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Electrical - Legacy control systems such as drives and temperature controllers are often in need of repair and/or outdated.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.

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