In the rapidly evolving landscape of polymer processing, thermoplastic elastomers (TPEs) have emerged as a versatile and indispensable class of materials, bridging the gap between rigid plastics and elastic rubbers. Their unique combination of thermoplastic processability and elastomeric flexibility has made them the material of choice across a wide range of industries, from automotive and electronics to construction and consumer goods. Zhuoyue, a leader in extrusion technology, is dedicated to providing state-of-the-art co-rotating parallel twin-screw extruders specifically engineered for the compounding and processing of TPEs, including TPE/SBS/TPU/TPR/TPV and other related composites. With a deep understanding of TPE material properties and industry application needs, Zhuoyue’s extruder series deliver unmatched performance, efficiency, and reliability, empowering manufacturers to unlock the full potential of these advanced materials.

1. An Overview of Thermoplastic Elastomers (TPEs)

Elastomer Termoplastik (TPEs), sometimes referred to as Thermoplastic Rubbers (TPRs), are a diverse family of materials that exhibit the dual characteristics of thermoplastics and elastomers. Unlike traditional cross-linked rubbers, which are infusible and insoluble once cured, TPEs can be melted and reprocessed using standard thermoplastic processing methods such as extrusion, injection molding, and blow molding, while maintaining excellent elastic recovery and flexibility at room temperature. This unique duality stems from their molecular structure: TPEs are typically either copolymers (polymers composed of two or more different monomer units) or physical blends of a plastic component and a rubber component, where the plastic phase forms a continuous matrix that softens and flows when heated, and the rubber phase provides elasticity and resilience.

The key advantages of TPEs over conventional rubbers and plastics have driven their widespread adoption in modern manufacturing. These advantages include: excellent processability (allowing for high-speed production and complex part geometries), recyclability (reducing material waste and environmental impact), good chemical resistance, superior mechanical properties (such as tensile strength, elongation at break, and abrasion resistance), and the ability to be colored, textured, or modified to meet specific application requirements. Additionally, TPEs offer cost savings in production due to shorter cycle times, reduced energy consumption, and the elimination of curing steps required for traditional rubbers.

As the demand for lightweight, durable, and sustainable materials continues to grow, TPEs have become increasingly important in industries such as automotive (for lightweighting and noise reduction), electronics (for flexible and durable components), and consumer goods (for comfortable and ergonomic products). To fully leverage the benefits of TPEs, manufacturers require processing equipment that can handle the unique challenges of these materials, including their sensitivity to temperature, shear rate, and mixing uniformity. Zhuoyue’s co-rotating parallel twin-screw extruders are specifically designed to address these challenges, ensuring consistent, high-quality TPE compounds with optimal performance.

2. The Six General Categories of Commercial TPEs

Commercial TPEs are classified into six main categories based on their chemical composition, molecular structure, and performance characteristics. Each category has unique properties that make it suitable for specific applications, and Zhuoyue’s extruder series are engineered to handle the processing requirements of each type, ensuring optimal compounding results. Below is a detailed overview of each category, including their structure, properties, and typical applications:

2.1 Styrenic Block Copolymers (TPS, TPE-s)

Styrenic Block Copolymers (TPS), also known as TPE-s, are the most widely used and versatile category of TPEs, accounting for a significant share of the global TPE market. They are composed of alternating blocks of styrene (a rigid thermoplastic monomer) and a diene (a flexible elastomeric monomer), typically butadiene, isoprene, or their hydrogenated derivatives. The most common TPS types include Styrene-Butadiene-Styrene (SBS), Styrene-Isoprene-Styrene (SIS), Hydrogenated SBS (SEBS), and Hydrogenated SIS (SEPS).

The unique block structure of TPS gives them their characteristic properties: the styrene blocks form hard, glassy domains at room temperature that act as physical cross-links, providing mechanical strength and shape stability, while the diene blocks form soft, rubbery domains that impart elasticity and flexibility. When heated above the glass transition temperature of the styrene blocks (typically around 100°C), the hard domains soften and flow, allowing the material to be processed like a thermoplastic; when cooled, the hard domains re-form, restoring the elastomeric properties.

Key properties of TPS include excellent flexibility, good tensile strength, low density, superior processability, and compatibility with a wide range of additives (such as plasticizers, fillers, and stabilizers). They also exhibit good resistance to water, oils, and chemicals, although hydrogenated TPS (SEBS, SEPS) offer improved resistance to oxidation and heat compared to non-hydrogenated types (SBS, SIS).

Typical applications of TPS include: automotive components (weatherstripping, door seals, dashboard trim, and shock absorbers), consumer goods (toys, grips, handles, and footwear soles), medical devices (catheter tubing, syringe plungers, and medical seals), and adhesives and sealants (hot-melt adhesives, pressure-sensitive adhesives). Zhuoyue’s extruders are optimized for TPS processing, with precise temperature control and efficient mixing capabilities to ensure uniform dispersion of additives and consistent material properties.

