Flexible Extrusion Process

Granules of material are fed into the hopper of the extrusion machine and are drawn down by gravity into the fees to the screw. The barrel and screw are heated by external heating elements, controlled by precision temperature controllers. As the screw turns, the granules move along the screw and they melt and are forced through a die which is located at the end of the barrel. The die contains the cross section of the profile of the extrusion required. The extrusion is then water cooled through water baths before being coiled and packaged.

Our processes range from single head dies, through to triple material extrusions, involving extremely complex dies and extrusion processes. The foamed products that we can produce require some of these complex dies, and are produced in a similar way to conventional extrusion, but with the added use of a chemical blowing agent to create a cellular structure.

In the foaming process, the foaming or blowing agent produces air-filled bubbles in the material. If you cut open the part and look closely, you will see that the bubbles form a cellular structure made up of “closed” cells individually surrounded by the plastic matrix.