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Plastic Extrusions Manufacturers and Companies

IQS Directory provides a comprehensive list of plastic extrusion manufacturers and suppliers. Use our website to review and source top plastic extrusion manufacturers with roll over ads and detailed product descriptions. Find plastic extrusion companies that can design, engineer, and manufacture plastic extrusion to your companies specifications. Then contact the plastic extrusion companies through our quick and easy request for quote form. Website links, company profile, locations, phone, product videos and product information is provided for each company. Access customer reviews and keep up to date with product new articles. Whether you are looking for manufacturers of coextrusions, plastic h channels, plastic extruded plates, or customized plastic extrusion of every type, this is the resource for you.

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Preferred Plastics is an ISO 9001:2000-certified custom plastic extruder, specializing in rigid, flexible & co-extruded products, including extruded tubing. Preferred offers a wide range of secondary & in-line services, including cutting, drilling, punching, routing, stamping and more. By choosing preferred plastics as your custom extrusion manufacture you will be relying on someone you can trust!
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Since 1973, Polytec Plastics has been a leader in the manufacture of high-quality plastic extrusions, plastic profiles & more. Our engineer team offers design assistance. Polytec Plastics can help you select the best possible material to fit your budget & application needs. Whenever possible we suggest using our selection of standard part tooling which consists of thousands of channels, rods, etc.
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Since 1978, SFR has been a leader in custom plastic profile extrusions, specializing in vinyl polymers for a variety of industries ranging from commercial furniture and store fixtures to industrial applications. We will assist you with your unique requirements. We`ll make your ideas take shape! We know how to remain a leader in custom plastic extrusion profiles - by keeping up with change.
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We have a long history of providing plastic extrusions. We will proudly serve you and we are committed to quality customer service. Our plastic extrusions are used in industries ranging from automotive to medical. These units are optimized for design, performance and quality. From pre-prototype to post production, we do it all. Please visit our website for more information!
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We can manufacture your plastic extrusions with various materials including: PVC, PU, PE, ABS, styrene, TPE, TPU, urethane and more. We can provide you with extruded profiles in a variety of shapes and sizes designed to be durable, flexible or rigid, while being compatible with almost any application. Our solutions and products are competitively priced and we will always provide you with outstanding after-sale support.
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We have the custom manufacturing and our stock items come in a variety of shapes, colors and designs. Our goal is to meet your specifications and we have highly trained engineers to do just that. We are partnered with different companies for maximum extrusion options and we are available for our customers at anytime. We are the plastic extrusions experts. If you need to speak with an extrusion specialist then please give us a call!
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A plastic extrusion manufacturer of extruded plastic products, GSH Industries manufactures custom plastic extrusion profiles. We have continually expanded & attained our position as a preferred supplier of quality products & engineering ingenuity at competitive pricing & on-time delivery. With our experience in the plastics field & our facility, we have positioned ourselves into the next century.
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Petro specializes in plastic extrusions, offering our customers many capabilities, such as customized shapes & extruded tubing, along with tape application, coiling & angle cutting. We have a full staff of engineers who can assist you & ship out stock products within 24 hours of your order. At Petro, we take extreme pride in our service & quality. We will deliver a product on time - every time.
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Here at Waltech Engineered Plastics, plastic extrusion is our specialty. We have the capability of fulfilling the detailed requests of our clients. We believe variety is vital in providing the best for our clients, which is why we offer our extrusions in a multitude of colors and materials. Contact us today!
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Industry Information

Plastic Extrusions

Plastic extrusion is a continuous molding process that produces a wide variety of plastic shapes and products.

Note: The term polymer extrusion is sometimes used interchangeably with plastic extrusion. This is not incorrect, though it is not the most precise way to describe the process. Technically, a polymer is a large molecule made up of many similar monomers, which are small molecules. These are not the kinds of polymers to which the words "polymer extrusion" refer. Instead, when the words "polymer" and "extrusion" are paired together, they refer only to elastomers, rubber and plastic.

Applications

The purpose of plastic extrusion is to create products and shapes of all kinds. Customers turn to the plastic extrusion industry because the process is reliable, versatile and fairly inexpensive.

Plastic extrusion is important to industries including: automotive manufacturing, building and construction, HVAC, plumbing, chemical processing, appliance, food and beverage, electronics and more.