2.2 Thermoplastic Polyolefin Elastomers (TPO, TPE-o)

Thermoplastic Polyolefin Elastomers (TPO), or TPE-o, are physical blends of a polyolefin (typically polypropylene, PP) and an elastomer (typically ethylene-propylene-diene monomer, EPDM). Unlike TPS, which are copolymers, TPOs are heterogeneous blends where the polyolefin forms a continuous matrix and the elastomer forms discrete rubbery domains. The properties of TPOs can be tailored by adjusting the ratio of polyolefin to elastomer, as well as the type and amount of additives (such as fillers, antioxidants, and UV stabilizers).

TPOs offer a unique combination of properties, including excellent weather resistance, good chemical resistance (especially to acids, bases, and alcohols), low density, high impact strength, and good processability. They are also cost-effective compared to other TPE categories, making them a popular choice for large-volume applications. Additionally, TPOs are recyclable and can be blended with other polyolefins to improve performance or reduce costs.

One of the key advantages of TPOs is their excellent resistance to UV radiation and ozone, which makes them ideal for outdoor applications. They also have good thermal stability, with continuous use temperatures ranging from -40°C to 120°C, depending on the formulation. TPOs are available in a wide range of hardness levels, from soft and flexible (Shore A 50) to rigid (Shore D 70), making them suitable for a variety of applications.

Typical applications of TPOs include: automotive components (bumper covers, fenders, door panels, and underbody shields), construction materials (roofing membranes, window seals, and decking), consumer goods (lawn and garden equipment, sports equipment, and luggage), and industrial components (hoses, gaskets, and seals). Zhuoyue’s extruders are equipped with specialized screw designs and temperature control systems to ensure uniform mixing of the polyolefin and elastomer phases, preventing phase separation and ensuring consistent material performance.

2.3 Thermoplastic Vulcanizates (TPV, TPE-v)

Thermoplastic Vulcanizates (TPV), also known as TPE-v, are a subset of TPOs that undergo a dynamic vulcanization process during compounding. Dynamic vulcanization involves heating the blend of polyolefin and elastomer to a temperature above the melting point of the polyolefin, while simultaneously adding a vulcanizing agent (such as sulfur or peroxide) to cross-link the elastomer phase. The result is a material where the elastomer phase is fully cross-linked (vulcanized) into discrete particles, dispersed within a continuous polyolefin matrix.

The dynamic vulcanization process gives TPVs superior properties compared to conventional TPOs, including higher elasticity, better compression set resistance, improved tensile strength, and enhanced resistance to heat, oils, and chemicals. TPVs also maintain their elastomeric properties over a wider temperature range, with continuous use temperatures up to 150°C, making them suitable for high-temperature applications. Additionally, TPVs are fully recyclable, even after processing, which is a significant advantage over traditional cross-linked rubbers.

Key properties of TPVs include excellent flexibility, good abrasion resistance, superior compression set (the ability to return to their original shape after being compressed), and good processability. They are available in a wide range of hardness levels, from Shore A 30 to Shore D 80, and can be formulated to meet specific application requirements, such as flame retardancy, UV resistance, or food contact compliance.

Typical applications of TPVs include: automotive components (engine gaskets, fuel system seals, and HVAC hoses), industrial components (hydraulic hoses, O-rings, and gaskets), consumer goods (appliance seals, tool handles, and footwear), and medical devices (sterilizable components and drug delivery systems). Processing TPVs requires precise control of temperature, shear rate, and vulcanization time, and Zhuoyue’s extruders are specifically designed to handle these requirements, with advanced mixing sections and temperature control systems to ensure uniform vulcanization and consistent material properties.

2.4 Thermoplastic Polyurethanes (TPU)

Thermoplastic Polyurethanes (TPU) are a class of TPEs composed of alternating blocks of hard and soft segments. The hard segments are typically derived from diisocyanates (such as MDI or TDI) and chain extenders (such as ethylene glycol or butanediol), while the soft segments are derived from polyols (such as polyester or polyether polyols). The ratio of hard to soft segments determines the properties of the TPU: higher hard segment content results in a harder, more rigid material, while higher soft segment content results in a softer, more flexible material.

TPUs offer a unique combination of properties, including excellent tensile strength, high elongation at break, superior abrasion resistance, good flexibility at low temperatures, and excellent resistance to oils, greases, and chemicals. They also have good processability, allowing for extrusion, injection molding, and blow molding into complex shapes. Additionally, TPUs can be formulated to be transparent, flame-retardant, or biodegradable, making them suitable for a wide range of applications.

