Here at Condale Plastics, quality is one of our core values! It is a crucial aspect of our plastic extrusion production process, it ensures the final products meet industry standards and, more importantly, your standards! So how do we ensure our profiles are the best they can be?
GD-HUB are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.
Firstly, to ensure we provide a quality service from start to finish, Condale Plastics is ISO: accredited. This means our quality management system ensures that your product and the service we deliver is up to expectations throughout the design, manufacture and delivery of each plastic profile.
Critically important to the production of quality extrusions are quality raw materials. We only purchase materials from reputable and approved material suppliers. Consistent standards of acceptance are maintained whether our raw materials are virgin or recycled. Our incoming products are quality assured and so should require little inspection. We will however undertake a cursory inspection of plastic pellets to check for contamination, impurities or defects that could affect the final product.
Our in-house maintenance team work closely with our production team to maintain our extrusion equipment in top condition. As you would expect, we operate a comprehensive planned maintenance system on all important and critical equipment.
Our tools are cleaned, inspected and lubricated in our tool-store to ensure that they are in good working condition and will produce the best plastic profiles possible. If a tool requires refurbishment or repair it will be sent over to our in-house tool room for the appropriate work to be carried out.
Optimal process conditions are specified in our work instructions. All extruders are fitted with the latest digital controllers to maintain process temperatures, speed and melt pressures at all times throughout a production run. Our calibration tables are also fitted with temperature, flow and vacuum indicators that enable our experienced machine operators to maintain the optimum conditions for our profiles and tubes.
For all of our products, we agree the key dimensions and other parameters (such as colour or finish) that will be measured during production. Tolerances will also be specified and agreed at that stage. Thereafter, for any order of a product, the dimensions and features will be checked against the set specifications during production to ensure they are within agreed tolerances.
Our machine setters carry out quality checks at periodic intervals throughout the production of an extrusion. These checks are recorded. If necessary, any non-conformances will be reported and adjustments made to the process conditions to correct any problem. In addition to the checks carried out by our machine setters, our Quality Control Inspectors conduct their own checks on a continual basis throughout the day and night. If an error is detected, the inspector will notify the setter and ask them to make any corrections.
Once a batch is complete, the inspection records will be checked prior to releasing the product for despatch. Once signed off as compliant, the plastic profile is ready to go!
In order to maintain high levels of quality control, it is vital that our team upholds our high standards! To keep our team on top of their game, we provide regular feedback to our production and quality teams with regard to non-conformances, complaints and occasionally compliments! Additional training is regularly given to employees on quality control procedures and changes to practices or standards that may affect them.
We continue to tweak and improve our processes based on customer feedback, analysis of production performance, and customer appraisals; updating our facilities with the latest extrusion technology also ensures that we progressively improve the standard of our products and service.
Plans for a new Quality Laboratory are well underway and will be implemented later this year! We are also looking to invest in some of the latest CAM equipment and lighting to improve our product assessment.
By implementing these changes and by maintaining our quality assurance strategy, our plastic extrusion processes can produce high quality products that are safe and reliable. The team here at Condale Plastics are ready and waiting to help you develop your plastic profiles and tubes.
Get in touch with one of the Condale team today or give the team a call on to discuss your application.
What Is Plastic Extrusion &#;The Ultimate Guide You Should Know
Plastic extrusion is a cost-effective and efficient plastic manufacturing method that enables the production of continuous lengths of plastic profiles, shapes, tubes, and other forms.
The process begins with thermoplastic material in the form of pellets, granules, or powder which are heated and melted, and then pressed through an extruder machine with the help of shaping devices such as extrusion molds. Subsequently, it undergoes cooling to solidify and harden, ultimately forming the required cross-sectional shape. This method is widely used in producing various plastic pipes, profiles, films, sheets, and more.
The History of the Plastic Extrusion Industry
The history of the plastic extrusion industry can be traced back to the late 19th and early 20th centuries. Initially, most people used simple manual mechanical tools for plastic processing.
The continuous development of technology has driven the upgradation of automation as well as the precision of extrusion processing. It has significantly increased production capacity, and reduced production costs, to achieve diversified product types. Nowadays plastic extrusion products are widely applied in construction, packaging, medical devices, and the automotive industries.