Products Produced

The plastic extrusion process is used to create plastic parts of all kinds. They range from engine components to electronic housings. Other examples of plastic extrusion products include: plastic PVC channels, plastic strip, plastic profiles, PVC pipe, all-purpose plastic tubing, medical tubing, weather stripping, decorative trim, functional trim, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings and wire insulation.



Plastic Extrusions
Plastic Extrusions Manufacturers
Plastic Extrusions Manufacturers
Plastic Extrusions - Creative Extrusion & Technologies, Inc.
Plastic Extrusions Manufacturers - Creative Extrusion & Technologies, Inc.
Plastic Extrusions Manufacturers - Polytec Plastics, Inc.
Plastic Extrusions Manufacturers
Plastic Extrusions
Plastic Extrusions
Plastic Extrusions Manufacturers - SFR Industries Inc.
Plastic Extrusions - SFR Industries Inc.
Plastic Extrusions - Preferred Plastics, Inc.


History

The earliest iterations of the plastic extruder were invented in the early 1800s. For instance, in 1820, Thomas Hancock invented a rubber "masticator," which was designed to reclaim processed rubber scraps. Not long after, in 1836, Edwin Chaffee developed a two-roller machine that allowed manufacturers to mix additives into rubber.

Plastic extrusion itself didn't really take off until the mid-1900s, when the first thermoplastic extrusion took place. The extrusion was performed in in Hamburg, Germany in 1935 by Ashley Gershoff and her husband Paul Troester. Shortly after, in Italy, Roberto Colombo of LMP developed the first twin screw extruders.

Today, the plastic extrusion industry is alive and well, and showing signs of growth, as plastic products are trusted over counterparts like metal or wood. To meet the higher demands, many plastic extrusion manufacturers have been upgrading facilities to allow for faster and larger volumes of plastic profile extrusions, coupled with more accuracy during product cutting. Sophisticated products are equipped with more intricate parts so manufacturers must have the capabilities to adhere to exact specifications even down to the smallest measurements.

Materials Process

Plastic extrusions are made from a variety of plastics and thermoplastics, including, among others: HDPE, LDPE, PETG, PVC, butyrate, polypropylene, and polystyrene.

Thermoplastics

    A thermoplastic is a plastic material that, when exposed to sufficient heat, becomes plasticized. A plasticized thermoplastic can be shaped into useful products and retain the shape once cooled. Thermoplastics are highly valued for this quality, and they are also valued because they can be recycled at the end of their lifespans and reshaped by the same process.

HDPE

    HDPE (high density polyethylene) is valued for its resistance to solvents, resistance to corrosion, high tensile strength, high strength-to-density ratio, durability and safety.

LDPE

    LDPE (low-density polyethylene), is tough and flexible, with excellent resistance to many acids, alcohols, bases and esters. Manufacturers can extrude it as either translucent or opaque.

PETG

    PETG (polyethylene terephthalate glycol-modified), known more commonly as polyester, can make rigid or semi-rigid plastic extruded parts. It is very lightweight, impact resistant and strong. In addition, it can act as a good barrier to gas, a fair barrier to moisture and a good barrier to alcohol, when treated.

PVC (Vinyl)

    PVC (polyvinyl chloride), also called vinyl, is the world's third-most produced synthetic polymer. PVC is hard and strong, but has poor heat stability without the addition of a heat stabilizer. It also has good insulative properties and is resistant to acids, fats, alcohols, bases and salts. PVC extrusion, using both rigid PVC and flexible PVC, is popular for products including pipes, PVC angle, small diameter tubing, floor coverings and siding.

Butyrate

    Butyrate is synthesized via the chemical modification of the natural polymer, cellulose. It is transparent, rigid, strong and durable, with excellent dimensional stability and high impact strength. It is also easy to extrude.

Polypropylene

    Polypropylene is the world's second-most widely produced synthetic plastic; polyethylene is the first. It offers low density and high resistance to many acids, bases and chemical solvents. It is also thermal resistant.

Polystyrene

    Polystyrene can be formed in a variety of containers, cutlery and packaging. While it is an inexpensive resin to purchase, it comes at a high cost to the environment. That is because it is slow to degrade, and has become an abundant form of litter.

Acrylic

    Acrylic extrusions are characterized by their optical clarity and durability. They are, for these reasons, often well suited to use as tubing in chemical processing, because their contents can be easily visible when inspected by workers.

