NEWEX · Project

Next-Generation Extruder That Processes Composites, Nanocomposites, and Food Materials

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Imagine a pasta machine, but for industrial plastics and composites. Conventional extruders push material through a heated barrel with a screw — but they struggle with advanced materials like nanocomposites or even certain food and pharmaceutical ingredients. This team redesigned the core parts of the machine — the barrel, the feed section, and the screw — using a patented rotating barrel concept. The result is a prototype extruder that can process materials that older machines simply cannot handle.

By the numbers

consortium partners across 5 countries

industrial SME partners who built metal components

57%

industry ratio in the consortium

EUR 1,251,000

EU contribution for development

total deliverables produced

demo deliverables including pilot prototype

The business problem

What needed solving

Manufacturers working with advanced composites, nanocomposites, and specialty materials (food, pharmaceutical, cosmetic) hit a wall with conventional extrusion equipment. Standard extruders cannot properly feed, mix, or process these difficult materials, leading to poor product quality, wasted raw materials, and limited product development options. Companies either accept these limitations or invest in expensive custom solutions with no guarantee of results.

The solution

What was built

The team built a complete pilot prototype of a new-generation extruder featuring three patented innovations: an active grooved feed section, a rotational barrel segment, and a special screw — all manufactured in metal by industrial SME partners. Supporting deliverables include 3D-printed physical models, an automation and control system, and auxiliary elements (sensors, heating elements, motor, hopper, extruder head).

Audience

Who needs this

Plastics extrusion companies processing nanocomposites or advanced polymer blendsFood extrusion manufacturers working with difficult-to-process ingredientsPharmaceutical companies using hot-melt extrusion for drug deliveryCosmetics manufacturers needing precision extrusion for specialty formulationsExtrusion equipment manufacturers looking to license next-generation technology

Business applications

Who can put this to work

Plastics & Composites Manufacturing

SME

Target: Plastics extrusion companies processing advanced polymer composites and nanocomposites

If you are a plastics manufacturer struggling to process nanocomposite or advanced composite materials on conventional extruders — this project built a prototype extruder with a patented rotational barrel segment and active grooved feed section that enables processing of materials that standard machines cannot handle. The consortium of 7 partners across 5 countries built metal parts and a pilot prototype, backed by EUR 1,251,000 in EU funding.

Food Processing Equipment

mid-size

Target: Food extrusion companies producing snacks, cereals, or textured proteins

If you are a food manufacturer looking for better extrusion technology for difficult-to-process ingredients — this project developed a new extruder design specifically tested for food materials. The special screw and rotational barrel segment improve material flow and mixing, potentially allowing you to work with ingredients that jam or degrade in conventional machines. All key components were manufactured in metal by industrial SME partners.

Pharmaceutical & Cosmetics Manufacturing

any

Target: Companies using hot-melt extrusion for drug delivery systems or cosmetic products

If you are a pharmaceutical or cosmetics company using extrusion for product formulation — this project's new extruder prototype was designed to handle cosmetic and pharmaceutical materials alongside industrial polymers. The automation and control system was specifically chosen to meet processing requirements, and the active grooved feed section gives better control over material intake. The 4 industrial partners in the consortium validated the design in real manufacturing conditions.

Frequently asked

Quick answers

What would it cost to adopt this new extruder technology?

The project received EUR 1,251,000 in EU funding to develop the prototype. Pricing for commercial units is not specified in the project data. Contact the coordinator at Lublin University of Technology or the industrial partners (Zamak-Mercator, SEZ-Krompachy, Borra) for licensing or purchase options.

Can this extruder work at industrial production scale?

The project built a pilot-scale prototype extruder with all key components manufactured in metal by SME partners. The deliverables include a complete machine with automation and control systems, heating elements, motor, and extruder head. Based on available project data, the design is validated at pilot scale but commercial-scale production readiness would need confirmation from the consortium.

Who owns the intellectual property and how can I license it?

The extruder concept is described as patented, covering the innovative active grooved feed section, rotational barrel segment, and special screw design. IP is likely held by the coordinator (Lublin University of Technology) and possibly shared with industrial partners. Licensing terms would need to be negotiated directly with the consortium.

What materials can this extruder actually process?

According to the project objectives, the extruder can process composite and nanocomposite materials, as well as food, cosmetic, and pharmaceutical materials. It is specifically designed to handle materials that conventional extruders cannot process. The rotational barrel and active grooved feed section are the key innovations enabling this.

How long did development take and what is the current status?

The project ran from January 2017 to May 2022 and is now closed. Over that period, the team progressed from design and 3D-printed physical models to metal-manufactured components and a complete pilot prototype with automation and control systems.

Are there industrial partners already using this technology?

The consortium includes 4 industrial SME partners: Zamak-Mercator (Poland), SEZ-Krompachy (Slovakia), and Borra (Czech Republic) who manufactured the metal components. These companies were directly involved in building the special screw, rotational barrel segment, and active grooved feed section. Based on available project data, they are the most likely first adopters.

Consortium

Who built it

The NEWEX consortium has a strong industry orientation with 57% of its 7 partners coming from the private sector. Four SME partners across Poland, Slovakia, and Czech Republic handled the actual metal manufacturing of extruder components, while 3 universities (Lublin University of Technology, Technical University of Kosice, University of Minho) provided the research backbone. The 5-country spread across Central and Southern Europe gives good coverage of the EU manufacturing base. For a business buyer, the fact that industrial SMEs already built the physical parts in metal — not just university lab models — adds credibility to the technology's manufacturing readiness.

POLITECHNIKA LUBELSKACoordinator · PL
TECHNICKA UNIVERZITA V KOSICIACHparticipant · SK
UNIVERSIDADE DO MINHOparticipant · PT

How to reach the team

Lublin University of Technology (Politechnika Lubelska), Poland — coordinator of the NEWEX project

Order a report on this consortium See POLITECHNIKA LUBELSKA profile →

Next steps

Talk to the team behind this work.

Want to explore licensing or purchasing this extruder technology? SciTransfer can connect you directly with the NEWEX research team and industrial partners. Contact us for a briefing.

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