Plastic extrusion processing methods have continuously innovated with the progress of material science and engineering technologies. It propels the development and application of new plastic materials and the iterative enhancement of more sophisticated extruders. It has become one of the most crucial and commonly used methods in plastic processing.
As with future technology upgrades, extrusion technology will drive the demand for energy-efficient and environmentally friendly production methods, as well as the increased need for sustainable plastic materials.
Types of Plastic Extrusion
1. Sheet Extrusion
Sheet extrusion is a versatile manufacturing process in the plastics industry where a continuous plastic sheet is produced with various properties, thicknesses, and dimensions. This process involves the use of an extruder which has the capability to melt, blend, and shape plastic raw materials into a specific form.
Plastic sheets are widely used in packaging, signage, construction materials, automotive components, and more. The process is efficient for large-scale production and allows for customization to meet specific requirements.
2. Blown Film Extrusion
Blow film extrusion is a process that involves shaping thermoplastic plastics into hollow three-dimensional forms through two main steps: extrusion and blow molding.
Specifically, it involves extruding a tubular-shaped parison, clamping it in a mold cavity, sealing the bottom, and then inflating it by introducing compressed air into the interior of the parison. It is a manufacturing process for producing hollow thermoplastic parts and is commonly used in the production of various plastic products such as bottles, containers, and pipes.
Although this process is relatively easy, there are some potential challenges, such as ensuring the uniformity of the melt to prevent uneven wall thickness or bubbles during blowing.
Additionally, the design of the mold is crucial to obtain the desired shape and size of the product. Controlling the cooling rates and temperature distribution poses a key challenge. These aspects require experienced engineers and operators, along with careful quality control and process optimization, to ensure the production of high-quality plastics.
Profile Extrusion refers to the production of plastic profiles with specific cross-sectional shapes with an extruder machine.
Profiles can be classified into two types based on material. One type is fully plastic profiles, and the other refers to composite profiles obtained by combining plastic and non-plastic materials.
Based on the flexibility of the profiles, they can be further categorized into flexible profiles and rigid profiles. Classification based on plastic varieties includes PVC profiles, PE profiles, ABS profiles, ASA profiles, and so on.
4. Wire and Cable Extrusion
Wire and cable extrusion is a process used to manufacture insulated wires and cables. This process involves the extrusion of plastic or rubber materials over conductive metal wires to provide electrical insulation and mechanical protection.
This process is particularly critical for the selection of raw materials based on different applications. This may involve choosing between thermoplastic and thermosetting materials and finding a balance for requirements such as heat resistance and chemical corrosion resistance.
Therefore, it is an essential step to analyze the application background of wires to select appropriate materials.
Simultaneously, efficient testing equipment and measurements are required to detect potential defects in the cables, such as air bubbles, foreign objects, cracks, etc. Precise quality control is necessary to avoid the generation of unevenness and other issues.
Lastly, it is essential to ensure high speed while maintaining quality throughout the whole production process
5. Two-Color Co-extrusion
Coextrusion is a composite extrusion process that allows two or more different materials to be simultaneously extruded through a single die to form a single product with a multi-layer structure.
This process is commonly used in the manufacturing of plastic products with different performance or functional layers. It allows for the combination of different materials with distinct properties, enabling the production of a composite product that exhibits multiple functions.
Dual-color coextrusion is the most common type, where two different-colored materials (which can also have different properties) are conveyed to the extrusion equipment through separate channels, producing a product with two different colors.
The two input resins must have similar or identical properties; otherwise, poor affinity could result in inadequate bonding. It is mainly used in processing plastic-steel profiles.
Currently, the predominant application is non-homogeneous coextrusion, with subdivisions such as PVC-ASA and PVC-PMMA. Among these, PVC-ASA technology is the most mature and effective. Especially in the architectural decoration industry, dual-color coextrusion plastic products can meet color and performance requirements while effectively saving costs.
Pipe extrusion is a common plastic processing method used to manufacture various tubular plastic products. In this process, plastic materials are heated, melted, and then extruded into the desired shape through a mold. The final pipe product is obtained through cooling and solidification.
