Plastics

For the plastics industry, PK offers a variety of blenders and dryers to accomplish specific needs. These processes include blending wood flour with phenolic resin and preparing master batches of color concentrates for extrusion. Polymers may be impregnated with peroxide for cross-linking, while liquid plasticizers are added to resins, fillers, stabilizers, and other materials. To improve flow properties, fluorocarbon polymers are agglomerated and dried with with one of our drying products. Blending and drying can be accomplished in a single PK Solids Processor. Additional operations involve solid-state polymerization, diffusional drying, and handling dry hot melts. These methods also support increasing the intrinsic viscosity of polymers and drying rubber compounds.

Product Solutions

Twin Shell Blender

Versatile blender provides quick charging and discharging, easy cleaning and low energy operation for plastics processing.

Solids Processor

Agglomerate tungsten carbide with wax solvent and dry a variety of metal powders to low moisture levels.

Tubular Vacuum Dryer

Large heat transfer surface area provides solid state polymerization and drying of PET, nylon, and other polymers in pellet form faster than conventional vacuum dryers.

Zig-Zag Continuous Blender

Continuously blend metal powders and organic binders for cold-rolling and disperse reagents.

Twin-Shell Vacuum Dryer

Efficient moisture removal and drying of polymer products under a controlled vacuum.

Continuous Tubular Dryer

Efficient, uniform drying for applications such as polymerization, Nylon and PET processing.

Engineered for the Performance & Consistency Demands of Plastics Processing

Plastic processing requires precise control over blending, moisture, and material consistency to ensure product quality, downstream performance, and efficient production. Patterson Kelley delivers advanced blending, drying, and powder-processing solutions engineered for polymer compounding, masterbatch production, and specialty-plastic applications.

PK Blenders are purpose-built to handle resins, additives, fillers, stabilizers, and liquid plasticizers with systems designed to improve blend uniformity, optimize flow properties, and support repeatable results from R&D through full-scale production. Our solutions support processes such as polymer conditioning, masterbatch blending, and solid-state polymerization.

Plastics Processing Pain Points We Solve

Blend inconsistency in multi-component polymer formulations

Segregation of resins, fillers, and additives

Moisture variability affecting extrusion and molding performance

Poor dispersion of color concentrates and additives

Dust control and material handling challenges

Scale-up inefficiencies from lab to production

Inconsistent feed to extrusion or compounding systems

Optimize Your Plastics Processing Line

We help plastics manufacturers achieve consistent material performance while improving efficiency and throughput.

PK engineers work directly with R&D and production teams to design systems tailored to:

Polymer type and material composition

Additive dispersion and blend uniformity targets

Moisture control and drying requirements

Throughput and production rates

Scale-up from lab and pilot to full production

Facility layout and system integration needs

Engineered for Plastics Powder Processing

High-Uniformity Blending for Polymers & Additives

PK’s blending technologies, including Twin Shell, Double Cone, Cross-Flow®, Slant Cone®, and Zig-Zag® Continuous Blenders, are engineered to deliver consistent mixing of resins, fillers, stabilizers, and masterbatch components without material degradation.

Integrated Drying & Polymer Conditioning

PK drying solutions, such as the Solids Processor (SP), Tubular Vacuum Dryers, and Continuous Tubular Dryers, provide controlled moisture removal, solid-state polymerization, and conditioning for polymers like PET, nylon, and specialty compounds.

Scalable Systems

From lab-scale testing with Blend Master units to full production systems, PK supports every stage of plastics manufacturing with scalable, process-driven equipment designed for consistent performance.

Why Choose Patterson Kelley

Plastics Manufacturers Need:

Consistent blending of multi-component formulations

Reliable dispersion of additives and color concentrates

Controlled drying for polymers and compounds

Scalable systems for compounding and extrusion processes

Reduced segregation and improved material flow

Equipment that supports continuous or batch production

Reliable handling of resins, pellets, and powders

PK Benefits

Uniform blends for improved product quality

Reduced segregation of additives and fillers

Improved downstream processing consistency

Energy-efficient drying and conditioning options

Reduced downtime and cleaning time

Long equipment life with industrial durability

Proven performance in polymer and plastics applications

Technical Advantages

Optimized vessel geometry for consistent blending

Precision control of speed and fill levels

Vacuum drying for moisture-sensitive polymers

Dust-tight and enclosed system designs

CIP-ready and easy-to-maintain configurations

Food- and industrial-grade material options

Batch control and process monitoring capabilities

Custom-engineered systems for polymer processing challenges

Scalable Systems From R&D to Production

Plastics manufacturers benefit from PK’s ability to support every phase of product development. From lab-scale testing with Blend Master and bench-top units, to pilot trials validating blend uniformity and moisture control, to full-scale production systems designed for continuous or batch processing, PK ensures performance at every stage.

Our lab testing services allow you to bring your materials to PK and validate blending, drying, and conditioning processes before investing in equipment.

Applications Across Plastics Manufacturing

PK supports a wide range of plastics processing applications:

Masterbatch blending and color concentrate preparation
Resin blending with additives, fillers, and stabilizers
Liquid plasticizer addition and coating
Polymer drying and moisture removal
Solid-state polymerization of PET and nylon
Agglomeration and conditioning of fluoropolymers
Rubber compound drying and processing
Preparation of materials for extrusion and molding

System Integration Capabilities

PK equipment integrates seamlessly into plastics processing environments, including:

Material transfer and conveying systems
Feeding systems for extrusion and compounding
Dust collection and containment systems
Pellet handling and storage systems
Vacuum transfer and pneumatic conveying
PLC-based batch control and automation systems
Packaging and downstream processing integration

Plastics Processing FAQs

How do you ensure uniform blending of resins and additives?

PK blending systems use optimized vessel geometry and controlled mixing action to evenly distribute additives, fillers, and color concentrates throughout the batch.

Why is drying important in plastics processing?

Moisture can negatively impact extrusion, molding, and final product quality. Controlled drying ensures consistent processing and improves material performance.

Can PK equipment handle both powders and pellets?

Yes. PK systems are designed to process a wide range of materials, including powders, pellets, resins, and compounded materials.

Is lab testing available before investing in equipment?

Yes. PK offers lab and pilot testing to validate blending performance, drying efficiency, and scalability with your specific materials.

Can PK systems integrate with extrusion or compounding lines?

Absolutely. PK engineers design systems that integrate seamlessly with extrusion, feeding, and downstream processing equipment.

We Have The Solution For Your Process.

Regardless of the processing industry, PK has been providing solutions to processors for more than a century.