There are two main types of TPUs: polyester-based TPUs and polyether-based TPUs. Polyester-based TPUs offer superior mechanical properties, abrasion resistance, and chemical resistance, making them suitable for applications such as industrial hoses, belts, and footwear. Polyether-based TPUs offer better low-temperature flexibility, water resistance, and biocompatibility, making them ideal for medical devices, sports equipment, and outdoor applications.

Typical applications of TPUs include: automotive components (airbags, seat belts, and suspension bushings), industrial components (hoses, belts, and gaskets), consumer goods (footwear soles, sports equipment, and phone cases), medical devices (catheters, wound dressings, and implantable devices), and electronics (cable jackets and connectors). Processing TPUs requires precise temperature control to prevent degradation, and Zhuoyue’s extruders are equipped with specialized screw designs and temperature zones to ensure gentle processing and consistent material properties.

2.5 Thermoplastic Copolyesters (TPC, TPE-E)

Thermoplastic Copolyesters (TPC), also known as TPE-E, are block copolymers composed of hard polyester segments and soft polyether segments. The hard segments are typically derived from aromatic polyesters (such as polyethylene terephthalate, PET, or polybutylene terephthalate, PBT), while the soft segments are derived from polyethers (such as polyethylene glycol, PEG, or polypropylene glycol, PPG). The block structure of TPCs gives them a unique balance of mechanical strength, flexibility, and chemical resistance.

Key properties of TPCs include excellent tensile strength, high elongation at break, superior fatigue resistance, good thermal stability, and excellent resistance to oils, greases, and chemicals. They also have good processability, allowing for extrusion, injection molding, and thermoforming into complex shapes. TPCs maintain their properties over a wide temperature range, with continuous use temperatures ranging from -40°C to 150°C, making them suitable for high-temperature and low-temperature applications.

TPCs are known for their excellent fatigue resistance, which makes them ideal for applications that require repeated flexing or stress, such as hinges, springs, and automotive suspension components. They also have good adhesion to other materials, such as metals and plastics, making them suitable for multi-material assemblies. Additionally, TPCs are recyclable and can be blended with other polyesters to improve performance or reduce costs.

Typical applications of TPCs include: automotive components (suspension bushings, door hinges, and exhaust hangers), industrial components (gears, bearings, and conveyor belts), consumer goods (sports equipment, toys, and furniture), and medical devices (surgical instruments and implantable devices). Processing TPCs requires precise control of temperature and shear rate to prevent degradation, and Zhuoyue’s extruders are equipped with advanced mixing sections and temperature control systems to ensure uniform processing and consistent material properties.

2.6 Thermoplastic Polyamides (TPA, TPE-A)

Thermoplastic Polyamides (TPA), also known as TPE-A, are block copolymers composed of hard polyamide segments and soft polyether segments. The hard segments are typically derived from aliphatic or aromatic polyamides (such as nylon 6, nylon 66, or nylon 12), while the soft segments are derived from polyethers (such as polyethylene glycol, PEG, or polypropylene glycol, PPG). The block structure of TPAs gives them a unique combination of mechanical strength, flexibility, and chemical resistance.

Key properties of TPAs include excellent tensile strength, high impact strength, superior abrasion resistance, good thermal stability, and excellent resistance to oils, greases, and chemicals. They also have good processability, allowing for extrusion, injection molding, and blow molding into complex shapes. TPAs maintain their properties over a wide temperature range, with continuous use temperatures ranging from -40°C to 170°C, making them suitable for high-temperature applications.

TPAs are known for their excellent adhesion to metals, which makes them ideal for applications such as automotive fuel lines and hydraulic hoses, where bonding to metal components is required. They also have good resistance to hydrolysis, which makes them suitable for wet or humid environments. Additionally, TPAs are recyclable and can be blended with other polyamides to improve performance or reduce costs.

Typical applications of TPAs include: automotive components (fuel lines, hydraulic hoses, and gearshift knobs), industrial components (hoses, gaskets, and seals), consumer goods (footwear, sports equipment, and luggage), and medical devices (catheters and implantable devices). Processing TPAs requires precise temperature control to prevent degradation, and Zhuoyue’s extruders are equipped with specialized screw designs and temperature zones to ensure gentle processing and consistent material properties.

3. Application Areas of TPEs

Thermoplastic elastomers (TPEs) are used in a wide range of industries due to their unique combination of properties, including flexibility, processability, daya tahan, and chemical resistance. From automotive and electronics to construction and consumer goods, TPEs are enabling innovation and improving the performance of products across multiple sectors. Below is a detailed overview of the key application areas of TPEs, along with specific examples of products and the TPE categories typically used:

3.1 Automotive Industry

The automotive industry is the largest consumer of TPEs, accounting for a significant share of the global TPE market. TPEs are used in a wide range of automotive components, from interior trim to under-the-hood parts, due to their lightweight, daya tahan, and ability to reduce noise, vibration, and harshness (NVH). The shift towards electric vehicles (EVs) has further increased the demand for TPEs, as they are ideal for lightweighting (to improve battery range) and for manufacturing flexible components such as charging cables and battery seals.

