Extreme Coatings A division of Surface Engineering & Alloy Company

2895 46th Avenue North , 33714 St. Petersburg, FL
USA

Telephone +1 727 528-7998
Fax +1 727 528-7995
ShelleyC@ExtremeCoatings.net

Trade fair hall

  • Hall 13 / B91-6
 Interactive Plan

Hall map

K 2016 hall map (Hall 13): stand B91-6

Fairground map

K 2016 fairground map: Hall 13

Our range of products

Product categories

  • 02  Semi-finished products,parts and reinforced plastics
  • 02.05  Products
  • 02.05.007  Coatings

Coatings

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.01  Machines and equipment for preprocessing and recycling
  • 03.01.001  Mixers
  • 03.01.001.01  Mixers, continuous type, for solids

Mixers, continuous type, for solids

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.02  Machinery and plant for processing
  • 03.02.001  Extruders and extrusion lines
  • 03.02.001.01  Extruders
  • 03.02.001.01.02  Twin screw extruders

Twin screw extruders

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.10  Parts and components
  • 03.10.001  Screws
  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.10  Parts and components
  • 03.10.004  Nozzles

Nozzles

  • 03  Machinery and equipment for the plastics and rubber industries
  • 03.10  Parts and components
  • 03.10.006  Machine blades

Machine blades

Our products

Product category: Screws

Feedscrews

What
The heart of an injection molding or extrusion machine is the feedscrew and barrel. The feedscrew is designed to transport, compress and inject or pump melt into a mold or through a shaping die. Feedscrews are most efficient when new and become mush less efficient with a small amount of wear.

Why
Protecting feedscrews from wear to maintain this like-new efficiency is how we began our support of the plastics industry in 1996. Demand from the automotive industry for light-weight, high performance materials lead to a revolution in plastics formulations that are very abrasive and corrosive to standard steels. In response to requests to improve feedscrew life we developed our CarbideX line of thermal spray coatings. The rest is as they say is “history”.

How
We utilize our coating process to encapsulate feedscrews with a hard, dense layer of high percent of fine carbides that outperforms all other alloys and tool steels in abrasive wear. The protective coating layer also isolates the feedscrew steel from the process and provides exceptional corrosion resistance. We have various formulas to apply based on your application(s) need.

We can offer a variety of coating options, full encapsulation or partial encapsulation or flight lands only for the entire flight length on any portion to tailor a high value solution to any specific requirement.

What you can expect
From experience with more than 25,000 coated feedscrews we offer our double life guarantee. Our CarbideX formulations will provide two to five times more longer life than anything you may have used before. Performance is typically 2-4 times the output compared to your standard feedscrew.

The Results
Tight tolerance of close tolerance system maintained
Cost per pound or kilogram/hour decreases
Screws last at least two times longer
Two to four times more production
Less preventive maintenance (DOWNTIME)
Barrel life is improved
Scrap rate decreases

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Product category: Screws

Parallel Twin Feedscrews

Twin feedscrews can now be coated to offer the highest wear resistance and, more importantly, superior corrosion resistance for tough materials like CPVC.  e highest wear resistance and, more importantly, superior corrosion resistance for tough materials like CPVC.

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Product category: Screws

Co-Rotating Twin Feedscrews

Co-rotating twin feedscrew extruders are the machine of choice to compound resins and add fillers to a product. These machines have the benefit of a small footprint, short L/D, high throughput rates at lower melt temperatures and a self-wiping action flight to flight.

These machines are usually starve-fed and the normal filled volume and pressure in the machines is very low. As conveying elements transition to kneading elements, filled volume approaches 100% and pressure spikes. It is in this transition that most wear occurs, in the last conveying element and the first kneading blocks.

Extreme Coatings has developed our SF coatings to bring our success in single and parallel twin screws to co-rotating screw designs.

