Plastic Extrusion Machinery | Plastic Extrusion Machines- an information site on Plastic Extrusion Machines

Plastic Extrusion Machinery | Plastic Extrusion Machines- an information site on Plastic Extrusion Machines

Plastic Extrusion Machinery

Plastics extrusion is a process of high volume manufacturing in which raw material is melted and formed into a continuous profile. Extrusion produces items such as window frames, adhesive pipe/tubing, weather stripping, and tape and wire insulation. It is also a process in which material is forced through a series of dies to create desired shapes. Many ceramics are manufactured by extrusion, because the process allows efficient, continuous production. In a commercial screw-type Plastic Extrusion Machinery, a screw auger continuously forces the plastic feed material through an die, resulting in simple shapes such as pipes, and cylindrical rods rectangular solid and hollow bars, and long plates.

Process

The process begins by heating the raw material. It is then loaded into the container in the press. A block is placed behind it where the ram then presses on the material to push it out of the die. Afterward the extrusion is stretched in order to straighten it. The extrusion ratio is defined as the starting cross-sectional area divided by the cross-sectional area of the final extrusion. One of the main advantages of the extrusion process is that this ratio can be very large while still producing quality parts.

Plastic

Plastic Extrusion commonly uses plastic chips or pellets, which are usually dried in a hopper before inserting it to the feed screw. The polymer resin or the raw material is heated to molten state by a combination of heating elements and shear heating from the extrusion screw. The resin with the help of a screw pushed through a die, forming the resin into the desired shape. The extruder is further cooled and solidified as it is pulled through the die or water tank. In some cases the extruder is pulled through a very long die, in a process called pultrusion.

A multitude of polymers are used in the production of plastic tubing, pipes, rods, rails, seals, and sheets or films.

Plastics are made by a chemical process called polymerization.

There are several different types of polymerization:

Condensation polymerization is a reaction where two molecules join into one larger one, releasing a molecule in the process. Examples of condensation polymers are Nylon-6,6 (a polyamide) and PET (a polyester).

Addition polymerization is where two molecules join to form one larger one without losing any atoms in the process. Examples of addition polymers are Nylon-6 (also a polyamide, but produced using a ring-opening process rather than a condensation process) and polystyrene (a polyolefin, generally produced using a free-radical propagation mechanism).

Machinery/ Machine

A Machine is device used to reduce an effort to give you an output of product or service. The entity could be a result of any substance or matter arranged in different different forms.

A machine is a device that uses energy to perform some activity. In common usage, the meaning is that of a device having parts that perform or assist in performing any type of work.

It is a chain process as you put in inputs like raw materials PP, PVC, etc which gives you a final product like plastic etc. Through this machine one can manufacture moulded plastics or unmoulded form. The unmoulded form can be like pet bottles, jars, car glove box. And molded plastics like plastic sheets, cling films etc. Manufacturing of machines differ from country to country.

Various types of machines:

Switch

Computer

Car

TV

Washing Machine

Sewing Machine etc

Various types of Plastic Extrusion Machinery:

Blown Film Machines

Cast Film Machines

PPTQ Blown Film Machine

Wide width Blown film machine

Zip Lock machine etc

Types of Plastic Extrusion Sheet Extrusion

Sheet Extrusion

The extrusion process in which various resins or related raw material for plastic making are used to produce flat sheets in continuous or non continuous form is called as Sheet Extrusion.

The sheets could be of various thicknesses from vehicle bed liners playground equipment, containers, and boats , packaging applications including cling films, cups, trays etc

The thinner gauges are thermoformed into packaging applications such as deli containers, drink cups, produce trays, baby wipe containers and margarine tubs. Flat sheet is welded into large containment systems for mining applications and municipal waste disposal which is the third primary use for extruded sheet which is a geomembranes system.

The most common polymer for use in sheet extrusion continues to be Polystyrene. It is the dominant material for thermoformed packaging and competes with ABS and PP in technical markets. End use applications include tubs and pots for yogurt, margarine, and desserts. Thermoformed packaging is also used in many other applications in the food industry for packing various kinds of products.

The most common technique used in extruding plastic sheet for the thermoforming industry is Single layer flat extrusion. Resin is fed into an extruder where it is plasticized into a melt.

Profile Extrusion

Profile Extrusion is produced by forcing uncured rubber through a die under heat and pressure, to form a part with a uniform cross section. This uncured rubber is then run through a heating unit to initiate the chemical cross linking reaction that causes the rubber to cure.