Specific automotive applications of TPEs include:

• Dust Covers: Used to protect automotive components such as suspension systems, steering systems, and drivetrain components from dust, dirt, and moisture. TPS (SEBS) and TPV are typically used for dust covers due to their excellent flexibility, abrasion resistance, and weather resistance.
• Quarter Windows: Flexible quarter windows are used in some automotive models to improve aerodynamics and reduce wind noise. TPU and TPC are typically used for quarter windows due to their excellent transparency, impact resistance, and UV resistance.
• Air Filters: TPEs are used in the construction of air filter housings and gaskets, providing a tight seal to prevent unfiltered air from entering the engine. TPO and TPV are typically used for air filter components due to their good chemical resistance and thermal stability.
• Handles and Grips: TPEs are used for automotive handles (such as door handles and steering wheel grips) to provide a comfortable, non-slip surface. TPS (SEBS) and TPU are typically used for handles and grips due to their excellent softness, grip, and durability.
• Weatherstripping and Seals: Door seals, window seals, and hood seals are critical for preventing water, air, and noise from entering the vehicle interior. TPO, TPV, and TPS are typically used for weatherstripping due to their excellent flexibility, compression set resistance, and weather resistance.
• Under-the-hood Components: TPEs are used for under-the-hood components such as engine gaskets, fuel system seals, and HVAC hoses. TPV, TPC, and TPA are typically used for under-the-hood components due to their excellent thermal stability, chemical resistance, and oil resistance.
• Interior Trim: TPEs are used for interior trim components such as dashboard trim, door panels, and seat trim. TPS (SEBS) and TPO are typically used for interior trim due to their excellent softness, colorability, and low VOC emissions (volatile organic compounds), which are important for improving indoor air quality.

Zhuoyue’s extruders are specifically engineered for automotive TPE applications, with precise temperature control and efficient mixing capabilities to ensure consistent material properties. The HTS series, in particular, is ideal for processing high-performance TPEs used in under-the-hood components, while the ZTE series offers cost-effective solutions for interior trim and other non-critical components.

3.2 Wire and Cable Industry

The wire and cable industry is another major consumer of TPEs, as TPEs offer excellent electrical insulation, flexibility, and durability, making them ideal for manufacturing a wide range of wires and cables. TPEs are used for both insulation and jacketing of wires and cables, and they are particularly suitable for applications that require flexibility, such as portable electronics, automotive wiring, and industrial cables.

Specific wire and cable applications of TPEs include:

• Power Cables: TPEs are used for the insulation and jacketing of power cables, providing excellent electrical insulation and protection against moisture, chemicals, and abrasion. TPU, TPC, and TPV are typically used for power cables due to their excellent electrical properties and durability.
• Ignition Cables: Ignition cables are used in automotive engines to transmit high-voltage electricity from the ignition coil to the spark plugs. TPEs are used for the insulation of ignition cables, providing excellent high-temperature resistance and electrical insulation. TPV and TPC are typically used for ignition cables due to their excellent thermal stability and chemical resistance.
• Headphone Cables: Headphone cables require flexibility, daya tahan, and good sound transmission properties. TPS (SEBS) and TPU are typically used for headphone cables due to their excellent flexibility, softness, and abrasion resistance.
• Connector Plugs: Connector plugs are used to connect wires and cables to electronic devices, and they require good electrical insulation, daya tahan, and ease of processing. TPS (SEBS) and TPO are typically used for connector plugs due to their excellent processability and electrical properties.
• Industrial Cables: Industrial cables are used in harsh industrial environments, requiring resistance to chemicals, oils, and abrasion. TPU, TPC, and TPA are typically used for industrial cables due to their excellent chemical resistance and durability.

Processing wire and cable insulation and jacketing requires precise control of extrusion temperature and speed to ensure uniform thickness and good adhesion to the conductor. Zhuoyue’s HTE series is particularly well-suited for wire and cable applications, as it combines high performance with high cost-effectiveness, delivering higher output while reducing energy consumption.

3.3 Construction and Transportation Industry

The construction and transportation industry uses TPEs for a wide range of applications, including building materials, transportation infrastructure, and marine components. TPEs are valued in this industry for their durability, weather resistance, and ability to withstand harsh environmental conditions.