We apply .030” (.75 mm) coating thickens (.060”, 1.4 mm overall) to an element that has been specially pre-ground to accept this layer of coating. A post coating furnace fusing ensures this layer has a metallurgical bond to the element before final grinding and polish.

The result is a high percentage carbide layer, higher than used on traditional twin feedscrew elements, which can provide from two to four times more wear life depending on fill loading.

Extreme Coatings is working with major equipment manufacturers to refine the process and improve application techniques and coating formulations.

The targeted use of carbide coated elements in high pressure zones of co-rotating extruders can help maximize equipment life, maintain consistent production, ensure product quality, and reduce operating costs.

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Product category: Screws

Continuous Mixing Rotors

Continuous mixers provide high intensity mixing of viscous materials and allow the incorporation of fillers in compounding applications. These are counter-rotating, non-intermeshing twin rotors that often feed a hot extruder downstream.

The leading edges of mixing zones are weld protected with cobalt based Stellite hard facing and hard chrome plating on the entire surface.

Our C1000 tungsten carbide has been used as chrome replacement in aggressive applications. C1000 doubles the working life of rotors compared to hard chrome plating. We apply a minimum of .010” to .015” (.25 - .38 mm) thickness with a 16-32 RMS (.2-.4 Ra) surface finish after coating.

C1000 has become an industry standard where aggressive processing is planned.

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Product category: Screws

Mixer Bodies

Continuous and batch mixer housings/chambers experience wear in high fill compounding applications. Just like with twin rotors, Extreme Coatings can protect these housings and liners with XC1000 tungsten carbide. This is a .015” (.38 mm) thick deposit of our wear-resistant 88% tungsten carbide. Our mirror surface finish ensures ease of cleaning between discrete batches or product changeover.

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Company news

Date

Topic

Download

Sep 20, 2016

FOR IMMEDIATE PRESS RELEASE

Extreme Coatings Presenting Wear Resistance Technology at the 2016 K Trade Fair for Plastic and Rubber Industries - Super-wear-resistant tungsten carbide coating of plasticizing feedscrews will be highlighted

St. Petersburg, FL USA - September 20, 2016

Extreme Coatings is the global leader for wear resistance technology, with more than thirty-five thousand (35,000) feedscrews coated over the past twenty (20) years.  The newest development from Extreme Coatings is CarbideX CPR for encapsulation of conical and parallel twin feedscrews.  This new and improved technology was prompted by environmental concerns with chrome plating and the need for better protection against wear and corrosion.

At the K-Show Extreme Coatings will present their full range of products and services and will educate visitors on wear resistance.  Visitors will see samples of tungsten and chromium carbide encapsulation on a variety of components, including single screw injection molding and extrusion screws, twin extrusion screws, continuous mixing rotors and their Cushion Master carbide tip assemblies for injection molding screws.  Detailed exhibits will explain how carbide provides two to five times longer equipment life.

Extreme Coatings’ Chrome Plating Replacement, or CPR, provides a viable alternative to chrome plating.  Unlike chrome plating, CPR is nearly porosity free, so corrosive gasses from PVC cannot attack the base of the screw.  Furthermore, CPR is environmentally friendly.  In applications where abrasive fillers cause premature wear, Extreme Coatings offers tungsten carbide encapsulation that provides superior wear resistance combined with a high level of corrosion resistance – minimizing wear and maximizing profit.

Curt Kadau, President of Extreme Coatings, explains, “Advancements in polymer technology demand parallel advancements in feedscrew and processing technology.  Extreme Coatings has kept pace with these advancements and will continue to develop new products to meet the demands of our customers.”

The K Show will be held October 19 – 26 in Dusseldorf, Germany. Extreme Coatings will be exhibiting in Hall 13, Stand B91-6.

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Sep 20, 2016

EXTRUSION: Tungsten Carbide Coating of Plasticizing Feedscrews

Coating addresses environmental concerns with chrome plating and the need for better protection against wear and corrosion.

