Learning how to operate, maintain and repair machines for extrusion is essential in many industries, such as food, metal and plastics manufacturing. Depending on what job you're aiming for, the amount of education and training you'll need will vary. Part designers and repair workers will need a much more intricate understanding of how an extrusion machine works, whereas an operator will just need to understand basic functions.

Simple training like extrusion machine operation can sometimes be taught through on-the-job training, but maintenance, repair and design positions will require more formal education. This can include taking classes, securing an apprenticeship or attending industry events. If you're considering extrusion machines education and training, think about the following:

1. Enroll in classes on extrusion machines at your local college or industry center.
2. Continue your education with extrusion machine industry events.
3. Enter into an apprenticeship with a professional in the extrusion machine industry.
   

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Take classes on extrusion machinery

Classes on extrusion machines usually center around how an extrusion machine is used in a particular industry. For instance, classes are often available on using extrusion machines in the food industry or in plastics manufacturing. This type of class can be found through some degree programs and many trade schools. There are classes available for almost every industry that extrusion machines are involved in, so make sure your class applies to the job at hand.

I recommend: Enroll in the Texas A & M Extrusion Technology Program, or attend a class in extrusion machinery at the Pennsylvania College of Technology.

Go to extrusion equipment industry events

You can find more extrusion information at industry events like trade shows, conferences and workshops, as well as career and network advancement opportunities. Conferences and trade shows allow you to learn more about the latest extrusion device models and browse the newest extrusion machines for sale. Workshops give you an opportunity to practice new skills or brush up on old ones, advancing your industry knowledge.

I recommend: Check extrusion machines at the European Thermoforming Conference, or learn more about extrusion equipment by attending a Society of the Plastics Industry event.

Become an apprentice in the extrusion machine industry

Apprenticeships that cover a variety of extrusion devices are available from many trade organizations, manufacturers and colleges. This type of program can give you hands-on experience in the operation, repair and maintenance of extrusion machines under the supervision of an experienced professional. An apprenticeship also gives you a better impression of your duties and responsibilities on-the-job.

I recommend: Enroll in an apprenticeship program that covers extrusion machines at Oakland Community College or G. James Glass & Aluminum.

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• •  Some jobs require specialized knowledge about a specific type of extrusion machine, like a single screw aluminium extrusion machine. This type of job usually requires basic knowledge of extrusion machinery, which is supplemented with on-the-job training.

Extrusion machines implement alignment guides and shaping dies to form continuous, uniform shapes from raw material. As the continuous shape exits an extrusion machine, the machine cuts the shaped material at regular short intervals or, in the case of plastic tubing, very long intervals.

Plastic, rubber and ceramics are common extrusion materials for automotive and construction applications. There is also copper and aluminum extrusion machinery. Machines for extrusion even process other metals, like steel for railings and titanium for aircraft.

There is both hot and cold extrusion machinery, and both work very hard in the shaping process, often at high pressure. There are also a lot of variables that affect the quality of the extruded product. Here are some product defects to watch for:

1. Product surface cracking results from excessively high temperatures, friction or speed, or from product sticking to the extrusion machine's surfaces.

2. Product piping (where impurities flow to the center) results from excessively high friction or temperature variations in the extrusion machine parts.

3. Interior product cracking results from a defect in the shaping process in the die of an extrusion machine.

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Buy hot extrusion devices for heavy-duty applications

Heat makes various materials more malleable. However, in the case of metals, hot extrusion requires temperatures ranging from 600 to 4000 degrees Fahrenheit and pressure anywhere from 500 to 100,000 psi. The disadvantage of hot extrusion is the cost of manufacturing and maintaining equipment that can handle such harsh conditions. The application will determine if hot extrusion is necessary.

I recommend: Sources of extrusion machines do not necessarily specialize in either hot or cold equipment. However, if you are in the market for a hot extrusion device, you might be interested in a source like Stopol, which sells both new and used extrusion machinery. Also, look for companies that offer a lot of services, like The Bonnet Company.

Buy cold extrusion devices and save on maintenance costs

Cold extrusion has many advantages over hot extrusion. For instance, oxidation is lower and cold working produces higher product strength. With cold extrusion it is also easier to achieve closer tolerances and quality product finishes. When possible, cold extrusion is usually preferable and less costly.

I recommend: The sources listed above have cold extrusion machines for sale. However, it's good to shop around for the best price and the best fit for your extrusion needs. J J Jenkins, Inc. has a wide range of products and works with you to design whole systems. Especially for sheet extrusion, also take a look at Welex.

Repair your extrusion equipment

Extrusion machines have a lot of moving parts and involve high forces, temperatures and pressures. This means you should not be surprised if your need repairs.

I recommend: Diamond America Corporation does on site repairs, orders replacement parts and refurbishes machines. Technical Process & Engineering, Inc. carries parts for many major manufacturers and also duplicates or manufactures custom parts.

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• •  You'll probably need to purchase equipment to stamp, bend and drill your product post-extrusion. Many companies that manufacture extrusion machines can also custom design this machinery for you.

