EXTRUSION

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EXTRUSION:
 Continuous Process

 In principle, the plastic raw material is plasticated by means of a screw

plastication unit and the molten material is continuously pumped out through a
standard orifice (die) in order to take the shape and then the shape is set by
cooling/sizing system.

 Example:Film,Pipe,Tube, Profile, Monofilament, Box Strapping etc.

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 CLASSIFICATION OF EXTRUDERS

1 Batch – Type
1.1 Ram Extruders
1.2 Reciprocating screw extruders

2 Continuous –Type
2.1 Screwless Extruders
2.1.1 Disk Extruders
2.1.2 Drum Extruders
2.1.3 Other Extruders
2.2 Screw Extruders
2.2.1 Single-Screw Extruders (SSE)
2.2.2 Twin-Srew Extruders (TSE)
2.2.3 Multi-Screw Extruders

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SINGLE SCREW EXTRUDER

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Single Screw Extruder
Parts & its functions

Screw Pump : Combination of Screw & Barrel

Hopper : Funnel like device, mounted on Hopper throat.
Holds a constant reserve of material.
Barrel : Cylindrical housing in which the screw rotates.
Hopper Throat : Circular opening at the feed end through which
the material enters the screw pump.
Drive System : AC/DC drives
Speed reduction gear box
Transmission system

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The Single-Screw Extruder consist of a screw rotating in
heated barrel or cylinder to which the material is fed.

 Feed hopper
 Extruder Screw and Barrel
 Drive system (motor, gear box, transmission)
 Thrust Bearing
 Heating and Cooling Elements
 Screen Pack and Breaker plate
 Die
 Temperature and pressure controls.

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Definition of terms

Compression Ratio - is the ratio between the channel depth is the

feed zone to that of the metering zone.
- Usually from 1.5 to 4:1
L/D ratio - Length to nominal dia of screw
- usually 20 to 22:1

Important Specification
Nominal dia of screw
Output(kgs/hr)

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Zones of Extruder & its Functions:
Feed Zone - Transport the material from hopper to
compression zone.
- Compacts, eliminates air gap
Compression Zone - Transport the material from compression to
metering zone.
- Softens the material
Metering zone - Melts, Mixes, the material pressurizes
and pumps the melt.

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 Screw Nomenclature
P is the screw pitch, distance between the centre of a two adjacent flights.
W is the channel width
L is the land width
 is the helix angle, defined as an angle between the flight to the transverse plane of the screw
axis.
D is the screw diameter, developed by rotating the flight about the screw axis.
R.D is the root diameter
Flight is the helical metal thread of the screw.
C is the channel depth o radial distance form the bore of the barrel to the root

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SCREW TYPES

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Extruder Screws
 General purpose screw
 PVC screw
 Nylon screw
 Two stage screw/vented screw
 Segmented screws is also available for special purpose

General purpose screw

PVC screw
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Nylon screw

P A SCREW

Two stage screw/vented screw

TWO STAGE SCREW

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Mixing elements
 Incorporated in the metering zone of screw
 Several designs
 Mainly to improve mixing, homogeneity

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THRUST BEARING
 The screw fits into a thrust bearing located behind the feed hopper.
 The function of the trust bearing is to absorb the thrust force acting on the
screw inside the extruder barrel

Typical Thrust Bearing as used in Single-Screw Extruders

Typical thrust bearing assembly – Single Screw Extruder
 The bearing prevents the screw from moving backward.
 Bearing life-time depends on the pressure and screw speed. For high speeds,
oversized being is needed.
 For twin screw extruders several smaller bearings joined in one shaft is used.
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BREAKER PLATE
AND
SCREEN PACK

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 BREAKER PLATE

Perforated circular metallic disc of about 4-5 mm thick.

Functions
- Support for Screen pack
- Converts the Spiral flow of melt in to stream lined laminar flow
- Holds back contamination and unmelted particles.

Fig.3.7
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SCREEN PACK

 Wire mesh 40,60,80

 Arrests the unmelted particles and contamination
 Helps in developing back pressure

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DIE DESIGN

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The role of a die is to form the melt into a desired linear product: fibres, films,
sheets, profiles, rods,etc.

The die is a channel, whose profile changes from that of the extruder bore to
an orifice, which produces the required form.

The dies can be classified using different criteria. For example, considering cross
section of the extrudate one may recognize dies to produce:

 Solid Cross-Sections

 Hollow Cross –Sections

Another classifications scheme is based on the die attachment to the extruder barrel:

 Straight –through dies

 Cross –heat dies

 Offset dies
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 SOLID CROSS - SECTIONS
 A Typical Die Design for extruding a solid rod is shown in fig.
 In the figure, DD is the diameter of die orifice, DB is the diameter of bore of
extruder barrel,  is the lead-in angle, and P is the die land.
 Because of the screen pack and breaker plate assembly, the pressure in the
extruder (PE) is reduced by the pressure loss across the assembly (PL).
 Since the die outlet is at atmospheric pressure, the working pressure is the die
pressure (PD) given by the difference: PD = PE – PL.

