Design and Development of a Prototype System for Temperature and Water Level Control in an Extruder Machine

Abstract

This research focuses on the design and development of a prototype system for temperature and water level control in an extruder machine, a critical component in modern industrial manufacturing. The study addresses challenges in operational stability by integrating advanced sensor-based monitoring and an automated control mechanism. A mixed-method approach was employed, combining experimental trials and computational analysis to validate system performance. The prototype system incorporates high-precision thermocouples for temperature measurement, ultrasonic sensors for water level detection, and a microcontroller-based control unit for real-time adjustments.

The results demonstrate that the system maintains temperature with an accuracy of ±1°C and limits water level fluctuations to within 5 mm under varying operational conditions. Additionally, the system improves energy efficiency by 15% compared to conventional manual systems, showcasing its potential to enhance productivity and sustainability in manufacturing processes. Performance evaluations reveal the system's reliability and precision, which are critical for applications in polymer processing, food manufacturing, and other extruder-based industries.

This study highlights the significance of automated control systems in advancing industrial sustainability and efficiency. Future work should explore the scalability of the system for larger industrial applications and incorporate predictive maintenance features to ensure long-term reliability.