Extrusion is the process of forcing a raw material through a die under extreme pressure to get the desired shape. Manufacturers of extrusion products can produce various profiles using the same extrusion machine. Commonly extruded materials include aluminum, copper, plastic and even ceramic. Extrusion products have applications in various industries, including automotive, food processing and construction.

If you want to use extrusion machines for your applications, you will need to be conversant with the technical terms of extrusion machines. This guide intends to familiarize you with the key terms for extrusion machines, such as extrusion die, extruder barrels, extrusion speed and screw and ram extruders.

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Extrusion dies

An extrusion die, an integral part of an extrusion machine, has one or more machined openings to produce the desired extruded parts or sections.

I recommend: AACOA, a supplier of extrusion products, offers a glossary technical terms that explains extrusion dies and their types. For information about extrusion dies, their design features and characteristics, you can browse through the website of Uddeholm (PDF), a manufacturer of tool steel.

Extruder barrels

An extruder barrel is the portion of the extruder (extrusion machine) that surrounds the screw or plunger.

I recommend: For information about extruder barrels, you can browse through the Extruded Profile website, a business-to-business (B2B) marketplace for extrusion products.

Screw extruders

A screw extruder forces the material out through the barrel and die, using a screw mechanism.

I recommend: For information about screw extruders, their types and advantages, you can browse through Tangram Technology Ltd.’s website, a service provider for the plastics products and window industries.

Ram extruders

A ram extruder moves the raw material through a barrel and die, using a plunger (commonly known as a ram) rather than the usual screw mechanism.

I recommend: Ceramic Industry, a magazine for manufacturers of advanced ceramic products, explains more about screw extruders and ram extruders.

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 supplier of industrial machinery components for the plastics industry.

Extrusion speed

Extrusion speed is an important specification of any extrusion process. Before selecting an extrusion machine, you must evaluate the required extrusion speed.

I recommend: Burak Aluminium offers a glossary of technical terms, including extrusion speed.

Direct or indirect extrusion

In direct extrusion process, a preheated billet, placed in a heavy walled container, is pushed through the die by ram pressure. The metal flows in the same direction that the ram has traveled. In indirect extrusion process, the die is at the ram end of the billet, and the product travels through the hollow ram in the opposite direction.

I recommend: For information about direct and indirect extrusion, you can read through the glossary of technical terms at Capital Aluminium Extrusions Ltd.

Hot or cold extrusion

Hot extrusion is carried out at high temperatures. At higher temperatures, the yield strength of a metal or alloy is less than its value at room temperature. Unlike hot extrusion, the cold extrusion process is carried out at room temperature. While selecting extrusion machinery, you will need to determine the type of extrusion process, as the machinery differs according to the process.

I recommend: eFunda, an informative website for engineering fundamentals, explains more about the hot and cold extrusion processes.

Extrusion machines pricing and costs primarily consist of the costs of the machinery itself, the maintenance costs and the operational costs. Extrusion is a popular manufacturing method for items with a fixed cross section. Material is pushed through a die that forces the material into the desired cross section and typically cut at specific intervals. There are several different materials that can be extruded, such as plastic, metals and sausage.

The primary advantages of extrusion over more traditional methods of manufacturing are the ability to easily create items with very complex cross sections and the ability to use a raw material that is brittle. The following categories show three types of costs on machines for extrusion:

1. Financing for extrusion devices. Extruders are frequently financed since the purchase of these machines would typically requires a great deal of a company's capital.
2. An extrusion machinery purchase. Many manufacturers also offer the outright sale of an extrusion machine.
3. Extrusion machinery parts. These machines require parts to be replaced frequently.
   

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Locate financing for an extrusion device

Some companies specialize in financing manufacturing equipment, such as extrusion machines. Leasing this type of equipment is a popular option since the machine may not be needed once a production run has been completed.

I recommend: Crest Capital specifically provides financing on extruders and offers free online quotes upon completion of an application. K.D. Capital Equipment provides set prices on extruders and also offers financing options.

Research the prices on extrusion machines for sale

New extruders are more likely to have the latest features. Many companies that sell new machines also buy and sell used equipment.

I recommend: Stopol Equipment Sales offers a variety of extrusion machines and also sells used extruders. You must request a quote for pricing on specific models. Townsend Engineering provides a completely automated sausage extruder with additional cost saving features.

Examine the cost of parts for extrusion machines

Extruders consist of many parts that must be regularly replaced. Companies that sell extruder parts typically carry a wide variety of parts for manufacturing equipment.

I recommend: Wexco sell manufacturing parts, such as extruder barrels, and also offers quotes upon completion of a form. Roofing Wholesale offers a set price on a tile extruder and also provides specific parts and accessories.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  Extrusion services involving metals as the raw material must use hot extrusion. The metal is heated close to its melting point to make it easier to push through the die. Metals, such as aluminum, with low melting points are therefore the easiest to extrude. However, it is frequently economical to extrude refractory alloys with very high melting points. Extrusion of metals is most economical with smaller quantities and each type of metal has a cross-over point at which it becomes more economical to use rolling instead of extrusion.