{"id":70,"date":"2026-11-06T19:06:37","date_gmt":"2026-11-06T11:06:37","guid":{"rendered":"https:\/\/kerkepm.com\/company\/factory\/"},"modified":"2026-11-11T13:13:13","modified_gmt":"2026-11-11T05:13:13","slug":"factory","status":"publish","type":"page","link":"https:\/\/kerkepm.com\/es\/company\/factory\/","title":{"rendered":"Factory &amp; Manufacturing"},"content":{"rendered":"<div class=\"k3\">\n<div class=\"wrap\"><div class=\"crumbs\"><a href=\"\/\">Home<\/a><span>\/<\/span><a href=\"\/company\/\">Company<\/a><span>\/<\/span>Factory<\/div><\/div><div class=\"wrap\"><div class=\"hero\">\n<p class=\"kicker\">Company \u00b7 Manufacturing<\/p>\n<h1>Inside the extruder factory: from screw blank to loaded test<\/h1>\n<p class=\"dek\">An extruder factory is judged by three things \u2014 the screws it can cut, the liners it can cast and the test it runs before the machine leaves. Here is the sequence in our Nanjing works, step by step.<\/p>\n<div class=\"byline\"><div><b>Location<\/b> Nanjing, Jiangsu<\/div><div><b>In-house<\/b> screws, barrels, shafts, dies<\/div><div><b>Gearbox<\/b> 24 h run-in<\/div><div><b>Test<\/b> no-load + loaded<\/div><\/div>\n<\/div><\/div>\n<div class=\"wrap\"><figure class=\"banner vhero\">\n<button class=\"plcover\" type=\"button\" data-vid=\"iBMgmu9fOLk\" aria-label=\"Play the Kerke factory tour video on this page\"><img decoding=\"async\" src=\"\/wp-content\/uploads\/2026\/11\/vid-projects-hero.webp\" alt=\"Kerke factory tour video \u2014 screw elements and extruder assembly in the Nanjing works\" width=\"1200\" height=\"675\" fetchpriority=\"high\"><span class=\"plplay\" aria-hidden=\"true\"><\/span><\/button>\n<\/figure><\/div>\n<div class=\"wrap\"><div class=\"grid\"><main>\n<nav class=\"wp-block-rank-math-toc-block k3-toc\" aria-label=\"On this page\"><b>On this page:<\/b><a href=\"#s1\">Quick answer<\/a><a href=\"#s2\">What the factory controls<\/a><a href=\"#s3\">Six steps<\/a><a href=\"#s4\">Screws and barrels<\/a><a href=\"#s5\">The loaded test<\/a><a href=\"#s6\">What to ask to see<\/a><\/nav>\n<section class=\"qa\" id=\"answer\"><h2 id=\"s1\">Quick answer<\/h2><p>The extruder factory covers six steps: <strong>screw and barrel machining, shaft and spline cutting, gearbox assembly with a 24-hour run-in, frame assembly and wiring, no-load testing, then a loaded test with your material<\/strong>. You receive the test video, pellet samples and the parameter sheet; a factory acceptance test can be attended on site.<\/p><\/section>\n<div class=\"stats\"><div class=\"stat\"><b>24 h<\/b><span>gearbox run-in<\/span><\/div><div class=\"stat\"><b>2<\/b><span>tests per line<\/span><\/div><div class=\"stat\"><b>100%<\/b><span>lines run with material<\/span><\/div><div class=\"stat\"><b>6<\/b><span>steps, all in house<\/span><\/div><\/div>\n\n<h2 class=\"sec\" id=\"s2\">What an extruder factory actually controls<\/h2>\n<p class=\"lead\">Marketing pages talk about motor power. An extruder factory is really four machining capabilities and one test bench: screw element hobbing, barrel liner casting, shaft spline cutting, die drilling \u2014 and a bench where the assembled line runs on real material.<\/p>\n<p>Everything downstream of that is assembly. If a supplier buys screws and barrels on the open market, its ability to fix a wear problem, change a conveying element or hold a tolerance on a replacement part is limited to what its vendor will accept. That is the practical difference between an extruder factory and an assembler, and it shows up two years later when a barrel needs relining.<\/p>\n\n<h2 class=\"sec\" id=\"s3\">Six steps, in order<\/h2>\n<ol class=\"flow\">\n<li><b>Screw elements.<\/b> CNC hobbing from 40CrNiMo blanks, heat treated, ground, then checked for interchangeability on the assembly shaft.<\/li>\n<li><b>Barrels.<\/b> Bimetallic liner by centrifugal casting, bored and honed; the liner grade is chosen for the filler \u2014 CaCO<sub>3<\/sub>, talc and glass fibre each wear differently.<\/li>\n<li><b>Shafts.<\/b> Spline cut and hardened; torque transmission is checked against the gearbox class, not against the motor nameplate.<\/li>\n<li><b>Gearbox.<\/b> Assembled, filled, and run in for 24 hours with temperature and noise logged at each bearing.<\/li>\n<li><b>Assembly and wiring.<\/b> Frame, barrels, heaters, thermocouples, water manifold, electrical cabinet to the drawing approved by the customer.<\/li>\n<li><b>Test.