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 HOLLOW SECTIONS
Hollow products like pipe or tubes are produced using the die design shown in
Fig.
 The outer diameter of tube is determined by the diameter of the outer die
ring orifice.
 The inner diameter is determined by the mandrel diameter
 To make the mandrel and outer die ring orifice concentric, centring screws
are provided.
 The mandrel is held in position by a spider. In the centre of the spider a
hole is drilled to supply air down the mandrel.
 To provide a smooth glossy extrudate, the die head is heated. A cold die
may cause blockage of the die.

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 STRAIGHT – THROUGH DIES
 Those dies whose axes are arranged to be in line with the direction of
supply of melt.
 Spider, Mandrel is needed for tubes
 Used for the extrusion of pipe, rod, profiles and sheet

CROSSHEAD DIES
 Arranged with their axes at an angle of 908 (458 and 308 are also used) to
the melt feed.
 No need for spider assembly.
 Used for the production of insulated wires, cables

• OFFSET DIES
 Combination of both straight – through die and off-set die.
 Used for the production of pipe.
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EXTRUDATE SWELL

 Extrudate is contraction in the direction of extrusion and expansion in the

cross-section while emerging from the die is called Extrudate Swell.

 The phenomenon (previously called die swell) is illustrated in fig.

 Numerically, the extrudate swell is defined as the ratio of the outer extrudate
diameter (DE) to the other diameter of the die exit (DD), i.e., B = DE / DD

 When the melt emerges out of the die lips, there will be expansion in the
direction perpendicular to flow and contraction in the direction parallel to
flow.

 Constrained molecules tends to relax at the die outlet. This leads to die swell.

 This is nullified by higher take off speed.

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Extrudate Swell may be reduced by :

 Decreasing the extrusion rate

 Increasing the melt temperature

 Increasing the die land

 Increasing the draw-down ratio.

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 Barrel
 High grade steel cylinders
 Has to withstand up to 400 atm.
Iron Based Alloy Complex non-ferrous alloys
More hard & less corrosion less hard & more corrosion
resistant resistant
 These expensive materials are used as liners in steel barrels.
 Barrels of Nitrided steel are also used.
 They are Cheap, hard, less resistant to corrosion.
Screw material
 Low carbon alloy steel
 Flight tips are hardened by flame hardening to prevent wear or nitriding the
entire screw.
 Chrome plated screws for vinyl polymers
 Special nickel alloy steel forCORPORATE
processing of saran.
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Twin Screw Extruders

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Twin Screw Extruder
 Two screws rotating inside a barrel.
 Intermeshing type are more popular.
 Different models/design available

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Basic Types
 Co-rotating
 Counter-rotating
 Mainly used for preparation of master batches/colour concentrates
 Co-rotating Twin screw - used for compounding all thermoplastics except
PVC.
 Counter rotating - preferred for PVC.

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TWIN SCREW EXTRUDERS SHOWING THE TWO SCREW
ARRANGEMENTS

Co - Rotating

Counter - Rotating

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Comparison between Co-rotating and Counter rotating

Sl.No. Co-rotating Counter rotating

Both screws either turn clock-wise One screw turns clockwise and other
1
or counter clock-wise. counter clockwise.

2 More complete self wiping Less self wiping

Less likelihood of material

3 More likelihood of material stagnation
stagnation

4 Better mixing Less than co-rating

Less shear compared to co-rotating and

5 Total shear is more
single screw extruder

6 Mostly for compounding of TP Mainly for PVC compounding

7 Positive pumping Positive pumping

Less power consumption than Less power consumption than

8
single screw CORPORATE TRAININGSingle
AND screw.
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 APPLICATIONS OF EXTRUSION
1. Film: Blown film, Cast film, Co-extruded films, BOF.
Material Used: PP,PVC, LDPE, HDPE, PET, Nylon etc.
2. Pipe/tube
Material: HDPE, LDPE, LLDPE, PVC etc.
3. Sheet
Material: HDPE, ABS, HIPS, PC etc.
4. Monofilament
Material: PP, Nylon etc.
5. Extrusion Coating/Lamination
Coated Playing Cards, Wrapping and LDPE laminated Woven sacks
Material: LD,PP,HDPE
6. Box Strapping
Material: PP, HDPE etc.
7. Tape/Woven Sack
Material: PP, HDPE
8. Wire Coating/Covering
Primary/Secondary insulation
Material: LDPE, PVC (Primary insulation) Nylon (secondary insulation)
9. Profiles (Door and window)
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 BLOWN FILM EXTRUSION
 Upward blown film - LD,HD,PVC, Nylon etc.
 Downward blown film - PP (Mainly to get clarity)
Process outline
 Melt emerging from extruder is inflated by air pressure (3 to 4 kgs/cm2)
 Bubble is properly stabilized and cooled
 Wound on the winder

 In Blown Film Extrusion a tube of plastic material is extruded out of the die,
while hot it is blown into a bubble, then cooled.

 The bubble is inflated by air pressure contained in between the die and the
seating provided by the nip rolls.