The pipe extrusion process can be employed to produce various types of pipes, ranging from small-diameter tubes to large-diameter drainage pipes. The advantages of pipe extrusion lie in its efficiency, relatively low costs, and the ability to produce continuous lengths of pipes.
7. Compounding Extrusion
Compounding Extrusion refers to the process of mixing different types of materials and extruding them to form composite materials with specific properties and characteristics. In the compounding extrusion process, the raw materials are mixed in the form of granules or powder, and then they undergo plasticization and extrusion through an extruder.
This technique allows for the blending of various materials, colors, additives, etc., to tailor the final product&#;s performance, appearance, and other features to meet the manufacturing requirements for customized products.
This technique is widely used in building materials, such as composite profiles, door and window frames, and wall protection panels with durable and UV-resistant features. Additionally, it is also used in the production of casings for electronic products that require wear resistance, corrosion resistance, and insulating properties.
The Major 5 Steps of the Plastic Extrusion Process
Step 1: Raw Material Preparation:
In the extrusion molding process, the first step involves preparing plastic pellets or pellet mixtures and additives. This requires analyzing customer requirements, performance specifications, and application backgrounds to select suitable materials. Commonly used materials include PVC, PP, PE, ABS, and other thermoplastic plastics.
Step 2: Feeding and Preheating:
The required raw materials are introduced into the hopper of the extruder. The extruder heats and mixes the plastic particles, melting them into a molten state. Throughout this process, it is crucial to control temperature and pressure to ensure the molten plastic&#;s dynamic flow and viscosity, ensuring the smoothness of the product surface.
Step 3: Extrusion Formation:
The molten plastic is pushed through the screw of the extruder towards the extrusion dies, where it takes the form of a specific cross-section. The mold design determines the final shape of the product.
Step 4: Cooling and Solidification:
After extrusion through the machine head, the extrudate needs rapid cooling to allow the plastic to solidify quickly. Cooling can be achieved using airflow, water, or other cooling mediums. It is quite crucial to control the cooling time to meet the product&#;s strength properties and dimensional stability.
Step 5:Cutting and Post-Processing
Once the plastic product has completely cooled and solidified, some extruded products may undergo stretching or cutting processes to achieve the desired length and shape.
Secondary Processing including
1&#;Punching&#; Commonly used equipment such as drilling machines, punching machines, laser cutting machines, or other specialized punching equipment are employed, depending on the size and shape of the holes.
2&#;Surface treatment: to ensure a smooth surface and neat edges. This may involve grinding, finishing, or other surface treatment methods.
3) Printing and Marking: Extruded products may require printing of logos, labels, or other markings to comply with regulatory requirements or provide additional information.
4)Packaging: The final extruded products typically undergo packaging for transportation, storage, and sale. Packaging may vary based on the product&#;s characteristics and customer requirements.
What Are the Advantages and Disadvantages of Plastic Extrusion?
The Advantages of Plastic Extrusion:
(1) Extrusion manufacturing processes can shape a variety of profiles and pipes, meeting the personalized demands of different markets. Additionally, the products exhibit excellent thermoplasticity, providing convenience for subsequent processing.
(2) Extrusion processing enables continuous production of large quantities of products with identical cross-sections, significantly improving production efficiency and reducing costs.
(3) Precise Product Dimensions: Extrusion processing can produce high-precision, consistently uniform products suitable for applications with stringent size requirements.
The Disadvantages of Plastic Extrusion:
(1) The design and processing of extrusion dies require a significant amount of time with a substantial investment of resources at the initial stage.
(2) Quality Issues in Non-Uniform Temperatures: When temperatures are inconsistent, profiles can easily develop quality problems such as shrinkage and surface defects.
(3) Limits on the Complexity of Cross-Sectional Types: Extrusion processing has certain constraints when it comes to achieving complex cross-section shapes; It is challenging to realize those highly complex cross-section shapes.
(4) High Energy Consumption: Although the extrusion equipment is simple, extrusion processing typically involves high temperatures and pressures, resulting in relatively high energy consumption.
(5) Limited Material Selection: Extrusion processing is primarily suitable for some thermoplastic materials. For special materials with high temperature or chemical performance requirements, it may not be as applicable.
(6) Inflexible Production Speed Adjustment: Because extrusion processing is a continuous process, adjusting production speed is relatively difficult, making it less suitable for situations that require frequent changes in production speed.
