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A Simple Explanation Of Plastic Extrusion
To anyone who has not worked or been involved in the manufacturing industry, it often seems a complete mystery how ordinary, everyday items like plastic, that are used throughout society, are actually made. In fact it is so interesting to the general public, that there is a television series showing viewers inside many manufacturing plants and revealing what up to now were almost like secrets. It is a testimony to human ingenuity that scientists and engineers have been able to devise a process like plastic extrusion, then build the complex machines that can turn that process into something of value to society.
A common, everyday material such as PVC Plastic begins its life cycle as a raw material in powder or pellet form.This powder or the pellets are funnelled into an extruder, which has a rotating screw inside it, and this pushes the plastic material through the machine. This rotating screw lies inside a cylindrical shaped heated barrel and as the plastic material passes through, it softens from the friction and heat.
The plastic material, now softened, is a continuous piece which is pushed through a die at the end of a barrel and is cooled and solidified in water. Still on a moving conveyor, the softened extruded material is pulled through take-off rollers and off the die, which is a metal plate attached to the end of the extruder. The plastic is shaped via the hole cut into the die which determines the shape of the end result. The cross-section of the finished plastic depends on the speed of the take-off rollers and the shape of the hole in the die.
There are a number of different extrusion processes used depending on the type of material needed and the specifications of the client. For example, manufacturers using a process called co-extrusion, can run the same production line but have it produce several different types of plastic at the same time.
The extrusion process is completely automatic, and while the initial purchase of the machines is expensive, there are considerable cost savings in labour throughout the life of the machine.The continuous dimension checks and automatic machine adjustments allow the plastic manufacturers to make anything from simple tubes and rods to complex window profiles. Large items such as pipe with a 150cm dimension can be produced using the extrusion process.
The plastic extrusion process is quite fascinating, and a tribute to the engineering minds who conceived it. Plastic is now used for all kinds of things, replacing metal in many instances. This has also lowered costs as generally, plastic is cheaper to produce. It is also much lighter, and this has created market opportunities for light-weight products. It seems that the sky is the limit for the uses of plastic.
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