Specific construction and transportation applications of TPEs include:

• Sealing Strips: Sealing strips are used in buildings (such as windows, doors, and roofs) to prevent water, air, and noise from entering. TPO, TPV, and TPS are typically used for sealing strips due to their excellent flexibility, compression set resistance, and weather resistance.
• Expansion Joints: Expansion joints are used in bridges, roads, and buildings to absorb thermal expansion and contraction, preventing cracks and damage. TPV and TPC are typically used for expansion joints due to their excellent elasticity, fatigue resistance, and durability.
• Subway Mats: Subway mats are used in subway stations to provide a non-slip surface, reduce noise, and improve passenger comfort. TPS (SEBS) and TPU are typically used for subway mats due to their excellent softness, grip, and abrasion resistance.
• Roofing Membranes: TPE roofing membranes are used for flat roofs, providing excellent water resistance, weather resistance, and durability. TPO and TPV are typically used for roofing membranes due to their excellent UV resistance and chemical resistance.
• Marine Components: TPEs are used for marine components such as boat fenders, dock bumpers, and hull seals, providing excellent resistance to saltwater, UV radiation, and abrasion. TPU and TPC are typically used for marine components due to their excellent water resistance and durability.

Construction and transportation applications often require large-volume production of TPE components, and Zhuoyue’s extruders are designed to handle high-output requirements while maintaining consistent quality. The ZTE series offers excellent cost-effectiveness for large-volume applications, while the HTS series is suitable for high-performance components that require superior durability.

3.4 Other Industrial and Consumer Applications

In addition to the major industries mentioned above, TPEs are used in a wide range of other industrial and consumer applications, leveraging their versatility and unique properties. These applications include:

• Drainage Pipes: TPE drainage pipes are used in residential and industrial applications, providing excellent flexibility, corrosion resistance, and durability. TPO and TPV are typically used for drainage pipes due to their excellent chemical resistance and ease of installation.
• Handles and Grips: TPEs are used for handles and grips in a wide range of consumer and industrial products, including tools, kitchenware, and sports equipment. TPS (SEBS) and TPU are typically used for handles and grips due to their excellent softness, grip, and durability.
• Coasters: TPE coasters are used to protect furniture from water damage and scratches, providing a non-slip surface. TPS (SEBS) and TPU are typically used for coasters due to their excellent softness, colorability, and ease of cleaning.
• Floor Mats: TPE floor mats are used in homes, offices, and vehicles to provide a non-slip surface, reduce noise, and protect floors. TPS (SEBS) and TPO are typically used for floor mats due to their excellent durability, abrasion resistance, and ease of cleaning.
• Footwear: TPEs are used in footwear applications such as shoe soles, insoles, and uppers, providing excellent comfort, flexibility, and abrasion resistance. TPS (SBS, SEBS), TPU, and TPV are typically used for footwear due to their excellent cushioning properties and durability.
• Medical Devices: TPEs are used in a wide range of medical devices, including catheters, syringe plungers, wound dressings, and implantable devices. TPU, TPC, and TPA are typically used for medical devices due to their excellent biocompatibility, sterilizability, and chemical resistance.
• Toys: TPEs are used in toys for children, providing a soft, safe, and durable material. TPS (SEBS) and TPU are typically used for toys due to their excellent softness, colorability, and non-toxicity (compliant with food contact and toy safety standards).

4. Technical Specifications of Zhuoyue’s Co-rotating Parallel Twin-screw Extruders

Processing thermoplastic elastomers (TPEs) requires specialized extrusion equipment that can handle the unique properties of these materials, including their sensitivity to temperature, shear rate, and mixing uniformity. Zhuoyue offers a comprehensive range of co-rotating parallel twin-screw extruders, each designed to meet the specific needs of TPE processing, from low-cost, high-volume applications to high-performance, precision compounding. The extruders are available in three main series: HTS, ZTE, and HTE, each with unique features and advantages to suit different application requirements and budget constraints.

All of Zhuoyue’s extruders feature a co-rotating parallel twin-screw design, which offers several advantages over single-screw extruders for TPE processing: better mixing uniformity (critical for TPE blends and composites), higher throughput, better temperature control, and the ability to process a wide range of materials and additives. The twin-screw design also allows for precise control of shear rate, which is important for maintaining the integrity of TPE molecular structures and preventing degradation.

4.1 ZG Series Gearboxes – High-efficiency Transmission and Power Proportioning Total Solution

At the heart of every Zhuoyue extruder is the ZG series gearbox, a high-efficiency transmission system that provides reliable power delivery and precise speed control. Developed and manufactured in-house by Zhuoyue, the ZG series gearboxes feature a symmetrical force-driven structure, which is different from the traditional parallel three-shaft structure used in many other extruders. This unique design offers several key advantages:

• High Torque: The symmetrical force-driven structure distributes torque evenly across the gears, allowing for higher torque capacity and improved durability, which is critical for processing high-viscosity TPEs and filled composites.
• High Speed: The gearbox is designed to operate at high speeds, enabling higher extrusion throughput while maintaining precise control.
• High Precision: The symmetrical design ensures precise alignment of the screws, reducing wear and tear and improving the uniformity of the extruded material.
• High Efficiency: The improved transmission efficiency reduces energy consumption, lowering operating costs for manufacturers.
• Low Noise: The symmetrical force distribution reduces vibration and operating noise, creating a more comfortable working environment.
• Improved Reliability and Safety: The robust design and high-quality materials used in the ZG series gearboxes ensure long-term reliability and safety, reducing downtime and maintenance costs.