<\/b> No-load run for direction, heaters and interlocks; then a loaded run with material, and the parameter sheet is written from what the machine actually did.<\/li>\n<\/ol>\n\n<h2 class=\"sec\" id=\"s4\">Screws and barrels: where the money goes<\/h2>\n<div class=\"tw\"><table><caption><b>Table 1.<\/b> Parts machined in-house and why the process matters at the customer's plant.<\/caption>\n<thead><tr><th scope=\"col\">Part<\/th><th scope=\"col\">Process<\/th><th scope=\"col\">Why it matters<\/th><\/tr><\/thead>\n<tbody>\n<tr><td><b>Screw elements<\/b><\/td><td>CNC hobbing, heat treatment, grinding<\/td><td>Wear life and interchangeability between identical elements<\/td><\/tr>\n<tr><td><b>Barrels<\/b><\/td><td>Bimetallic liner, centrifugal casting<\/td><td>Abrasive filler and glass fibre resistance<\/td><\/tr>\n<tr><td><b>Shafts<\/b><\/td><td>40CrNiMo, spline cut and hardened<\/td><td>Torque transmission at high filler loading<\/td><\/tr>\n<tr><td><b>Dies<\/b><\/td><td>Drilling, polishing, flow check<\/td><td>Pellet shape and output stability<\/td><\/tr>\n<tr><td><b>Gearboxes<\/b><\/td><td>Assembly plus 24 h run-in<\/td><td>Noise and bearing temperature at commissioning<\/td><\/tr>\n<\/tbody><\/table><\/div>\n<p>Spare elements are cut from the same program, which is why a replacement screw element ordered three years later still intermeshes with the original shaft \u2014 see <a href=\"\/machines\/spare-parts\/\">spare parts<\/a>.<\/p>\n\n<h2 class=\"sec\" id=\"s5\">The loaded test<\/h2>\n<p>Every line runs no-load, then with material. The loaded test is where surge, die pressure and pellet quality appear; it is also where the reference output on the quotation is confirmed or corrected. The customer receives a video of the run, a pellet sample by courier and the parameter sheet with temperatures, screw speed, feeder settings and measured output.<\/p>\n<p>On request, the factory acceptance test is attended on site, with the customer's own material and the customer's own acceptance criteria written into the checklist. Documents that travel with the machine are listed on the <a href=\"\/company\/certificates\/\">certificates page<\/a>.<\/p>\n\n<h2 class=\"sec\" id=\"s6\">What to ask to see on a factory visit<\/h2>\n<ul>\n<li>An assembled shaft with elements fitted \u2014 check whether element numbers are stamped and matched.<\/li>\n<li>A barrel section cut open, so the liner thickness is visible rather than described.<\/li>\n<li>The run-in log of a gearbox: bearing temperatures at hour 1 and hour 24.<\/li>\n<li>A loaded test in progress, with the parameter sheet being filled in by hand.<\/li>\n<li>The material store: if a factory has no resin on site, it is not testing with material.<\/li>\n<\/ul>\n<p>Visits are arranged through the <a href=\"\/company\/\">company page<\/a>; the standard machine range is on <a href=\"\/machines\/co-rotating-twin-screw-extruder\/\">co-rotating twin screw extruder<\/a>. Background on the process: <a href=\"https:\/\/en.wikipedia.org\/wiki\/Extrusion\" rel=\"nofollow noopener\" target=\"_blank\">extrusion<\/a>.<\/p>\n<h2 class=\"sec\" id=\"faq\">FAQ<\/h2><details><summary>Can I audit the factory before ordering?<\/summary><p>Yes - on-site visits and live video audits are by appointment; the machining shop, gearbox assembly and the test bay are all part of the standard tour.<\/p><\/details><details><summary>Which parts are made in-house?<\/summary><p>Screw elements, shafts, barrels and liners are machined in the works; gearboxes are assembled and run in for 24 hours there as well.<\/p><\/details><details><summary>What happens to every line before shipment?<\/summary><p>A wet-run test with the customer's material: temperatures, torque, vacuum and output are recorded, and the report ships with the machine.<\/p><\/details><script type=\"application\/ld+json\">{\"@context\": \"https:\/\/schema.org\", \"@type\": \"FAQPage\", \"mainEntity\": [{\"@type\": \"Question\", \"name\": \"Can I audit the factory before ordering?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"Yes - on-site visits and live video audits are by appointment; the machining shop, gearbox assembly and the test bay are all part of the standard tour.\"}}, {\"@type\": \"Question\", \"name\": \"Which parts are made in-house?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"Screw elements, shafts, barrels and liners are machined in the works; gearboxes are assembled and run in for 24 hours there as well.