Plastic extrusion companies are no different than any other business. You want to make your plastic extrusion process as efficient as possible. Making sure the people who operate plastic extrusion machinery have the necessary plastic extrusions education and training is a good start toward improving the bottom line. It’s imperative that everyone connected to the process have a thorough working knowledge of the plastic extrusion equipment.

Whether you’re the owner, the foreman, the engineer or the machine operator, you should have basic training in how to operate of the plastic extrusion machines in the shop or factory. While the education doesn’t need to be specific for any one particular plastic extrusion equipment manufacturer, it should be solid enough to give you the following information:

1. The physical aspects of plastics and plastics extrusion.

2. Adjusting the plastic extrusion die to get the custom plastic extrusions you need.

3. Basic plastic extrusion design and engineering.

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Train everyone in-house on plastic extrusion machines

You may have someone on staff that is an expert who can teach this class, or you can hire specialists to come into your shop for training. Either way this is a good investment.

I recommend: The Society of Plastics Engineers offers in–house training for plastic extrusion products. You can get plastic extrusion molding training from Milacron. It offers customized classes at your plastic extrusion plant.

Enroll in plastic extrusions education and training courses

You can find classes at local technical schools as well as community colleges. You can take individualized courses on the plastic extrusion process only, or you can include the courses as part of a certificate or degree.

I recommend: Receive hands-on training in the plastic extrusion process from the Plastics Institute of America. Penn State Erie offers training in the basics of plastic extruder machine operation.

Find online plastic extrusions education and training

Courses are available either as individualized sessions or as group training. Some plastic extrusion companies make their training available for all employees as part of a continuing education program. You can find generalized, basic courses, and you can also find advanced classes to meet your training needs.

I recommend: You can get plastic extrusions education and training from Paulson Training Programs. This non-vendor-specific training can give you a good understanding of the basics of plastic extrusion machines. You can also receive training in custom plastic extrusions. Paulson offers a number of courses you can customize for your needs. Learn about plastic extrusions from the interactive training offered by A. Routsis Associates.

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Helpful advice for making the most of this Guide

• •  If you send one person from your shop to receive specialized plastic extrusions education and training, make sure that person plans to remain in your employ for a number of years. This is especially important if this employee is to be your plastic extrusions trainer.

A plastic extruder takes semi-melted plastic and sends it through a plastic extrusion die. As the plastic extrusions cool, machines cut them to the right length. Plastic extrusion companies are able to produce custom plastic extrusions at a low cost because there is very little material wasted during the plastic extrusion process.

The majority of plastic extrusion companies use screw extrusion machines to make their plastic extrusion products. However some, plastic extrusion molding must be manufactured with a ram if the plastic's extrusion base material doesn’t melt to a soft enough material for a screw extrusion machine to efficiently mold it.

Custom plastic extrusions are only as good as the company that makes them. The plastic extrusion manufacturer you choose should meet certain standards:

1. Pay a visit to the plastic extrusion plant to make sure the plant operates with the latest in plastic extrusion machinery.

2. Seek references from a plastic extrusion manufacturer's past clients.

3. Find a full-service plastic extrusion manufacturer who can set up his equipment to meet your needs now and in the future.

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Search for plastic extrusion companies that provide standard products

If you can make use of plastic extrusion products, you can save money. Many plastic extrusion products on the market today are standard size and you may be able to adapt the existing product to meet your needs.

I recommend: The Spiratex Company has a large inventory of plastic extrusion products in a wide range of colors and sizes. While SFR Industries, Inc. offers a smaller inventory of standard products, you may exactly what you are looking for with them.

Work with plastic extrusion companies that have expertise in plastic extrusion design

Find a company with the plastic extrusion equipment and technical knowledge to create the plastic extrusion designs you need for your business.

I recommend: Crescent Plastics, Inc. and Applied Plastics are industry leaders in plastic extrusion design.

Get custom plastic extrusions

Find just the right combination of plastics. Locate plastic extrusion companies that can combine as many processes as possible to save you money.

I recommend: Fram Trak Industries, Inc. can combine the lamination process with the extrusion process so you can decorate your plastic extrusions as they come out of the machine. Intek Plastics can combine up to four different combinations of plastics to get the right strength for your needs.

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• •  Plastic extrusions can help you solve design problems by getting just the right mix of plastics. You can make plastic extrusions that have anti-friction as well as anti-static properties. Plastic extrusions can also be set to meet strict weight-bearing guidelines. The right combination of plastics can be both environmentally-friendly and still stand up to anything.

Plastic extrusion is a manufacturing process through which plastic is melted and shaped into a continuous profile. This process is useful for the production of a wide variety of products, including pipes, frames and channels.

