety features. All Wayne complete rebuilds feature a comprehensive upgrade of safety features.
* Electrical - Legacy control systems such as drives and temperature controllers are often in need of repair and/or outdated. Depending on the objectives for the machine, Wayne can repair the existing drives or replace them with modern equipment. In most cases, the existing temperature controls are replaced as it is not cost effective to repair old temperature controls. Wayne can install the latest technology such as AC Flux Vector drives and Auto-tuning temperature controllers with data acquisition capability
* Mechanical - Gearboxes, drive belts, bearings and shafts wear out over time, and seals fail causing oil leaks. Wayne's comprehensive gearbox rebuilding involves a complete strip down and disassembly of the gearbox to identify the parts that are in good condition and to replace/repair the ones that are not. When the gearbox is re-assembled it is ready for action again. Motors often need cleaning and rebuilding to deliver the rated torque to the gearbox.
* Process sections - Barrels, screws, heaters and feed sections also wear out over time. These are completely inspected and rebuilt/replaced as required. New screw designs and high temperature heaters can be introduced to meet the needs of processing exotic polymers and compounds. Foam injector ports and vents can introduce or remove gas from the melt stream- many possibilities are available.
Typically the cost to completely rebuild a machine can vary from 40% to 70% of the cost of a new machine. This depends on the condition of the machine and the amount of rebuilding required. New equipment such as melt pressure controllers, extra heating/cooling zones, instrumentation and other features can also be introduced at additional cost.
Yellow Jacket Line Product Overview by Process Type
In addition to the complete line of Wayne Yellow Jacket extruders from 1/4" to 6" for applications from under 1 lb./hour up to 2000 lbs./hour, Wayne manufactures a complete line of dies and downstream equipment for all different types of extrusion processes. This list describes the processes which can be performed by Wayne Yellow Jacket plastic extrusion machinery and what we specifically offer for each. Of course, we offer individual components such as a die or a takeoff in addition to offering integrated systems which consist of an extruder and downstream equipment. For customers who prefer them, we also offer complete turnkey systems with performance guarantee and start-up assistance with on site maintenance.
Blown Film
We build all kinds of Blown Film systems for up to 18" layflats. From very small desktop systems based on 1/4 inch extruders up to systems based on 1 1/2" extruders to make single and multi-layer blown film.
* Bantam Blown Film Equipment Lab desktop sized for up to 4" layflats
* Extruders 1/4" to 6" in low-boy and standard height styles
* Dies 1/2" to 3" for one, two or three layers standard, more layers optional
* Air rings and blowers for above dies
* Take-Offs 15" and 20" wide including top nip, lower nip and winder. Larger widths are available.
Cast Film
Complete cast film systems which range from desktop sized using 1/4" extruders up to 36" wide multilayer coextrusion types are available.
* Bantam Cast Film Equipment Lab desktop sized for up to 6" wide cast film
* Extruders 1/4" to 6" diameter
* Feedblocks for up to 7 layers with variable structures
* Dies Flex lip dies 4" width up to 36"
* Cast Film Take-Offs with chill roll, nip, winder up to 36".
Compounding & Pelletizing
* Bantam Compounding / Pelletizing Equipment Lab desktop sized
* Single Screw Extruders 1/4" to 6" up to 44:1 l/d, optional venting, injection ports
* Twin Screw Co-rotating Extruders 19mm to 50mm segmented screws & barrels, side feeders, gravimetric feeders, liquid injection, vacuum vents
* Water Troughs
* Pelletizers 2" and 3" throat widths
Co-Extrusion
* Extruders Vertical and Satellite 1/4" to 2 1/2"
* Feedblocks for up to 7 layers with variable structures
* Dies For every process listed, we provide co-extrusion dies where required
Fiber
* Extruders 1/4" to 6" diameter
* Fiber Monofilament Spinning System
Fiber Optic Sheathing
We build complete systems for small fiber optic sheathing from the payoff up to the winder! We also supply larger extruders and components on an individual basis.
* Payoffs Single and Dual Turret
* Crosshead Dies
* Extruders 1/4" to 6" for standard and high temperature polymers like FEP optional 90 degree control panels for crosshead die with optional overhung "L" design.
* Water Troughs
* Pullers 2" or 4" belt pullers with standard DC or high accuracy AC Flux Vector or servo drives
* Winders Single and Dual Turret
Laboratory & Research Samples
The entire line of Yellow Jacket extrusion equipment is available in laboratory scale sizes for research and development purposes. Complete lines for every process listed here are available from extruder to downstream equipment.
Monofilament
We offer a desktop monofilament system for laboratory research and development as well as the following individual components:
* Extruders 1/4" to 6" in low-boy and standard height styles
* Fiber Monofilament Spinning System
Pelletizing
Please see Compounding and Pelletizing
Profile & Rod
* Extruders 1/4" to 6" diameter
* Water Troughs
* Vacuum Tanks
* Pullers 2" or 4" belt pullers with standard DC or high accuracy AC Flux Vector or servo drives
* Cutters for profiles up to 1-1/4" with oil shear clutches or servo cutters
* Winders single or dual reel
Sheet
* Bantam Sheet Equipment Lab desktop sized up to 6" wide sheet
* Extruders 1/4" to 6" diameter
* Feedblocks for up to 7 layers with variable structures
* Dies Flex lip dies 4" width up to 36"
* Take-Offs with 3 chill rolls, nip, winder up to 36".
Tubing
Medical and Industrial tubing of all kinds can be made on Wayne Tubing Production Systems. We commonly produce single lumen,multi-lumen, coex stripe, coex multilayer, taper and bump tubing on Wayne systems. Full blown control systems with laser and ultrasonic control including Statistical Process Control are available. Complete PLC based line control is available for recipie storage and data acquisition. High accuracy is maintained by using precision servo drives to make the tightest tolerance tubing possible!
* Extruders 1/4" to 6" diameter
* Crosshead Dies Dies single lumen, multi-lumen, co-extruded stripe or multi-layer type dies
* Air systems to precisely control air pressure for free extrusion sizing in single and multi lumen tubes or to precisely control vacuum levels in vacuum tanks
* WaterTroughs for free extrusion
* Vacuum Tanks with high precision dry vacuum systems, recirculating water system, XYZ adjustment and water trough
* Pullers 2" or 4" belt pullers with standard DC or high accuracy AC Flux Vector or servo drives
* Cutters for profiles up to 1-1/4" with oil shear clutches or servo cutters
* Winders single or dual reel
Wire Insulation
We build complete small scale wire insulation systems and can supply the following individual components. We are well known as the authority in building high temperature machines for FEP and other highly corrosive polymers often used in wire production!
* Payoffs Single and Dual Turret
* Crosshead Dies
* Extruders 1/4" to 6" for standard and high temperature polymers like FEP optional 90 degree control panels for crosshead die with optional overhung "L" design.
* Water Troughs
* Pullers 2" or 4" belt pullers with standard DC or high accuracy AC Flux Vector or servo drives
* Winders Single and Dual Turret
