R&D and Services
Design and industrialization of customized solutions to optimize the plasticizing process
An integrated approach to address the ongoing challenges of plasticizing.
Plastics evolve rapidly, and production-process requirements evolve with them. New polymers and applications emerge every day; as a result, the market demands the development of new plasticizing geometries and new metallurgical and construction solutions that deliver long-lasting performance.
MRS provides customers with multidisciplinary expertise to design and industrialize customized plasticizing screws, plasticizing barrels, and complete plasticizing units. The solutions developed address current needs and strengthen the capabilities required to tackle future challenges.
Addressing the complexity of modern polymers
Contemporary polymers are no longer simple neat materials; they feature superior mechanical properties and a reduced Melt Flow Index (MFI). They are often additionally compounded with fibers, pigments, mineral fillers, blowing agents, and flame retardants, which affect:
- Flowability and rheological behavior
- Thermal profile and melting efficiency
- Wear of the plasticizing unit
- Overall processing conditions
- Beyond these process issues, there is now widespread use of post-consumer recycled (PCR) materials and blends of non-neat polymers, with high variability in composition. These materials are often contaminated and behave differently in plasticizing compared with virgin polymers.
MRS addresses these challenges with solutions that guarantee efficiency and consistency of the plasticizing process even with recycled and mixed polymers, without compromising finished-product quality.
Design approach
To develop high-performance solutions tailored to a specific plasticizing process, MRS integrates expertise in:
- Advanced metallurgy — selection of steels and heat treatments to improve resistance to wear and/or corrosion
- Polymer behavior in plasticizing — analysis of melting and flow behavior
- Design & development — screw and barrel geometries optimized for each process and protected by proprietary patents
- Process engineering — stability, automation, and control of production parameters
Structured process and continuous support
Every new project results from a rigorous, shared pathway:
- Technical analysis & consulting — understanding production processes and customer requirements
- Design & industrialization — definition of geometries, steels, and heat treatments best suited to the goal
- Validation under real conditions — analysis and optimization of plasticizing processes at the customer’s site
- Ongoing technical support — including on-site, during and after delivery
- Field feedback — operational experience that fuels the development of new solutions
Refurbishment of screws, barrels and other components
Refurbishing a component goes beyond repair: it restores full efficiency while optimizing cost, time, and operational reliability.
MRS refurbishes worn components with the same level of care, precision, and quality dedicated to new production. Each restoration is preceded by a comprehensive technical analysis of wear condition, operating conditions, and the production process, in order to recommend and deliver the best recovery process, selecting the most suitable materials and treatments.
