en.Wedoany.com Reported - Broadway has added a new USEON compounding line, equipped with a SAT-65 twin-screw extruder and a UWP500 underwater pelletiser, increasing its total capacity by 2,000 tonnes per year and enabling an hourly output of over 500 kg of high-performance plastic compounds.
The ISO-certified UK materials specialist was already providing large-volume compounds to multiple customers. With the new line operational, its range of processable polymers has been further broadened, capable of handling both soft materials (such as thermoplastic polyurethane TPU, polylactic acid PLA, ethylene-vinyl acetate EVA) and rigid materials (such as polycarbonate, glass-fibre reinforced nylon). Traditional strand pelletisers often encounter issues like stretching and uneven cooling when processing soft polymers, while rigid polymers become brittle after water cooling, also leading to pelletising difficulties. The underwater pelletiser cuts directly at the die face in contact with water, eliminating the stranding step, thereby improving efficiency and expanding material compatibility.
The new line supports the simultaneous addition of high-concentration colours and various functional additives (laser marking agents, processing aids, UV protectors) into a single formulation. A network of four bulk hopper pumps and pipelines conveys different materials to the feeding system, ensuring precise component proportioning. A melt pump stabilises output pressure and volume, reducing material fluctuations. Underwater pelletising prevents strand breakage, increases yield, reduces waste and dust, and produces uniformly shaped pellets. Broadway also integrates its in-house produced granular masterbatch directly into the compounding process, achieving precise and consistent colour in every batch without relying on external colour suppliers, thus shortening lead times.
In the biomaterials sector, Broadway collaborates with material innovators to develop commercialised biomaterial formulations. One such seaweed-based, plastic-free biopolymer is home compostable, suitable for single-use or hard-to-recycle components, and degrades without leaving microplastics behind. The new line provides greater toll compounding capacity for such partnerships. Furthermore, the company offers a variety of bio-filled compounds, with filler sources including industrial by-products like harvest waste, crushed eggshells, hemp, and bio-marine waste. The underwater pelletiser allows for higher filler loading, reducing reliance on petroleum-based plastics.
The new line is currently Broadway's largest compounding line, suitable for industries such as automotive, construction, consumer goods, and sustainable packaging, capable of handling large-volume orders cost-effectively while maintaining short lead times. The company stated that this investment aligns with its long-term growth strategy, reinforcing its commitment to performance and sustainability in plastics manufacturing.
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