Plastic Extrusion Part Design Guidelines
When designing a new plastic part, there are several important principles that should be followed throughout the whole design and production. They can help to ensure smooth extrusion processing and ultimately achieve high-quality plastic extruded products. Here are some general points for reference
Maintain the symmetry of the cross-section area to ensure an even flow of plastic resin, as well as ensure consistent wall thickness to avoid significant variations, preventing imbalances in product flow leading to deformation.
Utilize moderate rounded corners and smooth transitions to prevent stress concentration and enhance extrusion uniformity. Avoid sharp corners as they may cause uneven material distribution and cooling.
If the design includes hollow cross-sections, maintain consistent wall thickness to ensure uniform cooling and prevent warping and Include appropriate draft angles for easy mold release.
Minimize grooves and overhangs in the design for easy extraction of extruded parts from the mold. For complex features, consider secondary operations after extrusion.
Collaborate closely with mold designers to optimize mold geometry, ensuring uniform extrusion flow and cooling.
Select suitable extrusion materials based on product requirements with the consideration of its melting temperature, flowability, mechanical performance, thermal stability, etc. Also pay attention to the material shrinkage during the cooling process and adjust the design to compensate for these changes.
Implement an appropriate cooling and annealing process to ensure even cooling and shrinkage of extruded parts, meeting the required material performance and reducing internal stresses.
Allocate tolerance ranges for critical dimensions.
Set appropriate mold release draft angles to ensure easy removal of extruded parts from the mold.
Conduct prototype testing to validate the design, identifying and resolving potential issues.
Establish quality control procedures to ensure each extruded part conforms to specified standards and specifications.
Adhere to relevant environmental and safety standards, ensuring extrusion production processes comply with regulations and standards.
Record key extrusion parameters and production data for future quality control and improvement.
The above guidelines are just a short part. There should be more in other comments.
What are the Common Polymers Used in Plastic Extrusion
1. Polyvinyl Chloride (PVC):
2. Polyethylene (PE):
3. Polypropylene (PP):
4. Acrylonitrile Butadiene Styrene (ABS):
5. Polystyrene (PS):
6. Polycarbonate (PC):
7. Polyamide (Nylon):
8. Polyethylene Terephthalate (PET):
9. Polyvinylidene Fluoride (PVDF):
The selection of plastic resin depends on specific requirements such as strength, flexibility, chemical resistance, and thermal stability that align with the desired properties and intended applications of the extruded product.
Quality Control and Testing Procedures in Plastic Extrusion Manufacturing
Quality control and testing procedures during the plastic extrusion processing are crucial to ensure the final extruded product with high-quality requirements. Below is a general guide
Raw Material Inspection:
Take initial sampling and testing of raw materials, including appearance, physical, and chemical properties, to ensure they meet product specifications and quality requirements.
Extruder Parameter Setting-up:
Set up the extruder according to the specifications of the particular material characteristics including the temperature zones, screw speed, and other parameters.
Mold Design and Fabrication:
Designing extrusion dies is a critical aspect of the plastic extrusion process, as it directly influences the final shape and dimensions of the extruded product. Most of the dies are fabricated by professional die makers. The specific characteristics of the extrusion line and material should also be fully considered. It is essential for a successful die design.
Extrusion Process Monitoring:
Use automated control systems or sensors to monitor key parameters during the extrusion process, such as temperature, pressure, and speed. Implement an alarm system to identify and correct potential issues promptly.
Dimension Measurement:
Use appropriate measurement tools to measure key dimensions of extruded products, such as diameter, wall thickness, and length. Regular monitoring and adjustment during production may also be necessary to maintain product quality.
Appearance Inspection:
Perform visual inspections of extruded products to ensure a smooth surface with no bubbles or defects.
Physical Performance Testing:
Use relevant testing equipment to perform physical performance tests such as tension and bending, ensuring product strength and durability.
Random Sampling and Batch Inspection:
Conduct random sampling to ensure consistency and stability in the production process. Perform comprehensive inspections for each production batch to ensure traceability of product quality.
Recordkeeping and Document Management:
Record all key parameters, test results, and operational records during the production process. Ensure that all records are easily retrievable and traceable for analysis and improvement when needed.