Extreme Coatings, St. Petersburg, Fl., will introduce CarbideX CPR for encapsulation of conical and parallel twin feedscrews at K 2016 (Hall 13, Stand B91-6). Extreme Coatings says its Chrome Plating Replacement, or CPR, provides a viable alternative to chrome plating. Unlike
chrome plating, CPR is nearly porosity free, so corrosive gasses from materials like PVC cannot attack the base of
the screw.

In applications where abrasive fillers cause premature wear, Extreme Coatings offers tungsten carbide encapsulation for greater wear resistance combined with a high level of corrosion resistance. At the show, the company will have samples of tungsten and chromium carbide encapsulation on a variety of components, including single screw injection molding and extrusion screws, twin extrusion screws, and continuous mixing
rotors, as well as Extreme’s Cushion Master carbide tip assemblies for injection molding screws.

Plastics Technology - Online, Posted 9/20/2016

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Sep 1, 2016

Plastics Machinery, Product Innovations: Coating Strengthens Granulator Blades

Granulator Blade Coatings Extreme Coatings, St. Petersburg, Florida, now is offering a coating that transforms a standard steel blade into a carbide-edge blade. The company, which normally handles coatings for screws, markets the blade coating and its application through WITAK INC. The coating is especially useful for processors dealing with tough materials. For example, it offers protection against calcium carbonate, which is often used as a filler material in plastic trash cans.

What’s New? Use of a 0.001-0.002 inch-thick CarbideX C1000 tungsten carbide coating on granulator and grinder blades.

 Benefits: Tougher, more resilient cutting surfaces where blades require less frequent sharpening and have a greater service life.

Plastics Machinery, Issue September 2016, page 49, plasticsmachinery.com

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Jun 1, 2016

Coating formulations preserve, enhance plating

Tungsten and ceramic coatings from two suppliers raise the bar on wearand
corrosionresistancefor plasticizing equipment.

The efficiency of plasticizing equipment decreases dramatically when
mechanical and physical components that process the polymers wear. “When
the clearance between the outer diameter of the feed screw and the inner
diameter of the barrel increases to twice the gap tolerance set by the original
equipment manufacturer, output can decrease by 25 percent,” said Greg
Quinn, senior VP for the plastic and rubber industry, Extreme Coatings
Engineered Surfaces. The St. Petersburg, Fla., company supplies tungstencarbide
coating formulations.

“A widening of the gap between the top of the screw flight and the inner barrel
wall of as little as 0.015 inch can cause excessive scrap generation and
machine downtime,” Quinn said.

Poor melt quality is more likely as the wear increases. When wear widens the screw and barrel clearance, a
processor has several choices to remedy the problem.

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About us

Company details

With more than thirty-five thousand (35,000) coated feedscrews over the past twenty (20) years, Extreme Coatings is the global leader for wear-resistant coating solutions, offering effective, solution-oriented approaches, incorporating advanced thermal spray technology and proprietary coating formulations.

Extreme Coatings encapsulates complex industrial components, protecting them from wear and corrosion. Higher wear resistance in feedscrews provide longer service life, increased productivity, and decreased machine downtime.

The newest development from Extreme Coatings is CarbideX CPR for encapsulation of parallel twin feedscrews.  Environmental concerns with chrome plating and the need for better protection against wear and corrosion initiated the development for new and improved technology.

We use state-of-the-art HVOF thermal spray technology to apply wear and corrosion resistant coatings. Extreme Coatings is a world leader for Tungsten Carbide Coatings on injection molding and extrusion feedscrews and mixing rotors in the plastics industry.

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Company data

Sales volume

20 - 100 Mill. US $

Export content

max. 25%

Number of employees

31 - 100

Foundation

1996

Area of business

Services for the plastics and rubber industries

Target groups
  • Plastic product manufacturing
  • Rubber manufacturing / processing

Company information as a PDF file