If you want to be a supplier of plastic extrusion products, you will need to get acquainted with various technical terms associated with the extrusion process and the different types of plastics. This guide covers some technical terms, such as resin, thermoplastic and polymer.

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Resin

Resin is a solid or semi-solid organic (carbon based) material, either natural or synthetic. Various resin materials are used for manufacturing plastic extrusion products.

I recommend: wiseGEEK, an information resource, provides explanation about the different types of resins.

Polymer

Polymer compounds have a large molecule composed of many smaller molecules linked together. The process of forming a polymer by combining large numbers of chemical units or monomers into long chains is called polymerization.

I recommend: Chemicals Technology, an informative website, offers definitions for various technical terms, such as polymer. In addition, you can read through detailed information on polymer at the Laboratory of Atomic and Solid State Physics at Cornell University.

Thermoplastic

A thermoplastic is a polymer that melts on heating and solidifies to a very glassy state on cooling. Thermoplastics can go through melting/freezing cycles repeatedly. This quality makes this polymer an ideal material for plastic extrusion products.

I recommend: You can read through the glossary of electrical terms at Röchling Glastic, a supplier of high performance composites. General Composites is another composite supplier that provides definitions for various terms, including polymer and thermoplastics.

Thermoset

Unlike thermoplastic, a thermoset polymer can not be melted/frozen repeatedly. A thermosetting plastic hardens permanently on cooling and you will need to consult an expert if you want to extrude thermoset plastics.

I recommend: Mid-Michigan Society of Plastics Engineers (PDF), a knowledge resource for plastics industry professionals, offers information about thermoset plastics. In addition, you can read through information at Knowledgerush.com.

Hot extrusion

As the name indicates, hot extrusion is carried out at high temperatures. At higher temperatures, the yield strength of the plastic is less than its value at room temperature.

I recommend: You can read through an explanation of the hot extrusion process at GlobalSpec, an online information resource.

Cold extrusion

The cold extrusion process is carried out at room temperature. However, extrusion at room temperature might induce some stresses in the extruded product.

I recommend: You can read through the cold extrusion process at Heckler AG, a metal forming company.

Purging

Purging is the process of cleaning one type of material or color from an extruder by forcing it out with a new material or color.

I recommend: You can read through the basics of purging at Xaloy Inc. (PDF), a service provider of plastic extrusions.

Billet

A billet is the raw, solid material kept in the extrusion die for further processing. Dimensions of the plastic extrusion products depend upon the billet dimensions.

I recommend: Automation Supplies, a manufacturer of aluminium extraction frameworks, provides information on billet.

Plastic extrusions pricing and costs include the operation and maintenance of the equipment, number of units to be produced and secondary procedures to be performed on each item. Plastic extrusion is a manufacturing process that adapts itself well to mass production. The raw material is melted and formed in a continuous profile, needing only to be cut at specific intervals to form the individual product.

These items may consist of closed tubes such as pipes, weather stripping and wire insulation. Plastic extrusion also can produce flat products like sheet or film. Plastics extrusion costs may be grouped into any of the following three categories:

1. Companies that produce products with plastic extrusion equipment. These companies may be used when an appropriate product is not available off the shelf.
2. Plastic extrusion equipment. This typically refers to a specific die but may also include other parts needed for plastic extrusion.
3. Standard plastic extrusion products. These products are mass production items and typically are produced in large quantities.
   

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Find prices on custom plastic extrusions

Some applications for plastic products require an unusual or unique set of specifications. These products typically require a custom quote and offer a range of physical characteristics.

I recommend: Astro Plastics specializes in custom extrusions and has two production facilities to save freight costs. PBS Plastics provides custom plastic tubes and has an online form for price quotes.

Look at the cost of plastic extruder equipment and parts

Plastic extruders are typically expensive pieces of equipment available only to larger businesses. They are frequently leased or purchased by the specific piece.

I recommend: Oxford Engineered Materials provides an overview of the tooling dies for plastic extruders, including a price range. K.D. Capital Equipment leases plastic extrusion machines and provides a variety of financing options.

Get prices on standard plastic extrusion products

Many products produced by plastic extrusion have a variety of common uses. The pricing is typically determined by the complexity of the part and the quantity to be made.

I recommend: Creative Plastic Products bases its price estimates on the length and complexity of the cross section. Custom Profiles typically uses long runs to offer economical prices.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Thermoforming is a common factor in the cost of a plastic extrusion process. After a plastic sheet is extruded, it's heated to a specific temperature until it becomes pliable and can be molded into a new shape. Thermoforming frequently uses a vacuum to draw the plastic into a mold in a process known as vacuum forming. This process is commonly used to form plastic containers for holding liquids. Thermoforming can also be used to bend extruded products into simple pieces, such as window frames, or more complex shapes like computer housings.