Employee Training and Quality Awareness:
Provide regular training to operators to enhance their skills and quality awareness.
Continuous Improvement:
Regularly assess the entire quality management system. Implement continuous improvement measures to enhance production efficiency and product quality.
Possible Plastic Extrusion Issues and Troubleshooting
Poor Surface Quality:
Possible Causes:
Insufficient cooling
Mold wear
Troubleshooting:
Adjust the cooling system to ensure consistent cooling temperatures.
Inspect the mold and replace worn parts.
Ensure the cooling system is operating normally and adjust cooling parameters as needed.
Inspect and replace any worn or misaligned mold components.
Material Flow Obstruction:
Possible Causes:
Impurities in the hopper
Screw or barrel wear
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Troubleshooting:
Clean the hopper to ensure no impurities enter the extrusion system.
Check and replace worn screws or barrels.
Abnormal Noise from the Extruder:
Possible Causes:
Loose components:
Damaged screw or bearings:
Troubleshooting:
Tighten any loose parts.
Check and replace damaged screws or bearings.
Incomplete Melting of Material:
Possible Causes:
Incorrect temperature settings
Improper screw design
Troubleshooting:
Adjust the temperature control system.
Consider replacing it with a suitable screw design.
Internal Bubbles or Defects in Extruded Products:
Possible Causes:
Extrusion speed too fast
Insufficient cooling
Troubleshooting:
Reduce the extrusion speed.
Adjust the cooling system to ensure thorough cooling.
Extruder Motor Overheating:
Possible Causes:
Overloading of the motor.
Insufficient cooling of the motor.
Troubleshooting:
Reduce the extruder screw speed.
Improve motor cooling, such as adding or enhancing cooling systems.
Inconsistent Temperature Control:
Issue: Fluctuations in the temperature of the extruder or die.
Possible Causes:
Malfunctioning temperature control equipment.
Poor insulation.
Troubleshooting:
Calibrate and maintain temperature controllers.
Check and repair insulation to prevent heat loss.
Extruder Surging or Hunting:
Issue: Unstable extruder screw speed or output.
Possible Causes:
Inconsistent material feeding.
Worn-out gearbox or drive components.
Troubleshooting:
Ensure a consistent and uniform material feed.
Inspect and replace worn components in the drive system.
Die Swell Variation:
Possible Causes:
Changes in material formulation.
Variations in processing conditions.
Troubleshooting:
Maintain consistent material properties.
Monitor and control processing parameters.
Poor Dimensional Stability:
Issue: Extruded product does not maintain consistent dimensions.
Possible Causes:
Inadequate cooling.
Residual stresses in the material.
Troubleshooting:
Improve cooling conditions.
Optimize material formulation to minimize stresses.
Excessive Screw Residence Time:
Issue: Prolonged exposure of the material to high temperatures.
Possible Causes:
Slow screw speed.
Inadequate cooling.
Troubleshooting:
Increase screw speed to reduce residence time.
Enhance cooling systems.
Die Drool:
Issue: Unwanted dripping or oozing of material from the die.
Possible Causes:
High melt viscosity.
Inadequate die purging.
Troubleshooting:
Optimize material formulation for lower viscosity.
Implement effective die-purging procedures.
Excessive Energy Consumption:
Issue: Higher energy usage than normal.
Possible Causes:
Inefficient equipment.
Poor insulation.
Troubleshooting:
Upgrade to energy-efficient equipment.
Improve insulation to reduce heat loss.
Inconsistent Output:
Issue: Fluctuations in extrusion output.
Possible Causes:
Inconsistent material feeding.
Worn-out or damaged screw elements.
Troubleshooting:
Ensure uniform material feeding.
Inspect and replace worn components.
Melt Temperature Variations:
Issue: Inconsistent melt temperature.
Possible Causes:
Inadequate temperature control.
Heater malfunctions.
Troubleshooting:
Calibrate and maintain temperature controllers.
Inspect and replace faulty heaters.
Warpage or Distortion
of the extruded product.
Possible Causes:
Inconsistent cooling.
Residual stresses in the material.
Troubleshooting:
Improve cooling uniformity.
Optimize material formulation to minimize stresses.
