Extrusion is one of the most popular processes that manufacturers adopt to create a comprehensive range of objects of a fixed cross-sectional profile. In this methodology, the material is pushed through a die of the wanted cross-section. Before we go deeper into other aspects of extrusion methodology, let’s take a look at its history:
History of Extrusion Molding
It was the 1870s when extruders were first developed aiming at the production of sausages. When it comes to the evolvement of the single-screw extruder, it came into existence in the year 1930s aiming at mixing semolina flour and water to mass-produce pasta. It was also heavily used to produce ready-to-eat cereals to shape different types of pre-cooked dough. The shear rate was very low in both these applications. Over time, things got even more advanced, and directly expanded curls were also produced making use of extruders. It was all during the late 1930s and 1940s. Since then extrusion methodology has come a long way playing a pivotal role across all crucial industries.
Extrusion methodology is extremely popular around the globe because of the following factors:
- Extrusion methodology can create even the most complex cross-sections
- Through extrusion, even the most brittle materials can be processed and treated because materials being processed meet only shear and compressive strength
- Through extrusion technique, manufacturers can enjoy and an excellent surface finish can also be ensured.
Drawing is also the same process but has limitations. In the drawing process, the tensile strength is used to pull it through the die. This process does not give any freedom as far as the number of changes to be carried out in a single step is concerned. Drawing is one of the most popular medium of creating objects such as wires, metal bars, and many times tubes also.
Extrusion might be of both of the following types:
- Continuous – theoretically producing indefinitely long material
- Semi-continuous – producing many pieces.
Both the processes can be performed on hot and cold materials. It takes state–of–art infrastructure provided by the leading manufacturers and suppliers of Polyethlene extrusion lines and facilities of PTFE coating lines.
Manufacturing companies around the globe make use of extrusion molding to create a large number of products. Some of the most common ones include rain gutters, PVC pipes, macaroni, and even straws.
Here are some of the most prominent advantages of extrusion technology:
Low cost
When it comes to evaluating extrusion molding on the front of costing, it scores very heavily over all other procedures available. The extrusion process is both effective and efficient because it makes use of thermoplastics that can undergo hardening and melting as many times as required. What’s more, the leftover materials that are discarded on other methodologies as waste can be easily reused when an extrusion facility provided by some of the top manufacturers and suppliers of Polyethlene extrusion lines and PTFE coating line is in place.
This results in lesser demand for raw materials as well as disposable costs. The new-age extrusion machines that process thermoplastics operate continuously and thus they bar all the mechanical failures and downtime. This methodology also brings down the chances of inventory shortage while permitting round-the-clock unstoppable manufacturing.
Unmatched flexibility
Another top reason behind the ever-growing popularity of extrusion molding methodology lies in the unmatched flexibility that it offers to the manufacturers. This methodology provides considerable flexibility when it comes to making products or objects with a constant cross-section. To understand the concept better, just imagine the cutting of a cheese block in a large number of pieces. All these pieces will maintain a rectangular shape regardless of the piece or pieces that you choose to pick.
Since the cross-section does not show any change in its geometry, the extrusion process can create even the most complex shapes, for instance, decorative trims. By making some minor changes, manufacturers can make use of extrusion molding methodology for varied plastic sheets. The variations involved in the extrusion molding process also permit the manufacturers to create objects that have a mixed plastic nature on the material level including hard and soft surfaces. Top manufacturers and suppliers of Polyethlene extrusion lines and PTFE coating line are making constant efforts to further improve their machines and equipment for even better flexibility.
Post-extrusion alterations
No other methodology can offer as many post-extrusion alterations as extrusion molding does. In this method, the material (plastic) remains hot the moment it leaves the extruder, and this provides the manufacturers with the flexibility to make all the desired alterations. Manufacturers use a large number of rollers, dies, and shoes. They make certain manipulations in the extruded plastic as per the specific requirements.
Miscellaneous
- Effective, efficient, and practical method for producing a comprehensive range of plastic products
- Fast and efficient more than any other methodology at producing continuous shapes in varying lengths
- Large volume of production with the least possible wastages
- With the sophisticated machinery, there is a wide scope of creating diverse shapes and sizes
- Possibility of complex shapes creation with varying thickness, textures, colors, etc.
- Manufacturers can also use a large number of additives. These improve the products’ properties, quality, durability, reliability, and fire resistance while bringing down friction or static.
- This methodology is well-known for cheaper tooling when compared to any other plastic manufacturing methods.
Concluding Remarks
Supermac Industries came into existence in the year 1974. The company is catering to numerous industries today operational in the cables sector. Some of them include power, optical fiber, house wiring control cables, and medical lines. As one of the leading manufacturers of Polyethlene extrusion lines and PTFE coating line, the company boasts of a diversified product portfolio. It includes a complete range of extrusion machines, crossheads, caterpillars, capstans, screws and barrels, take-ups, and pay-offs. Right from the very beginning, the company has focused on providing fully customized solutions to its customers.
