Plastic Extrusion Design, Operation and Troubleshooting

Start Date End Date Venue Fees (US $)
26 Oct 2025 Manama, Bahrain $ 4,500 Register

Plastic Extrusion Design, Operation and Troubleshooting

Introduction

Objectives

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in process, maintenance and operations management. The pace and level of the training workshop is customized to the understanding of the delegates. Ongoing back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “Competency Transfer

Who Should Attend?

Course Outline

Introduction to plastic materials:

Day 1 & Day 2

  • Extrusion.
  • Extrusion - Basic Requirements
  • Extruder
  • Single Screw Extruder
  • Twin Screw Extruder
  • Feeder
  • Screw
  • Die
  • Polymer Melt
  • Extradite Swell
  • Extrusion and Process Parameters
  • Extrusion – Processing Operations
  • Extrusion - Setting the Operating Conditions and defining the Screw Geometry
  • Advantages & Shortcomings 
  • Single Screw Extrusion.
  • Single Screw Extrusion Process
  • Raw Material Supply
  • Raw Material Blending and Mixing
  • Drying
  • Feeding Polymer to the Extruder
  • Extrusion
  • Secondary Operations
  • Inspection, Packaging, and Shipping
  • Extruder Safety
  • Single Screw Extruder:
  • Introduction
  • Equipment
  • Drive
  • Feed
  • Screw, Barrel, and Heaters
  • Die and Adapter
  • Controls
  • Extruder Devolatilization
  • Vertical Extruders
  • Plastic Behavior in the Single Screw Extruder
  • Feed Zone
  • Polymer Melting or Plastication
  • Melt Conveying
  • Mixing
  • Extruder Throughput Calculations
  • Devolatilization
  • Die
  • Single Screw Design
  • Barrier Screw
  • Mixing Screw
  • Screw Wear
  • Screw Compression Ratios
  • Screw Performance
  • Single Screw Processing Conditions
  • Extruder Temperature Profiles
  • Extruder or Production Run Setup
  • Start-Up
  • Steady-State Operation
  • Shutdown and Product Changes
  • Single ScrewShear Rates, Pressure Drops, and Other Extruder Calculations
  • Shear Rates
  • Extruder Screw Calculations
  • Different Extruder Section Output Calculations 
  • Application scenarios

Day 3 & Day 4 

  • Twin Screw Extrusion
  • Twin Screw Extrusion Process
  • Raw Material Supply
  • Raw Material Blending and Mixing
  • Drying & Devolatilization
  • Feeding Polymer to the Extruder
  • Extrusion
  • Secondary Operations
  • Inspection, Packaging, and Shipping
  • Extruder Safety
  • Twin Screw Extruder:
  • Drive
  • Feed
  • Screw, Barrel, and Heaters
  • Die and Adapter
  • Controls
  • Plastic Behavior in the Twin Screw Extruder
  • Feed Zone
  • Polymer Melting and Plasticating
  • Melt Conveying
  • Mixing
  • Downstream Feeding
  • Devolatilization
  • Pumping
  • Die
  • Melt Pressure Profile
  • Residence Time
  • Twin Screw Design
  • Conveying
  • Mixing Elements
  • Screw design applications
  • Twin Screw Processing Conditions
  • Extruder Temperature Profiles
  • Screw Speed
  • Process Variables
  • Extruder or Production Run Setup
  • Start-Up
  • Steady-State Operation
  • Shutdown and Product Changes
  • Twin Screw Shear Rates, Pressure Drops, and Other Extruder Calculations
  • Shear Rates
  • Extruder Screw Calculations
  • Different Extruder Section Output Calculations 

Day 5

  • Troubleshooting - Extrusion
  • "Bridging" at the Throat of the Feed Hopper
  • Brittle/Braking/Tearing
  • Contamination/Black Specks and Spots
  • Die Lines
  • Entrapped Gasses/Air Bubbles
  • Excessive Die Swell
  • Material Accumulation at Die
  • Low Gloss
  • Material Non-Homogeneous
  • Variable Thickness
  • Variable Output/Surging
  • Plate-Out on Die Lip
  • Troubleshooting Mechanical Extrusion Problems
  • Problem 1: Extruder Screw Does Not Turn
  • Problem 2: DC Motor Will Not Start
  • Problem 3: Drive Train Problems
  • Problem 4: Rupture Disk Failure in the Barrel
  • Problem 5: Barrel/Screw Wear
  • Problem 6:Screw Turns and No Material Exits the Die 
  • Problem 7: Extruder Shuts Itself Off
  • Problem 8: Melt Flows Out of the Barrel Vent
  • Problem 9: Leaking Polymer at the Breaker Plate or Die
  • Problem 10: Extruder Throughput Rate is Lower than Anticipated
  • Problem 11: Temperature Overrides Set Point
  • Problem 12: Extruder Surging Caused by the Equipment
  • Problem 13: Poor or Insufficient Polymer Mixing
  • Problem 14: Throughput Variation Over Time

Accreditation

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