Process Details

The plastic extrusion process is very standardized, and there are few deviations between extrusion operations in terms of the basic principles of extrusion. Operating temperatures and output speeds may vary depending on the properties of the plastic material, but plastic extrusion processes resemble each other very closely aside from these differences.

Step 1

    The extrusion process begins with a collection of raw plastic materials in a hopper suspended above a conveyance channel. These materials may be one plastic or a plastic composite.

Step 2

    When a panel at the bottom of the hopper is removed or retracts, gravity directs the plastic into the channel.

Step 3

    Inside the channel is a long shearing screw that forces the plastic down the channel as it turns. The friction caused by the turning of the screw causes the plastic to become molten. Some extruders feature supplementing electrical heating elements to aid in the melting of the plastic. By the time the plastic reaches the end of the channel, it is ready to be shaped.

Step 4

    When the molten plastic reaches the extrusion die at the end of the channel, it is forced through, taking its shape as a result. The plastic emerges on the other side of the die as newly extruded plastic material.

Step 5

    The plastic is quickly cooled, which causes it to harden and keep its shape.

Step 6

    The extrusion can then be cut and prepared for shipment or sent for additional processing like labeling, painting, anti-static treating or another surface treatment.

Design and Customization

When designing both standard and custom plastic extrusion products, manufacturers consider factors including best extrusion material, best manufacture process, die shape and die size. Material selection is based on matching up the required properties of an application with a material that exhibits those properties. The manufacture process, whether that be hot extrusion, cold extrusion or warm extrusion, is chosen based on the application requirements as well. Examples include tolerances, stress, production volume, etc.

Manufacturers offer a variety of custom extrusion options, include custom profile extrusion, custom tubing extrusion, custom plastic pipe extrusion, extrusion coating lamination.

Machinery Used

Plastic extrusion tooling is fairly straightforward. It involves the use of an extruder machine and dies.

Extruder

    In this case, the extruder is composed of a hopper, where the material is held and heated, a conveyance channel, where the molten material is carried towards the die, and a shearing screw, which helps pressurize and push the material towards the die.

Die

    At the end of the channel is a die, which is a specially-designed tool used to form raw materials into usable products. In the case of plastic extrusion, a die is a metal plate cut with a hole through which the plastic is forced.

    Every die is different; they are specially designed to accommodate individual processes. The simplest possible die designs are nothing more than simple shapes. A circle-shaped produces a plastic rod, while a square-shaped die produces a continuous plastic square. Plastic profile extrusions like pipes, require dies fitted with special pins that allow hollow places to form. Textured plastic sheets like floor mats can also sometimes be produced by extruders. Plastic sheet dies would be flat with grooves to create the texture.

Variations and Similar Processes

Extruding Standard Profiles

    To make a plastic profile extrusion, manufacturers send resin through a barrel, which melts the plastics. Then, the molten plastic is molded by different set of dies, based on the requirement. For instance, to make hollow sections, manufacturers place a mandrel within the die. Similarly, for multi lumen tubes, they tool a couple of pins into the die, and as the molten plastic moves through the pins, it extrudes two holes in the product. Sometimes, manufacturers apply positive pressure to supplant the whole process and to adjust the size of the lumen.

Extrusion with Multiple Extruders (Coextrusion)

    When they need to extrude plastic in multiples layers, manufacturers turn to a process called co-extrusion. Coextrusion allows for two or more types of plastic resin to be mixed together, so that they can create a product with both of their qualities. To do so, manufacturers use multiple extruders that melt the different resins at the same time and then deliver them together into a forked conveyance channel. Once on the channel, the different materials are directed, mixed together steadily and delivered to a single die.

Extrusion for Making Plastic Shopping Bags

    The method used for making shopping bags and plastic films is known as blow film extrusion. The method is similar to standard plastic extrusion, but it employs a different type of die, which is shaped as a cylinder with an annular opening. As the molten material leaves the barrel of the extruder, a couple of rolls pull the material, thus changing the gauge of the molten resin. Then, the die, which is tooled with an air outlet, blows air into the cylindrical plastic profile, giving it its final shape. At the end, a cooling mechanism, typically a cooling ring, is affixed to cool the film. To regulate the thickness of a product, the rate of revolution of the rolls is changed according the needs of the product.

Extrusion for Making Kernels

    Some machines make plastic pellets by extruding different types of resin together. The machines follow the same procedure as that of standard extrusion, however, the extruded products are not profiles or tubes, but rather beads, which act as a raw material for manufacturing processes.