The ZG series gearboxes are available in a range of sizes and configurations to match the specific requirements of each extruder series, ensuring optimal performance and efficiency for TPE processing.

4.2 Core Technical Features of Zhuoyue’s Extruders

In addition to the ZG series gearboxes, all of Zhuoyue’s co-rotating parallel twin-screw extruders share a set of core technical features that make them ideal for TPE processing:

• Small Die with Multiple Teeth: The extruder die is designed with multiple small teeth, which improves the uniformity of the extruded material and reduces die swell, a common issue in TPE processing.
• Stable Running, Noise Reduction Optimized Load Equalization Structure: The extruder’s load equalization structure is optimized to reduce vibration and noise, ensuring stable operation even at high speeds and high torques.
• Optimized Tooth Orientation and Tooth Profile: The screw teeth are oriented and profiled to improve mixing efficiency and material conveying, ensuring uniform dispersion of additives and consistent material properties.
• Reduced Shock Vibration and Noise, Increased Gear Carrying Capacity and Reliability: The optimized gear design reduces shock vibration and noise, while increasing the gear carrying capacity and overall reliability of the extruder.
• Maximum Specific Torque 16.5Nm/Cm³: The extruders are capable of delivering a maximum specific torque of 16.5Nm/Cm³, which is sufficient for processing even the most demanding TPEs, including filled composites and high-viscosity materials.
• Stable Output Accuracy Without Degradation: The extruders maintain stable output accuracy over long periods of operation, with no degradation in material properties, ensuring consistent product quality.
• Long Service Life (72,000h): The high-quality materials and robust design of the extruders ensure a long service life of up to 72,000 jam, reducing the need for frequent replacement and maintenance.
• High Maximum Speed (Up to 1200rpm): The extruders are capable of operating at speeds of up to 1200rpm, enabling high throughput and efficient production of TPE components.

4.3 HTS Series – High-end, High-performance Extruders

The HTS series is Zhuoyue’s flagship line of co-rotating parallel twin-screw extruders, designed for high-end, high-performance TPE processing applications. This series represents the highest level of excellence in Zhuoyue’s product range, combining advanced technology, robust construction, and superior performance to meet the most demanding requirements of TPE manufacturers. The HTS series is available in three sub-series: HTS BASIC, HTS PLUS, and HTS SUPER, each tailored to specific application needs.

4.3.1 HTS BASIC Series

The HTS BASIC series is designed for medium-performance TPE processing applications, offering a balance of performance, flexibility, and cost-effectiveness. This series uses medium torque transmissions from leading European manufacturers, ensuring reliable performance and precise control. The HTS BASIC series offers the flexibility of choice through different configuration combinations, allowing manufacturers to tailor the extruder to their specific application requirements.

Key features of the HTS BASIC series include:

• Medium torque transmissions from leading European manufacturers
• Flexible configuration options to suit different TPE processing needs
• Precise temperature control and efficient mixing capabilities
• Suitable for processing a wide range of TPEs, including TPS, TPO, and TPU
• Ideal for medium-volume production of TPE components

The HTS BASIC series is an excellent choice for manufacturers who require reliable performance and flexibility, without the need for the highest torque and speed capabilities of the HTS PLUS and HTS SUPER series.

HTS BASIC Model Parameters

To better match the medium-performance positioning and flexible configuration of the HTS BASIC series, its model parameters are designed to cover most common TPE processing needs. The following table details the specific parameters, which can be flexibly selected according to different production volumes and material requirements, ensuring the extruder can stably process TPS, TPO, TPU and other common TPEs.

With medium torque transmission and flexible configuration, the HTS BASIC series can meet the basic processing needs of most common TPEs, and the parameter selection is flexible to adapt to different production volumes.

Model	Specific torque（N.m/Cm³）	Main motor power（Kw）	Output speed（rpm）	Slot depth ratio D0/Di
25	11	15	600	1.55
35	11	37	600	1.55
35	11	55	1000	1.55
50	11	75	600	1.55/1.68
50	11	110	900	1.55/1.68
65	11	160	600	1.55/1.68
65	11	220	900	1.55/1.68
75	11	220	600	1.55/1.68
75	11	315	900	1.55/1.68
95	11	315	600	1.55/1.68

4.3.2 HTS PLUS Series

The HTS PLUS series is designed for high-performance TPE processing applications, such as engineering plastics and filled masterbatches, which require higher torque and more efficient mixing. This series uses high-torque transmissions developed and manufactured in-house by Zhuoyue, ensuring superior performance and reliability. The HTS PLUS series is optimized for processing high-viscosity TPEs and filled composites, delivering uniform mixing and consistent material properties.