FAQ about Plastic Extrusion
Q1. What Products Can Be Created with Plastic Extruders?
Q2. What Is the Lifespan of Plastic Extrusion Products?
Generally, the lifespan of plastic materials such as PP, PE, and PS is around 20 years. ABS plastic products can last up to 10 years indoors and a maximum of 5 years outdoors. Other plastic products typically have a lifespan of 3 to 5 years.
Q3. What Industries Use Plastic Extrusion?
Plastic profiles such as PVC door and window frames, PVC sheets, wall panels, etc. have excellent weather resistance, environmental friendliness, and thermal insulation performance, which makes them widely used in architectural decoration and construction areas
2. Packaging Industry
Various packaging products such as plastic frames, plastic boxes, and pallets can be produced by plastic extrusion processing with superior characteristics like lightweight, easy processing, and low cost. These parts are widely used in the modern packaging industry.
3. Automotive Industry
In the automotive industry, the plastic extrusion process is used to produce various automotive components such as door panels, dashboards, luggage racks, and more. These plastic products are characterized by their lightweight, impact resistance, and ease of processing. They are widely applied in the manufacturing of automobiles, enhancing both the safety and comfort of vehicles.
In the electronics industry, plastic extrusion molding is utilized to produce various electronic casings, plugs, and other products. These products exhibit excellent insulation properties, resistance to chemical corrosion, and electromagnetic shielding capabilities, making them an essential component of the modern electronics industry.
Q4. How Long Does It Take for Plastic Extrusion To Finish?
It takes a long process for a whole new plastic extrusion project.
Project Analysis + Tooling Design & Production Prototypes + Customer Approval + Mass Production. The whole process may take at least 45 days.
Q5. How Accurate Is Plastic Extrusion?
Plastic Extrusion processing often faces challenges in achieving the preciseness of metal machining. However, when high precision demands are required to seamlessly coordinate with other components. Meticulous calibration and tuning of mold design and extrusion machine parameters are necessary steps. Meantime, quality assurance measures and testing procedures are implemented at various stages of production to ensure precise dimensions, surface treatments, and other relevant characteristics. This ensures the accuracy expected by the customer is fulfilled, even though achieving the tight tolerances can be challenging in the extrusion process.
Q6. How to control the Plastic Extrusion Temperature?
One of the crucial aspects of temperature control in the extrusion process is the temperature control system of the extrusion machine. Effective management of these key elements plays a vital role in the melting, flowing, and forming of materials, ensuring the overall quality of the extrusion process. The main key factors such as heating and cooling zones, precise calibration of temperature sensors, management of preheating devices, and adjustment of mold temperatures should be managed with high attention.
Q7. Is Plastic Extrusion Expensive Compared to Die Casting?
From the perspective of mold fabrication, the manufacturing cost of extrusion dies is indeed much lower than that of die casting. However, die-casting processes are well-suited for complex and large-scale production of metal products with high precision. Overall, the average processing cost with die casting is significantly lower compared to other processes in the end.
Q8. Plastic Extrusion vs Plastic Injection Molding
Extrusion and injection molding are both crucial methods in plastic processing, but injection molding has a broader range of materials, including those with lower melt strength. However, extrusion is suitable only for materials with good thermal melting strength.
Injection molding is more inclined towards high-precision complex plastic products. Although the initial mold cost is relatively higher compared to extrusion, it offers cost benefits for large-scale production. It is adaptable to a high-volume production scale, ensuring faster turnaround times. Extrusion, on the other hand, is more suitable for producing simple plastic products with consistent cross-sections.
Q9. Plastic extrusion vs aluminum extrusion
Aluminum extrusion is a metal processing involving heating aluminum to a temperature sufficient for softening, and then pressing it into various shapes through molds, such as tubes and profiles.
This method is commonly used in the production of aluminum alloy profiles for items like window frames, door frames, automotive components, and electronic heat dissipators. Aluminum extruded products typically exhibit high strength and lightweight characteristics.
Plastic extrusion is a thermoplastic process. Plastic particles are heated to soften and then extruded through a die to form continuous cross-sectional profiles. This method is frequently employed in the manufacturing of plastic pipes, profiles, sheets, films, and more. Common application areas include construction, electronics, packaging, and other industries.
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