Extrusion with 3D Printers

    Thanks to the development of modern 3D printers, plastic can now be extruded into elaborate shapes and structures. 3D printing gives fabricators the opportunity to fabricate any shape imaginable. In place of molten resin, this process uses a filament as feedstock.

Plastic Injection

    Plastic extruded parts are considered a subsidiary of injection molded plastics, which are manufactured using another plastic molding technology, plastic injection. During plastic injection molding, plastic pellets are heated until molten in a hopper, then injected into two hollow cavities. Then the cavities clamp together under pressure, and left for a short amount of time to cool and solidify. Once solid, the two halves of the mold are separated, and the plastic product is ejected out of the mold by a set of ejector rods or pins.

    Plastic injection molding is chosen for both prototyping and mass production, because it can create tight tolerance products at high-volume runs.

Benefits

Efficiency

    Plastic extrusion is high speed, high-volume and low-cost production. It is highly efficient, especially when compared with other molding methods.

Low Wastage

    In plastic extrusion, the manufacturer can reuse plastic leftover after trimming or cutting again and again.

Formability

    Plastic is easy to melt, which results in a quicker production run and low energy intake.

Low Cost

    Because plastic extrusion machinery can run continuously, the process has low chances of inventory shortage, which keeps prices low. Moreover, cheap feedstock, reduced tooling costs, and low disposal expenditure mean this is the ultimate low-cost production method.

Flexibility

    Plastic extrusion molding offers flexibility when products are required to have consistent cross-sectional profiles. Flexibility also comes in another form; manufacturers can easily tweak the process to produce plastic sheets or make products that mix plastic attributes.

Allows Post-Extrusion Alteration

    Plastic takes time to cool down; it remains hot after it is removed from the precision extrusion machine. This makes it easy for manufacturers to implement changes to the plastic after the completion of the extrusion process, using a variety of tools like rollers, shoes and dies.

Versatility

    Plastic extrusion is an exceptionally versatile process, that allows for plastic extruded parts that have intricate shapes with different thicknesses, hardness's, sizes, colors and textures; the only catch is the cross section needs to remain the same throughout.

Things to Consider

For the best results, you need to maintain stable head pressure, have consistent temperature at heating zones, and create uniform melt flow. Most of the problems originate from these three factors. We've outlined other factors that you must consider below.

Variations in Concentration of Raw Materials

    From homogeneity of the molten resin to the finish of the product, all quality is directly determined by the raw material. For thin gauge extrusion especially, process conditions need to be stable, without any major pressure surges (pressure oscillations). In a standard setting, pressure oscillations of ±50 psig are considered acceptable, but anything above that influences production. To achieve stable process conditions, avoid variation in concentration of raw materials in terms of virgin and regrind blends.

Melt-bank Uniformity

    The lack of melt bank uniformity can cause many variations in the product, ranging from spotty finish to irregular polishing patterns. To check the presence of dull spots on the finished product, regulating the chrome-roll temperature is essential. The temperature should be kept high to discourage freezing of the bank. The other way is to shorten the distance between the die-lip exit and the primary nipping rolls- the ideal distance is 4 to 8 inches. However, there are factors that limit the distance between the die lip and primary rollers, such as area covered by the die, the die deckles, and appendages. To avoid this problem, the die should be tooled with contours to reduce the cross-section area.

Design of Rolls

    When production of thin gauge is involved, rolls should have capacity to manage high roll loads. For this purpose, special rollers known as spherical tapered rollers are considered suitable. However, when spherical tapered rollers are installed in an extruder, additional equipment, such as bearing journals and roll shafts, also need to be designed appropriately in the extruder.

Roll Deflection

    The common problem that all fabricators face is deflection of the roll. To rectify this problem, three solutions are available. The first involves a crowned roll, which has a pre-ground camber. This technique, however, limits the range of the production because the dimension and geometry of the camber remain fixed. The second method involves counter-bending rolls, however, just like the first method, the technique limits the production window. The last solution involves roll skewing. The roll skewing method, unlike the first two solutions, is highly versatile and removes deflection in a wide range of operations.