This production line can productively produce profile product. It has high output capacity, durability and plastic evenly with recent technology and optimized design.

Process:

The plastic is fed in the machines, the material is conveyed continuously forward by a rotating screw inside a heated barrel being softened by both friction and heat. The softened plastic is then forced out through a die and directly into cool water where the product is solidified. From here it is conveyed onwards into the take-off rollers, which actually do the pulling of the softened plastic from the die.

Typical Materials for Plastic Profiles

(High Density Polyethylene) HDPE

(Low Density Polyethylene) LDPE

Linear Low Density Polyethylene) LLDPE

PETG

PVC Flexible

Butyrate

Polypropylene

Polystyrene

ABS The most commonly used material for general purpose extrusions is PVC.

Over-Jacketing Extrusion

Over-Jacketing Extrusion is produced by forcing uncured rubber through a die under heat and pressure, to form a part with a uniform cross section. This uncured rubber is then run through a heating unit to initiate the chemical cross linking reaction that causes to cure the rubber.

Other related extrusion processes are

Sheet Extrusion

Profile Extrusion

Pipe Extrusion

Lamination

Foam etc.

Pipe Extrusion

In the extrusion of plastic pipe wherein the pipe is in a semi- molten or self supporting state on exiting a die, the inner surface of the extruder is cooled by a device which applies suction for establishing flow of a cooling fluid which contacts the inner surface of the extruder. In a further process the flow of cooling fluid established for cooling the extruder additionally cools a cavity within a middle part of a die or. The process of forcing the polymer melt through a shaping die that is circular is defined as Pipe extrusion. The extruder from the die is cooled, sized and the formed pipe is pulled to the winder or a cut off device with the aid of haul off device.

COATING AND LAMINATION

Extrusion laminating is a process related to extrusion coating, but the difference here is that extrusion-coated layer is used as an adhesive layer between two or more substrates. A secondary layer is applied to the extrusion coating while it is still hot. It further monitors the melt curtain before the chill roll before the sandwich is formed. The sandwich is then pressed together by pressure rolls. In addition to providing adhesion, the extrusion-coated layer may also serve as a moisture barrier.

In extrusion coating, resin is melted and formed into thin hot film. It measures the extruded film as it is coated onto a moving, flat substrate such as paper, paperboard, metal foil, or plastic film. The coated substrate then passes between a set of counter rotating rolls.The extrusion coated layer may protect a printed substrate or act as a moisture barrier which press the coating onto the substrate to ensure complete contact and adhesion.

CO- EXTRUSION

The advantage of coextrusion is that each ply of the laminate imparts a desired characteristic property, such as stiffness, heat-seal ability, impermeability or resistance to some area or environment.

The process of extruding two or more materials through a single die with two or more dies arranged so that the extruders merge and weld together into a laminar structure before chilling. Each material is fed to the die from a separate extruder, but the orifices may be arranged so that each extruder supplies two or more plies of the same material. Coextrusion can be employed in film blowing, free film extrusion, and extrusion coating processes. The benefits of coextrusion is that each ply of the laminate imparts a desired characteristic property, such as stiffness, heat-sealability, impermeability or resistance to some environment, all of which properties would be impossible to attain with any single material.

CAST FILM EXTRUSION

Process that involves the extrusion of polymer melts through a slot or flat die to form a thin, molten sheet or film. This film is "pinned" to the surface of a chill roll (typically water-cooled and chrome-plated) by a blast of air from an air knife or vacuum box. Process by which a polymer is extruded from a slot dies onto the surface of a water-cooled roll. Film is clearer and has more sparkle than blown film.Stretch films manufactured by the cast film extrusion process are called cast films. Stretch film extruded by the cast method typically have greater tear resistance, greater aesthetic values and are quiet to unwind, which is not typically found in film manufactured by the blown method. Plastic film produced from synthetic resins (such as polyethylene) by the cast process. In this process, the molten resin is extruded through a slot die onto an internally cooled chill roll.

Foam Extrusion

During the chemical foam extrusion process chemical foaming and plastic resin agents are mixed and melted. The chemical foaming agent decomposes liberating gas which is dispersed in the polymer, melts and expands upon exiting the die. Due to the insulation properties of the foam structure foamed profile extrusions require more intense cooling than solid profiles.

Calendaring

Calendering is a process that usually uses four heated rolls rotating at slightly different speeds. PVC is the most commonly calendered material. Again the material is fed into the rolls, heated and melted, and then shaped into sheet or film.

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