Sawa Electronic regenerate screws and barrels of injection molding machines and extruders in the range up to diameter of 900 mm with lengths up to 8 m. We are a European leader in servicing components of plasticizing systems used in the plastics, food and rubber industries. We have innovative numerical hardfacing machines, using the highest quality plasma arc welding materials for refurbishment.

We perform honing and nitriding the barrels.
• With plasma technology, we carry out hardfacing of the surface of the screw flights to restore the proper diameter, hardness and wear resistance of the flights.
• We are able to change the geometry of the screw by, for example, hardfacing additional flights, adding a mixer, blender or maddock shearing element to improve processing performance.
• We perform spray coating with carbide, which provides extraordinary hardness and wear resistance.
• We also use surface coating e.g. of bushing with bearing bronze.

PTA hardfacing involves melting a powder of suitable composition in a plasma arc in a gaseous atmosphere which together with a slightly melted substrate, such as the top of a screw flight, forms a hardfacing layer. The plasma arc temperature varies between 15'000 °C and 20'000 °C.

For more than 15 years, at Sawa Electronic we have been performing:
• PTA hardfacing using innovative, proprietary digitally controlled machines,
• manual PTA hardfacing as an auxiliary and complementary process.

We work with powder welding consumables, exclusively developed for us in Germany by the world leader in this field, implemented by us in production for the refurbishment of plasticizing systems. These are iron or cobalt-based powders containing, among other things, chromium, molybdenum, and silicon, as well as carbides, with varying hardness according to the customer needs.

The primary and fundamental advantage of the plasma technology we use is the purity and precision, as well as the absolute repeatability of the process during the creation of the hardfacing layer. The material used in the form of powder guarantees high hardness and mechanical and chemical resistance of the hardfacing layer (to acids, alkalis and oxidation), which is the key challenge posed during refurbishment of the screws of plasticizing systems.

We provide:
• new screws, barrels, cylinders, check valves, feed zone bushings, etc. for extrusion and injection equipment in the plastics, food and rubber industries,
• nitrided, bimetallic, tool steel and stainless steel components with special reinforcing coatings – depending on technological and raw material requirements.

New components are produced based on drawing documentation provided by the customer or prepared by our specialists on the basis of parts of plasticizing systems in stock.

We cooperate with our clients in the selection and design of screw geometry according to individual needs, type of raw material, type of machine, nature of production and final product.

We carry out comprehensive wear measurements of system components, examining their hardness, diameter, and finally provide an inventory report.

Our specialists design and manufacture plastic extrusion equipment from Ø45 to Ø100.

For example: the picture shows an extruder for PVC processing with a screw diameter of Ø45, 25 L/D and a capacity of up to 50 kg/h, where 4 temperature control zones are used, with ceramic heaters, air fans, a motor, and an 11 kW inverter.

We use analog or PLC devices for temperature control. Processing parameters are controlled from the control panel or control cabinet.

The extruder meets all safety requirements and standards.

We perform comprehensive repairs of extruders, including:
• reducer repairs and upgrades,
• screen changer repairs,
• adaptations of new components for extruders,
• spray coating of e.g. shafts or mandrels, using carbide, which provides extraordinary hardness and abrasion resistance,
• surface coating e.g. of bushing with bearing bronze,
• other works related to machinery operating in the plastics industry.

In addition, we:
• join broken screws,
• repair damaged screws and barrels,
• remove blocked or broken screws from barrels as well as get out screws with worn screw flights out of barrels.

We carry out comprehensive wear measurements of system components, examining their hardness, diameter, and finally provide an inventory report.