For more advice or for plastic extrusion services, reach out to a reliable contract manufacturer. Not sure where to start? No worries! To make your life easier, we've provided a list of our top plastic extrusion company picks. Find it by scrolling near to the top of the page. The best way to find the right manufacturer for you is by browsing their respective sites, picking out three or four you like, and then reaching out to each of them with your questions and specifications. Be on the lookout for the one that provides the best customer service. Remember, the right manufacturer will work with you to create affordable solutions that adhere to all your requirements; there's no reason to settle for subpar service. Good luck!


Plastic Extrusion Terms

Adiabatic Plastic Extrusions - Plastic extrusions whose only source of heat is the conversion of the drive energy through the viscous resistance of the plastics mass in the plastic extruders.
 
Back Pressure - The resistivity of molten plastic material to forward flow.
 
Barrel - The part of the plastic extruders encasing the screw or plunger.
 
Barrel Liner - The sleeve forming the inner surface of the plastic extrusions barrel.
 
Calendering - The plastic extrusions process of pressing or smoothing material between rollers.
 
Cladding - Sometimes referred to as sidings it is extruded PVC-U boards that are used as outdoor weather-resistant fade panels.
 
Compound - Any plastic material prepared for subsequent manufacturing processes, specifically plastic extrusions, molding or calendering.
 
Compression Section - The transition section of a screw channel in which a reduction in the screw channel volume occurs.
 
Cooling Tank - A tank typically containing water through which plastic extrusions are constantly passed for cooling.
 
Cure - The technique of cross-linking a plastics material.
 
Decompression Section - The section of two-stage plastic extruders in which an increase in screw channel volume occurs.
 
Die - The component on plastics extruders affixed to the plastic extruder's head through which the melt is pushed to form the desired profile.
 
Die Plate - In moulds, the main support for the punch or mould cavity.
 
Dry Blend - A free flowing blend of compound or resin and other ingredients as prepared for an additional manufacturing operation specifically for plastic extrusions or molding.
 
Extrudate - The product or result of the plastic extrusions process. An extrudate is a product or material forced through a shaping orifice as a continuous body.
 
Extruder Size - The minimal inner diameter of the plastic extruders barrel
 
Extrusion Coating - A coating technique in which molten plastic feeds directly from plastic extruder dies into a nip-roll assembly combined with the substrate.
 
Haul-off - Also called a caterpillar, it is an apparatus used for the continous removal of extrudate from the die.
 
Heat Aging - The unique process of aging a thermoplastic or thermoset product and examining the percentage of retained physical and chemical properties after exposure to heat for a prolonged period of time.
 
Melt - Any plastic extrusions material heated to a plastic condition.
 
Melt Strength - A term that refers to the strength of molten plastic.
 
Outer Die Ring - The element of tubing tie that shapes the outer surface of a tube.
 
Pellets - Resins or mixtures of resins with compounding additives in the shape of similar-sized tablets and granules that have been extruded or chopped into short segments to prepare them for molding or extrusion operations.
 
Ram Extruder - A barrel with a temperature control, wherein a plunger pushes material in a melted state to the die.
 
Resin - Any of several physically similar polymerized synthetics or chemically altered natural resins, such as thermoplastic materials (polyvinyl, polystyrene, polyethylene) or thermosetting materials (epoxies, polyesters, silicones used with fillers, stabilizers, pigments).
 
Screw - A helically grooved rotating element inside the barrel of screw plastic extruders. The main purpose of a screw is to melt and feed raw material from the feeder to the die, but it also homogenizes, compresses and pressurizes the material.
 
Screw Extruder - A machine comprised of a barrel with a temperature control. It houses one or more rotating screws, which pass plastic materials from the feed aperture and move them in the form of melt under pressure through a die.
 
Take-up - An apparatus for reeling extruded plastics material.
 
Thermoset - A term that refers to the family of materials that can be melted only once during the original processing and cannot be reprocessed after the original part is made.
 
Thermoplastic - Any material, such as polyethylene, Santoprene and ABS, that can be remelted and reprocessed without considerable loss of properties or scrap loss.
 
Torpedo - An apparatus at the discharge stage of the screw for finishing homogenizing and blending of the melt.
 
Trunking - An extruded PVC-U channel used to contain and protect pipes or cables.
 
Vacuum Sizing - A procedure utilizing a sizing die with a vacuum applied to the outer surface of the extrudate.
 
Vinyl - A generic term for PVC, it is one of various compounds of ethylene that are polymerized to form resins and plastics (e.g. polyvinyl or polyethylene plastics).




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