Lesson 1Die and calibration tooling: die types for pipes and profiles, mandrels, vacuum sizing, land length and swell controlLooks at die and calibration tools for making pipes, profiles, and sheets. It explains flow distribution, mandrels, land length, swell control, and vacuum sizing, showing how tool design affects accurate dimensions and smooth surface finish.
Pipe, profile, and sheet die typesFlow distribution and manifoldsMandrels, pins, and spider supportsDie land length and swell controlVacuum sizing plates and sleevesLesson 2Haul-off and downstream: belt pullers, caterpillar haul-off, speed synchronization with extruderGoes over haul-off and downstream pulling equipment like belt and caterpillar units. It covers traction control, nip pressure, and matching speed with the extruder to keep product dimensions steady and surface quality good.
Belt pullers vs caterpillar haul-offSpeed synchronization with extruderNip pressure and slip preventionEffect on wall thickness and ovalityIntegration with downstream cuttersLesson 3Cooling and sizing equipment: water cooling baths, spray rings, cooling tanks, calibrators, vacuum sizing systemsChecks out cooling and sizing gear used after the die, like water baths, spray cooling, and vacuum calibrators. Discusses heat removal rates, dimension control, internal stresses, and how cooling affects warping.
Water baths and spray ring designCooling tanks and residence timeCalibrators for profiles and sheetsVacuum sizing for pipes and profilesCooling rate, stress, and warpageLesson 4Screw geometry and selection: screw diameter ranges, L/D ratio, flights, compression and metering zonesExplains screw geometry parts and how they affect melting, mixing, and pressure build-up. Covers diameter, L/D ratio, flight design, compression and metering zones, plus tips for picking screws for different plastics and production rates.
Screw diameter and L/D ratio effectsFeed, transition, and metering zonesFlight depth, pitch, and channel volumeBarrier and mixing section optionsScrew selection for materials and outputLesson 5Instrumentation and gauges: melt pressure transducers, die pressure, barrel temperature sensors, flow meters, infrared profile measurementCovers main extrusion instruments like melt and die pressure sensors, barrel temperature sensing, and flow measurement. Stresses where to place sensors, how to calibrate them, read data, and how signals trigger alarms, safety locks, and automatic control.
Melt and die pressure transducersBarrel temperature sensors and placementFlow meters and mass flow monitoringInfrared profile and surface temperatureCalibration, drift, and signal filteringLesson 6Hopper and material handling: dryers, feeders, gravimetric vs volumetric dosing, contamination controlFocuses on hopper design and handling materials, including drying, moving, and dosing. Compares weight-based and volume-based systems, stresses moisture and dirt control, and shares best ways to avoid clumping and separation.
Hopper design, liners, and bridgingDryers and moisture specification limitsPneumatic and mechanical conveyingGravimetric vs volumetric dosingContamination and metal detectionLesson 7Additive and color feeding systems: side feeders, loss-in-weight feeders, masterbatch feeders, pigment dispersion basicsLooks into feeding systems for additives and colours, comparing volume and weight designs. Covers side feeding to twin screws, masterbatch dosing, pigment mixing quality, and ways to stop separation and colour streaks.
Volumetric vs loss-in-weight feedersSide feeders for fillers and regrindMasterbatch feeders and color dosingPigment dispersion and streak controlRefill systems and material segregationLesson 8Types of extruders: single-screw vs twin-screw — principles, advantages, typical applicationsCompares single-screw and twin-screw extruders, explaining how they work, melting and mixing, and how design affects output, energy use, and fit for mixing compounds, recycling, or making profiles and films.
Single-screw operating principle and meltingTwin-screw co-rotating vs counter-rotatingDistributive and dispersive mixing behaviorTypical applications and material suitabilityEnergy efficiency and throughput comparisonLesson 9Cutting and finishing: flying saws, cold cutters, trimming units for profilesDescribes cutting and finishing units for extruded items, like flying saws and cold cutters. Explains matching line speed, controlling burrs and dust, dimension accuracy, and trimming profiles to final specs.
Flying saws for continuous profilesCold cutters for pipes and tubesCut length control and tolerancesBurr, dust, and chip managementEnd finishing and chamfer optionsLesson 10Extruder main components: barrel zones, feed throat, screw, gearbox, heaters, thermocouples, melt pumpPoints out the main mechanical and heating parts of an extruder. Explains barrel zones, feed throat, screw, gearbox, heaters, thermocouples, and melt pump, and how design and upkeep affect steady output.
Barrel zones and cooling circuitsFeed throat design and ventingGearbox, motor, and torque limitsHeaters, thermocouples, and controlMelt pump function and pressure build
