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Practical guides to plastic extrusion: foam lines, twin screw compounding and the polymers they process.

Monthly demand, density, extrusion time and yield worked back to a required output of about 529 kg/h, against the line models

Latest guideFoam extrusion

How to Choose an XPS Production Line: Capacity, Configuration, Budget, and Factory Requirements

When selecting an XPS production line, investors usually start with two questions: How much can it produce per hour, and how much does the complete line cost?

18 min read

Read the guide →

Also new

Compounding & extruders

Twin-Screw Extruder Throughput Bottlenecks: How to Find the Real Bottleneck

7 min read

Compounding & extruders

Why Is the Melt Temperature Higher Than the Set Temperature in a Twin Screw Extruder?

8 min read

Foam extrusion

XPS board, PET foam and the blowing agents behind them: how to size, configure and run a foam extrusion line.

Foam extrusion lines →

Monthly demand, density, extrusion time and yield worked back to a required output of about 529 kg/h, against the line models

How to Choose an XPS Production Line: Capacity, Configuration, Budget, and Factory Requirements

18 min read

XPS scrap ground, force-fed, extruded on a tandem line and pelletized into PS pellets that go back into new XPS board

How to Recycle XPS Foam

3 min read

XPS foam board with its closed cells, compared with EPS in thermal conductivity, compressive strength and water absorption

The Ultimate Guide to XPS Foam Board

6 min read

Foam extruder with blowing agent injection, mixer, active seal and a cooling section with 30 % more cooling capacity; foam board, sheet and beads

How to rise to the challenge for foam extrusion?

2 min read

Cut sandwich panel with a PET foam core between two skins, beside a wind turbine: 100 % recyclable, 150 °C in processing, 100 °C in service

PET Foam Core: A Better Alternative to PVC Foam Core

5 min read

Lambda value of XPS board reached with three blowing agent recipes

How to Figure Out the Portfolio of Blowing Agents for XPS Production

3 min read

Tandem XPS production line in five stations: feeding, twin screw, cooling extruder, die, downstream

How to Configure Your XPS Production Line

4 min read

CO2 handling from the storage tank to injection into the extruder, with the temperature at each stage

How to Control Your CO2 in XPS Production Line

7 min read

Compounding & extruders

Twin screw compounding in practice: formulations, throughput limits, melt temperature and the choice of extruder.

Compounding lines →Twin screw extruders →

Feed rate raised step by step across feeding, extrusion, venting, filtration, pelletizing and cooling: stable at 600 kg/h, quality drifting at 700 kg/h

Twin-Screw Extruder Throughput Bottlenecks: How to Find the Real Bottleneck

7 min read

Twin screw extruder with barrel heaters set to 220 °C and the melt leaving at 240 °C

Why Is the Melt Temperature Higher Than the Set Temperature in a Twin Screw Extruder?

8 min read

PE compounding and pelletizing line with filler, black and white masterbatch pellets: 80 % CaCO3, 40–50 % carbon black, 70 % TiO2

PE Compounding, Extrusion & Pelletizing: Applications, Formulations and Extruder Solutions

13 min read

Polypropylene: melting point 160–170 °C, density 0.90–0.92 g/cm³, and six processing routes from filler masterbatch to XPP foam

Polypropylene (PP) Compounding & Extrusion Guide – Manufacturing, Processing & Recycling

8 min read

Split feeding on an L/D 52 twin screw extruder: 15 % PP resin by the main feeder, 82–85 % CaCO3 by the side feeder, one natural and two vacuum vents

PP + 80–85% Ultra-High Filler Masterbatch: An Engineering Deep Dive into Stable High-Throughput Compounding

5 min read

Single screw extruder with one screw in the barrel beside a twin screw extruder with two intermeshing screws

Single Screw Extruder vs Twin Screw Extruder

6 min read

Materials & processing

Reference guides to common polymers: grades, properties and how each one is processed. Sheet extrusion and rubber recycling are covered here too.

Polyethylene: repeat unit, density 0.910–0.965 g/cm³, melting point 100–130 °C; resin compounded and made into film, pipe and bottles

Polyethylene (PE): Types, Applications and Processing

12 min read

Polypropylene: repeat unit, density 0.90–0.91 g/cm³, melting point 164–170 °C; resin compounded with mineral filler and glass fibre into modified PP

Polypropylene (PP) Plastic: Types, Uses and Processing

13 min read

Polyethylene terephthalate: repeat unit, density 1.38 g/cm³; bottles ground to flakes, extruded and pelletized into rPET

Guide to Polyethylene Terephthalate (PET)

13 min read

Polystyrene: repeat unit, light transmittance 88–92 %, heat deflection 70–90 °C; GPPS, HIPS, EPS beads and XPS foam board

Polystyrene (PS): Properties, Uses and Processing

11 min read

Polyvinyl chloride: repeat unit; two-stage compounding on a twin screw and a single screw extruder with water ring pelletizing, below 170 °C

Polyvinyl Chloride (PVC): Properties, Uses and Processing

7 min read

Liquid crystal polymer: repeat unit, melting point 280–360 °C; resin compounded with glass fibre into modified LCP for connectors

Liquid Crystal Polymer (LCP): Properties, Types and Processing

3 min read

PET resin extruded, calendered on three rolls into A-PET sheet 0.12–1.6 mm thick and thermoformed at 90–120 °C into trays; inset: micro-foamed sheet

The Ultimate Guide to PET Sheet

5 min read

A waste tire, tire powder, a SAT75 and SAT95 extruder line with pelletizing, and TPE pellets: tire powder, PP and oil compounded into TPE

About Tire Rubber Recycling

6 min read

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