\"}}, {\"@type\": \"Question\", \"name\": \"What happens to every line before shipment?\", \"acceptedAnswer\": {\"@type\": \"Answer\", \"text\": \"A wet-run test with the customer's material: temperatures, torque, vacuum and output are recorded, and the report ships with the machine.\"}}]}<\/script><\/main>\n<aside><div class=\"sidecard\">\n<b>Want to see the works?<\/b>\n<p>Send the material and the line you are considering \u2014 we arrange a factory visit or a video walk-through of the assembly bay and the loaded test.<\/p>\n<form class=\"kside\" novalidate>\n<input type=\"text\" name=\"name\" placeholder=\"Name *\" required>\n<input type=\"email\" name=\"email\" placeholder=\"Work email *\" required>\n<input type=\"text\" name=\"whatsapp\" placeholder=\"WhatsApp \/ phone\">\n<input type=\"hidden\" name=\"product\" value=\"Factory visit enquiry\">\n<input type=\"hidden\" name=\"form\" value=\"factory-aside\">\n<textarea name=\"message\" rows=\"3\" placeholder=\"Material, line model, visit timing\"><\/textarea>\n<button type=\"submit\" class=\"btn\">Send enquiry<\/button>\n<p class=\"ok\" hidden>Thanks \u2014 the team replies within one working day.<\/p>\n<\/form>\n<\/div><\/aside>\n<\/div><\/div>\n<script>\ndocument.querySelectorAll('.k3 .vhero .plcover').forEach(function(b){\nb.addEventListener('click',function(){\nvar f=document.createElement('iframe');\nf.src='https:\/\/www.youtube.com\/embed\/'+b.dataset.vid+'?autoplay=1&rel=0';\nf.title='Kerke factory tour video';f.allowFullscreen=true;\nf.allow='accelerometer;autoplay;encrypted-media;picture-in-picture';\nb.replaceWith(f);});});\n<\/script>\n<script>\ndocument.querySelectorAll('.k3 .kside').forEach(function(f){\nf.addEventListener('submit',function(ev){\nev.preventDefault();\nvar d=new FormData(f),o={};\nd.forEach(function(v,k){o[k]=v;});\nif(!o.name||!o.email||o.email.indexOf('@')<0){return false;}\no.action='kerke_lead';o.page_url=location.href;\nvar btn=f.querySelector('button');btn.disabled=true;btn.textContent='Sending\u2026';\nfetch('\/wp-admin\/admin-ajax.php',{method:'POST',body:new URLSearchParams(o)})\n.then(function(r){return r.json();})\n.then(function(r){\nif(r&&r.success){f.querySelector('.ok').hidden=false;btn.style.display='none';\nwindow.dataLayer=window.dataLayer||[];window.dataLayer.push({event:'generate_lead',form:'factory-aside'});}\nelse{btn.disabled=false;btn.textContent='Send enquiry';}})\n.catch(function(){btn.disabled=false;btn.textContent='Send enquiry';});\nreturn false;});});\n<\/script>\n<script type=\"application\/ld+json\">{\"@context\": \"https:\/\/schema.org\", \"@type\": \"WebPage\", \"name\": \"Extruder Factory\", \"description\": \"Inside the extruder factory: machining, assembly and loaded test.\", \"url\": \"https:\/\/www.kerkepm.com\/company\/factory\/\", \"publisher\": {\"@type\": \"Organization\", \"name\": \"Kerke Extrusion Equipment\", \"email\": \"kerkepm@gmail.com\", \"address\": {\"@type\": \"PostalAddress\", \"addressLocality\": \"Nanjing\", \"addressCountry\": \"CN\"}}}<\/script>\n<\/div>\n\n","protected":false},"excerpt":{"rendered":"<p>Home\/Company\/Factory Company \u00b7 Manufacturing Inside the extruder factory: from screw blank to loaded test An extruder factory is judged by three things \u2014 the screws it can cut, the liners it can cast and the test it runs before the machine leaves. Here is the sequence in our Nanjing works, step by step. Location Nanjing, [&#8230;]\n","protected":false},"author":0,"featured_media":0,"parent":68,"menu_order":62,"comment_status":"closed","ping_status":"closed","template":"page-blank.php","meta":{"footnotes":""},"application":[],"app_group":[],"class_list":["post-70","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages\/70","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/types\/page"}],"replies":[{"embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/comments?post=70"}],"version-history":[{"count":0,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages\/70\/revisions"}],"up":[{"embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/pages\/68"}],"wp:attachment":[{"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/media?parent=70"}],"wp:term":[{"taxonomy":"application","embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/application?post=70"},{"taxonomy":"app_group","embeddable":true,"href":"https:\/\/kerkepm.com\/es\/wp-json\/wp\/v2\/app_group?post=70"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}