 The bubble is flattened by a pair of collapsible frames before it passed

through the nip rollers.
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The film blowing operation can be accomplished theoretically in any of the
following conditions:
 Horizontal
 Vertically Upward
 Vertically Downward

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 Choice of any one or the other
of the three methods is dictated
by the plastic material and
process limitations.
 The horizontal direction is very
rarely used.
 The vertical upward blowing is
preferred, e.g. for PE and PVC.
 The vertical downward blowing
is used for the manufacture of
high clarity PP film.
 This process requires water
quenching of the bubble for fast BLOWN FILM TERMINOLOGY
cooling which is rendered
convenient by this position.
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 Film Blowing, Mono- and Multi-layer
and Double Bubble Film Blowing

3-layer 2 extruders 3-layer 3 extruders 5-layer 3 extruders

5-layer 4 extruders 7-layer 4 extruders 7-layer 5 extruders

FILM BLOWING
There are two techniques of
making film. One is the cast film
process. The other is the blown film
process. The difference in qualities is
that the blown film is more christalline
than the cast film
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 MULTILAYER BLOWN FILM

Please check below a number of layer-designs from 2 layer up

to 7 layers. The glue-layers are of great importance where two
different polymers are not compatible
3-Layer head for 2 extruders -Layer head for 3 Extruders

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 Advantages of Multi-layer Film

Two to seven layers depending on the application.

It possesses good barrier properties against gas and
moisture.
High tensile,impact and tear strength.
Good stiffness,optical,carrier and printing properties.
 e.g. LDPE/HDPE/LDPE,LLDPE/LDPE..etc.

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 Sheet Extrusion
Sheet is produced by forcing molten thermoplastic through a long horizontal
slit die. The extruded hot web passes around metal cooling rolls and is then
cut up or rolled up.

Material used :

HIPS is the most important sheet material. HDPE, PVC, ABS are also used.
Sheet grades usually have high melt viscosity.

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Sheet Extrusion Line
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SHEET EXTRUSION ON 3-ROLLER CALANDERS

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 Dies
Dies used in sheet extrusion are similar to that of flat film dies. Various cross-
section of a flat sheeting die is shown in fig

Various Cross-Sections of Flat Sheeting Dies: Circular,

Tear drop, Angular and Flat Teardrop
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 Extrusion coating
 The plastic is coated over a substrate like paper, by extruding through a slot
die downward between two rolls.
 Substrate is fed between the molten plastic and the roll and is joined with the
plastic by pressure between rolls without the use of an adhesive.
 Material used LDPE & PVC
PP, HDPE, Ionomer etc. are also used.
 Equipment compresses of
 Pre treatment unit
 Coating unit
 Take off & winding

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Paper ANDfor Extrusion Process
Coating
Wire Coating/Cable Covering
Unit comprises of
 Cooling Trough
 Un wind unit (For conductor)  Take off/ wind up.
 Pre treatment unit
 Wire coating unit
Steps Involved
 Wire/conductor is unwound & straightened by Tension
 Control Unit.
 Pre treated to promote adhesion of molten plastic
 Then passed through the Cross head die of the coating unit
 Coated wire is then cooled by passing through cooling trough
 Wound on the winder CORPORATE TRAINING AND
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 Wire Coating Extrusion Line

Diagram of a production line for the coating of wire or cable with plastic. The conductor
to be covered unwinds at the left, is preheated, passes into the crosshead die (center). The
extruder is behind the die, and feeds it with molten plastic, which coats the conductor. The
finished product is cooled, tested and wound up at the right.

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Die used
 Tubing die

USED MAINLY FOR PRIMARY

INSULATION

 Pressure die

USED MAINLY FOR SECONDARY

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 CORRUGATED PIPES
 The characteristics of corrugated plastic pipes depend on profile and
material.
 Corrugated pipes have either parallel ring grooves or a continuous
helical groove.
 The pipes design can be single walled or twin walled.
 Most common thermoplastics are PVC, PE,PP, PA and
fluoropolymers.
 The most important advantages are
 Considerable raw material savings
 High pressure resistance with good flexibility.
 High impact strength
 Good hydraulic characteristics
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 Process
Essentially IIIr to extrusion of pipes except that the die and
the calibration units are specially designed to produce corrugation on
the pipes.

The cylindrical part of the pipe die head extends into the closed area
of a revolving mould block chain. The plastic tube is pressed against
the profiled, revolving mould block halves by internal air pressure or
by vacuum calibration.

As it passes through the forming machine, it is cooled by contact

with the mould blocks, and by that time it reaches the end of the
chain, the tube must be sufficiently cooled to leave the rotating
mould blocks in a stable form.

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a--Pipe die head with Insert c-- Shaping die e -- Vacuum connection
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Double walled corrugated pipe
production:
The manufacturing process is the same as with
standard corrugated pipes, but when the first tube has been
formed, the second tube is laid smoothly on the inner
surface of the still plastic corrugation and welded to the first
with the aid of a sizing mandrel.

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Double Walled Corrugated Pipe Production
a -- Die for coextrusion
b --Through flow guide
c --Mandrel extrusion for inner layer
d -- Shaping die
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