HDPE MBBR Bio Carrier Extrusion Line

This complete extrusion system is engineered for continuous manufacturing of HDPE MBBR moving bed biofilm carriers, widely applied in municipal sewage treatment, industrial wastewater treatment, aquaculture water purification and other biological water treatment projects. The line adopts mature profile extrusion technology to produce hollow multi-rib MBBR media with stable dimensions, controllable density and excellent suspension performance.

Main Components & Technical Description

1. SJ65 Single Screw Extruder

The SJ65 single-screw extruder serves as the core plasticizing unit. It is equipped with an optimized screw with suitable length‑diameter ratio specially developed for HDPE. The screw and barrel are treated with nitriding to achieve high wear resistance and long service life. The feeding section adopts forced feeding structure to ensure stable material feeding, even when adding masterbatch, anti-UV additives or recycled HDPE. Independent temperature control zones are arranged along the barrel, with precise heating and cooling closed‑loop control to guarantee homogeneous plasticization, stable melt pressure and consistent extrusion output. The main drive adopts frequency conversion / servo drive for stepless speed regulation, which can flexibly adjust production capacity according to production requirements.

2. One-out-Four Multi-cavity Extrusion Die

This custom 4‑cavity extrusion mould is designed for standard MBBR carrier profiles such as K3. The internal flow channel is precisely processed and polished to ensure balanced melt distribution for each cavity. Reasonable runner structure avoids material stagnation and overheating degradation. The mould can form the complete internal rib structure of MBBR carrier in one step, ensuring uniform wall thickness for every single carrier. The mould flange is standardized for quick disassembly. When switching to other specifications including K1, K2 and K5 MBBR media, only the mould and corresponding sizing sleeves need to be replaced.

3. Vacuum Cooling and Calibration Tank

The vacuum calibration tank is the key unit to maintain the profile geometry. It combines vacuum shaping and circulating water cooling. Negative vacuum inside the tank supports the hollow profile, preventing collapse, deformation or shrinkage of the delicate inner ribs right after exiting the die. The tank is fitted with circulating chilled water system, water level regulator and observation window. The cooling speed can be adjusted to control product density precisely, so that the finished MBBR carrier can stay in a suitable suspension state inside the biochemical tank without fully sinking or floating on the water surface.

4. Belt-type Haul-off Machine

The belt haul-off device adopts double-sided clamping traction structure. High-friction anti-slip traction belts grip the extruded profile evenly without squeezing and damaging the hollow carrier structure. It supports synchronous speed linkage with the extruder. The traction speed can be finely adjusted. Stable and constant pulling speed directly controls the final wall thickness, outer diameter and length tolerance of MBBR media. The clamping pressure can be manually or automatically adjusted to adapt to different HDPE formulations and profile stiffness.

5. Fixed-length Cutting Machine

This high-speed rotary cutting machine is specially configured for short MBBR carriers. It tracks the running speed of the profile synchronously and performs flying cut without stopping the line. The cutting blade is sharp and durable. It cuts the continuous extruded profile into preset fixed lengths, delivering neat, flat and non-crushed cutting ends. Length parameters can be set on the control panel. The cutting frequency automatically follows the line speed to keep consistent cutting accuracy during long-time continuous production.

Complete Production Process

HDPE pellets + functional additives → Gravimetric / volumetric feeding → SJ65 extruder plasticization and melting → One-out-four die forming → Vacuum calibration & water cooling → Belt haul-off and speed synchronization → Synchronous fixed-length cutting → Finished MBBR carriers discharging

Core Advantages

1. Continuous 24-hour stable operation, suitable for large-volume commercial production of MBBR bio media.
2. Good overall synchronization among extruder, haul-off and cutter, low reject rate.
3. Flexible mould switching to produce mainstream MBBR carrier models.
4. Precise density control to meet fluidization requirements in moving bed bioreactors.
5. Compact layout, easy operation and convenient daily maintenance.
6. Support adding anti-ultraviolet masterbatch to produce outdoor anti-aging MBBR fillers.