Key features of the HTS PLUS series include:

• High-torque transmissions developed and manufactured in-house by Zhuoyue
• Optimized screw design for improved mixing efficiency and material conveying
• High throughput and energy efficiency
• Suitable for processing high-performance TPEs, including TPV, TPC, TPA, and filled composites
• Ideal for high-volume production of high-quality TPE components

The HTS PLUS series is an excellent choice for manufacturers who require high performance and reliability for demanding TPE processing applications, such as automotive under-the-hood components and industrial hoses.

HTS PLUS Model Parameters

As a high-performance series optimized for high-viscosity TPEs and filled composites, the HTS PLUS series is equipped with Zhuoyue’s self-developed high-torque transmission, which brings higher torque density. The specific parameters below reflect its advantages in stable output and high efficiency, perfectly supporting the demanding processing scenarios such as automotive under-the-hood components and industrial hoses mentioned earlier.

Equipped with Zhuoyue’s self-developed high-torque transmission, the HTS PLUS series has higher torque density, which is suitable for processing high-viscosity TPEs and filled composites, with stable output and high efficiency.

Model	Specific torque（N.m/Cm³）	Main motor power（Kw）	Output speed（rpm）	Slot depth ratio D0/Di
25	13	18.5	600	1.55
35	13	45	600	1.55
35	13	75	1000	1.55
50	13	90	600	1.55/1.68
50	13	132	900	1.55/1.68
65	13	185	600	1.55/1.68
65	13	250	900	1.55/1.68
75	13	250	600	1.55/1.68
75	13	355	900	1.55/1.68
95	13	355	600	1.55/1.68

4.3.3 HTS SUPER Series

The HTS SUPER series is Zhuoyue’s highest-end line of co-rotating parallel twin-screw extruders, representing the advanced level of extruder development in China. This series uses Zhuoyue’s newly developed ultra-high torque transmission, which is specifically designed for the high-torque and high-speed characteristics of this series. The structural design of each key component of the extruder has been newly optimized to handle the most demanding TPE processing applications, ensuring superior performance, efficiency, and reliability.

Key features of the HTS SUPER series include:

• Ultra-high torque transmission developed by Zhuoyue
• Newly optimized structural design of key components for high-torque and high-speed operation
• Unmatched mixing efficiency and material uniformity
• High throughput and energy efficiency
• Suitable for processing the most demanding TPEs, including ultra-high-performance TPV, TPC, TPA, and filled composites
• Ideal for high-volume production of premium TPE components

With its torque density of 16.5Nm/Cm³ and slot depth ratio of 1.55/1.68, the HTS SUPER series features the highest free volume at 16.5 torque density in the industry. In addition to its robust construction, this line is coupled with a larger motor size to be a true workhorse for continuous 24/7/365 production, making it the ideal choice for manufacturers who demand the highest level of performance and reliability.

HTS SUPER Model Parameters

As Zhuoyue’s highest-end series, the HTS SUPER series adopts ultra-high torque transmission and optimized key components, which endow it with the highest torque density and speed in the product line. The following parameters fully demonstrate these advantages, making it capable of handling the most demanding TPE processing scenarios and realizing 24/7/365 continuous stable production.

As Zhuoyue’s highest-end series, it adopts ultra-high torque transmission and optimized key components, with the highest torque density and speed, suitable for the most demanding TPE processing scenarios.

Model	Specific torque（N.m/Cm³）	Main motor power（Kw）	Output speed（rpm）	Slot depth ratio D0/Di
25	15.5	22	600	1.55
35	16	55	600	1.55
35	16	90	1000	1.55
50	16	160	600	1.55/1.68
50	16	220	900	1.55/1.68
65	16.5	300	600	1.55/1.68
65	16.5	450	900	1.55/1.68
75	16.5	450	600	1.55/1.68
75	16.5	650	900	1.55/1.68
95	16	700	600	1.55/1.68

4.4 ZTE Series – Cost-effective, Practical Extruders

The ZTE series is designed for manufacturers who require a cost-effective, practical solution for TPE processing. This series offers an excellent price/performance ratio, with parameters designed to suit most TPE materials and applications. The ZTE series maintains the core structural advantages of Zhuoyue’s extruder products, while optimizing the configuration to achieve a more favorable cost performance, making it the first choice for small and medium-sized enterprises (SMEs) and manufacturers with basic production needs.

