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Journals / Journal of Engineering Technology and Applied Sciences / 2026 / Cilt: 11

Transient Characterization of Single Screw Plastic Extrusion Process: The Internal Model Control Design Approach

Kelly Osas Osatohanmwen(Ambrose Alli University, Ekpoma)0009-0006-7051-7277
Ikponmwosa İgnatius Omorodion(Ambrose Alli University, Ekpoma)0009-0005-9830-9878
Oruame Eddy Aigboje(Ambrose Alli Univeristy)0000-0003-2491-8206
Pages
51–64
Publication Date
2026-09-12
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

The study bridges theoretical control theory with practical implementation, offering a replicable template for extrusion process optimization.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:This study presents an optimized Internal Model Control (IMC) design for transient response enhancement in single-screw plastic extrusion, addressing critical industry challenges in product quality and process efficiency.
📊
Key Findings & Data:Initial system performance exhibited suboptimal metrics (2.15% overshoot, 12.8 s settling time, 5.64 s rise time), unsuitable for precision manufacturing.
💡
Conclusion & Impact:The study bridges theoretical control theory with practical implementation, offering a replicable template for extrusion process optimization.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Control System · extrusion · MATLAB

Abstract

This study presents an optimized Internal Model Control (IMC) design for transient response enhancement in single-screw plastic extrusion, addressing critical industry challenges in product quality and process efficiency. Initial system performance exhibited suboptimal metrics (2.15% overshoot, 12.8 s settling time, 5.64 s rise time), unsuitable for precision manufacturing. Through MATLAB-based implementation, the proposed IMC controller achieved zero overshoot, a 0.336 s rise time, and 0.583 s settling time – outperforming conventional PID and digital compensators by 82.9–100% in key performance indicators. A systematic evaluation of controller orders (1 st – 3 rd ) and time constants (0.1 – 1.0) revealed the superiority of 2nd/3rd-order IMC, demonstrating 94% faster settling and 100% overshoot elimination compared to prior work [8]. The design incorporated robust tuning parameters (τ = 0.1 s) validated under real-world variability (±5% screw speed fluctuations, ±8% material property changes), ensuring industrial applicability. Novel transient characterization of extrusion dynamics during startup and material transitions, scalable control framework requiring no retuning across polymer grades (PP, HDPE, ABS) and energy savings (12 – 18%) and scrap reduction (25 – 40%) through optimized dynamics were the key contributions as well as simplified tuning via MATLAB. The study bridges theoretical control theory with practical implementation, offering a replicable template for extrusion process optimization.

🔖

Cite This Article

Osatohanmwen, K. O., Omorodion, I. İ., Aigboje, O. E. (2026). Transient Characterization of Single Screw Plastic Extrusion Process: The Internal Model Control Design Approach. Journal of Engineering Technology and Applied Sciences, Cilt: 11, 51–64. https://doi.org/10.30931/jetas.1527467

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  76. Chen, Z., Wang, H., Liu, X., “Deep learning-based model predictive imc”, Journal of Manufacturing Processes 109 (2024): 78–91.
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  78. Martinez, P., Rodriguez, A., Fernandez, M., “Stability analysis of polymer extrusion under variable shear rates”, Journal of Polymer Engineering 43(2) (2023): 145–160.
  79. Kim, S., Park, J., “Thermal dynamics in single-screw extrusion: experimental validation of isothermal assumptions”, Polymer Testing 114 (2022): 107685.
  80. Harris, R., Lewis, T., “Robust control design for industrial extrusion processes”, Control Engineering Practice 131 (2023): 105402.
  81. Foster, J., Mitchell, T., Chen, L., “Multi-material validation of extrusion control sys-tems”, Journal of Manufacturing Processes 85 (2023): 102–118.
  82. West, M., Brooks, T., “Energy efficiency optimization in polymer extrusion”, Internati-onal Journal of Production Economics 256 (2023): 108732.
  83. Gray, P., Morgan, R., “Quality control in profile extrusion: scrap reduction through ad-vanced process control”, Control Engineering Practice 119 (2022): 104982.
  84. Harris, R., Lewis, T., “Industrial implementation of model-based control in extrusion”, Journal of Process Control 129 (2023): 103045.