Power Rating Calculation

Only by writing a whole book on the enormous number of possibilities.

Pilot-scale trials.

Equipment manufacturers will be pleased to help with pilot-scale equipment, especially if there is a prospect of a purchase from them. Even if a purchase is not forthcoming, an equipment manufacturer of repute will want to be involved in field pilot-scale trials to see what the potential is to apply their equipment to the problem at hand to acquire application information for current and prospective equipment development.

It starts by making phone calls to prospective equipment vendors, which task falls outside the scope of the forum to assist.

No.

If you have no idea what to do, the process of educating you to that level would take months of intense training.

Do as PWSlack has said.

well I'd say 4-5 years of school and study might get you there

You try to check you cable extrusion line, I guess. For instance, there are many type of extruders-destined for specific operation as conductor insulation or jacket insulation provided with a pressure die or vacuum die. There are many types of screw. For instance was 3 types Maillefer extruder screws. See for instance:

http://www.mailleferextrusion.com/srt/corporate/product/list?location.id:=1370#

An extrusion line is provided-except the extruder-with other elements-like pay-off and take-up devices, wire heater [if necessary] and so on. See:

http://www.sampsistemi.com/media/ss/extrusion/sampsistemi_extrusion_en_v006.pdf

As Tornado said you need an entire book. But, not a single one. Also you need at least 3-5 years experience in cable manufacturing.

See:

http://www.ptonline.com/columns/how-much-horsepower-do-you-need

And try Google "extruder manufacturers"

The question should have been, "How do I find the power, "required <to run> a processes machine eg on extruder,on a mixture,on a shredder...."

Sizing the motor is childs play!

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Well, SIMPLISTICLY, if you are the ELECTRICAL Engineer and your only task is to select the proper motor, then you simply go to the Mechanical Engineer involved in the project and say "How much torque is required at what speed at the motor shaft to operate this machine?" and from there, you select a motor that matches.

But if you are the Mechanical Engineer and you need to ask this question, then I suspect you are NOT really an ME.

Or if you are the EE, and some boss is EXPECTING you do do the work of an ME, then your boss is a cheapskate trying to get something from you that you are not properly qualified to do (as evidenced by your having to ask this question). You should avoid that at all costs, because if he gets away with it, there is no limit to what else he will start asking you to do.

Or finally if NOBODY involved in this is an Engineer of any sort, then you are in over your head. This is what Engineers are paid to do, go hire some.

No. 2 has to be the most appropriate way forward.

I like the suggestion you gave at the end. Matching gearbox and motor shaft sizes is quite cunning and totally logical.

I agree and must actually say more about 3:

It doesn't take too much into consideration how RPM and Momentum are conceived. For heavy applications motors drive gearboxes with multiple belts parallel and make a ratio there too. This is also a point that needs attention. VFD's and VFC or other electronic controllers make it more flexible, but I remember the days that these matches had to be optimal to meet process conditions.

Thank You

Are you building the machines yourself or fitting motors to existing machines?