Key features of the ZTE series include:

• Excellent price/performance ratio
• Parameters designed to suit most TPE materials, including TPS, TPO, and TPU
• Reliable standard transmission system
• Stable operation and low maintenance costs
• Suitable for low to medium-volume production of TPE components
• Ideal for general-purpose TPE applications, such as consumer goods and basic industrial components

The ZTE series is an excellent choice for manufacturers who pursue practicality and economy, without compromising on quality and reliability. It is particularly well-suited for SMEs and manufacturers who are new to TPE processing, as it offers easy operation and low maintenance requirements.

ZTE Model Parameters

Consistent with its cost-effective and practical positioning, the ZTE series is designed with simple and practical parameters, which can fully meet the basic processing needs of most general TPE materials. For small and medium-sized enterprises and manufacturers new to TPE processing, the parameters listed below are easy to match with production needs, while ensuring low maintenance costs and stable operation.

With excellent cost performance, the ZTE series has simple and practical parameters, suitable for most general TPE materials, and is the preferred choice for small and medium-sized enterprises with basic production needs.

Model	Specific torque（N.m/Cm³）	Main motor power（Kw）	Output speed（rpm）	Slot depth ratio D0/Di
25	6	7.5	600	1.55
35	6	18.5	600	1.55
50	6	55	600	1.55/1.68
65	6	110	600	1.55/1.68
75	6	160	600	1.55/1.68
95	6	300	600	1.55/1.68

4.5 HTE Series – High-performance, Cost-effective Extruders

The HTE series is designed to bridge the gap between the high-end HTS series and the cost-effective ZTE series, combining high performance with high cost-effectiveness. This series is specifically engineered to reduce energy consumption while delivering higher output, making it an excellent choice for manufacturers who require both performance and efficiency.

Key features of the HTE series include:

• Combines high performance with high cost-effectiveness
• Reduced energy consumption with higher output
• Reasonable torque and power configuration for stable and efficient production
• Dual-speed options for partial models, expanding the application range
• Suitable for processing a wide range of TPEs, including TPS, TPO, TPU, and TPV
• Ideal for medium to high-volume production of TPE components, such as wire and cable insulation and jacketing

The HTE series is an excellent choice for manufacturers who require higher performance than the ZTE series, but do not need the ultra-high performance of the HTS SUPER series. It offers a balance of performance, efficiency, and cost-effectiveness, making it a versatile solution for a wide range of TPE processing applications.

HTE Model Parameters

Bridging the gap between the HTS series and ZTE series, the HTE series integrates high performance and cost-effectiveness. Its reasonable torque and power configuration, as well as the dual-speed options supported by some models, effectively achieve energy saving and high output. The specific parameters below fully reflect this balance, making it suitable for medium to high-volume production scenarios such as wire and cable insulation and jacketing.

Combining high performance and cost-effectiveness, the HTE series has reasonable torque and power configuration, partial models support dual-speed options, and achieves energy saving and high output.

Model	Specific torque（N.m/Cm³）	Main motor power（Kw）	Output speed（rpm）	Slot depth ratio D0/Di
25	9	11	600	1.55
35	9	30	600	1.55
35	9	45	1000	1.55
50	9	75	600	1.55/1.68
50	9	110	900	1.55/1.68
65	9	160	600	1.55/1.68
65	9	220	900	1.55/1.68
75	9	250	600	1.55/1.68
75	9	315	900	1.55/1.68
95	9	400	600	1.55/1.68

5. Conclusion

Thermoplastic elastomers (TPEs) have become an indispensable class of materials in modern manufacturing, offering a unique combination of thermoplastic processability and elastomeric flexibility. From automotive and electronics to construction and consumer goods, TPEs are enabling innovation and improving the performance of products across multiple sectors. To fully leverage the benefits of TPEs, manufacturers require specialized extrusion equipment that can handle the unique challenges of these materials, including their sensitivity to temperature, shear rate, and mixing uniformity.

Zhuoyue’s comprehensive range of co-rotating parallel twin-screw extruders, including the HTS, ZTE, and HTE series, are specifically engineered for TPE processing, delivering unmatched performance, efficiency, and reliability. With advanced features such as the ZG series high-efficiency gearboxes, optimized screw designs, and precise temperature control systems, Zhuoyue’s extruders ensure uniform mixing, consistent material properties, and high throughput, empowering manufacturers to unlock the full potential of TPEs.

Whether you require high-end, high-performance extruders for demanding TPE applications (HTS series), cost-effective solutions for general-purpose applications (ZTE series), or a balance of performance and efficiency (HTE series), Zhuoyue has the perfect extrusion solution for your needs. With a deep understanding of TPE material properties and industry application needs, Zhuoyue is committed to providing advanced extrusion technology and comprehensive support to help manufacturers succeed in the competitive global market.