Before kickstarting any industrial-related operation, one crucial factor needs to be available and sufficient. That is none other than raw materials We are talking about “Resin,”; the core raw material used in the plastic sheet extrusion line. Resin comes in the form of small plastic pellets that are synthetically made. The extrusion process begins by feeding the Resin into the feed Hopper that commences the extrusion process. From there, it undergoes decomposition and plasticization in the Barrel. The heating and pressurizing of molten Resin continue until the extrudate is finally cooked. The Resin exits the Barrel via the Die and gets shaped into different shapes.
How Important Is The Resin?
Depending on the kind of Resin you are using, you can produce many different plastic products including sheets from your plastic sheet extrusion line. You can get; Plastic sheets, Plastic film, and many more products. The end products are always a result of an extrudate resin from the beginning of the extrusion production line. Therefore, resin takes a top level, and it’s a must-have material first before anything else.
But now, a problem comes in when selecting the suitable Resin to use. It is always a complex process that needs no jump-ins but extensive research and analysis. It matters a lot since the type of Resin you plan to use determines how the end products shall come out. Additives and other materials must be blended and mixed into the Resin. It is such a huge burden, especially for beginners. Thankfully, this article has got all the necessary factors that one needs to apply when choosing or selecting the perfect material for your plastic sheet extrusion line. Read on!
What Are The Factors To Consider?
Here are factors that will guide you in choosing the right and perfect resin for the plastic sheet extrusion line. If applied and executed well, you will eventually see a difference and perhaps an improvement in the product’s quality.
Cost is the number one factor you must consider before picking or selecting a polymer resin for extrusion. Currently, the market is full of tons of raw Resin. However, suppliers differ in terms of cost. Some sell their Resin cheaply and others expensive. It is best not to make a hurried decision and pick on the costliest thinking of quality or the less expensive thinking of saving cost. Before making a decision, you have to ensure that the Resin you plan on securing meets all the necessary standards. Only by doing so will you produce satisfying end products.
However, never go for something higher than your budget limit. Purchasing a resin is essential. But at the same time, the production line will also need an injection of funds so that things run smoothly. We are talking about other materials such as additives, composites, and fillers. Always consider cost before purchasing one.
2. Durability and quality
Since the specific type of Resin used for extrusion determines the end product’s nature, durability and quality are crucial factors. Before choosing the material for the plastic sheet extrusion line, ensure that the type of material used produces nothing but the expectation. The end products need to be solid and durable enough and have a long life before total depreciation. No customer wishes to purchase a Plastic product that is weakly and performs poorly.
Factors determining quality and durability of PVC resin products
Below are several structural factors within a plastic product that affects its quality and durability;
- Shear strength– Shear strength is the ability to withstand tremendous forces within the internal structure of a Plastic extrudate. In that matter, the type of Plastic material you pick on has to have more shear strength. Otherwise, the products with low shear strength will eventually break apart or tear apart when loads of weight and pressure is applied.
- Hardness and wear resistance– The material/resin you plan on selecting needs to have the correct hardness characteristics and wear resistance. Most extrudates need to come out forming complex products. Plastic sheets mainly get applied in areas that require high hardness. Therefore, you must ensure the Resin has the correct hardness properties. In addition to that, the Resin also has to show high wear resistance. Products that get applied in areas with lots of friction must be wear-resistant.
- Stress and weight– A perfectly extruded product using the perfect Resin bear products that meet the stress and weight abilities. The product must withstand a lot of pressure applied to it and also be able to withstand the significant weight.
Temperature is one all-around factor. Not only does it affect the selection of Resin to use but also the end product. To begin, we start with Melt temperature. The melt temperature stands for the temperature required to melt down the material in the extruder. One must determine the material’s melt temperature before feeding the material into the extrudate. The temperature properties of the materials have to be determined so that regulation gets done perfectly. Therefore, the material decomposes a lot or plasticizes evenly.
The temperature of the end product must also get evaluated. That is; supposing you plan on producing products that get applied in areas of high heat exposure. In that case, you want to alter the temperature properties of the Resin. Adding additives to the mixture makes the product heat resistant. Too much heat breaks down the material’s structure, causing shape distortion or affecting the product’s durability.
4. Environmental properties
Its environmental compatibility will also factor in picking the suitable material for use in an extrusion line. That means the product can perform flawlessly even in a harsh situation. You have to check on its permeability properties. Again, will the outcome withstand intense UV rays for long? Finally, does the product act well in terms of insulation?
Answers to all the questions above can be answered only from Resin’s composition and properties. Ensure you select the suitable material whose properties match the environment it gets applied to.
Flexibility is the ability of the material to bend under very high stress and weight. You have to consider this parameter when shopping for plastic Resin. Flexible material will be able to sustain stress and weight in whichever manner it’s going to be applied. If you are planning on producing hard products, they must also meet the required flexibility range.
Stands for the measure of how thick and sticky a semi-fluid material is. Viscosity matters a lot when picking the correct type of Material/Resin to use in an extrusion line. It is responsible for the internal structural characteristics of any Plastic product. Its matters a lot, especially when more than two or more different types of Resin get blended. Therefore, you must ensure that viscosity of the Resin two Resin match together.
7. Chemical compatibility
Chemical compatibility is necessary. Determines how the Resin reacts with reagents added to the mixture. Additives, fillers, and composites need to be added and mixed with the Resin as well. That is for improved functionality. It is wise only to use data analysis of the Resin before the feeding process begins. You prevent unwanted deformations to the product.
The resin supplier is responsible for giving out resin data analysis showing how various composites react with resin. Before feeding the resin into the extruder, consider testing the Resin in cases where there is no data. Only by doing so will you eliminate the clouding doubts about the Resin.
8. Material shrink rate
During the extrusion process, the material undergoes several changes. As molding of the Resin into desired shapes goes on, shrinking happens to occur. Too much shrinking is terrible as it negatively affects the product’s form and quality. You need to go for the material with a lower shrink rate rather than the opposite way.
Types Of Plastic Resin for Plastic Sheet Extrusion Line
Resins come originally from plants. However, due to the high global demand and the low resin quantity from plants, the need for synthetic resin has grown tremendously over the years. Plastic materials come in various types. They include;
Amorphous resin is the type of resin that has no specific melt temperatures. They are as follows;
i. Polyvinyl Chloride (PVC)
It comes in the third position after PET and PP. One arguable reason PVC ranks well in the list of plastic extruders is its quality. PVC is very durable and can perform just right, even in the harshest environments. It’s most preferable when making PVC foam boards that get applied in Building and construction and furniture production. The hardness and strength make PVC a great choice when applied in such fields.
ii. Low-Density Polyethylene (LDPE)
LDPE is the most suitable plastic Resin when producing flexible and durable products. It portrays high chemical properties, sufficient shear strength, and moisture resistance and is also cost0effective. Is most preferable application environment is one that has low temperatures. LDPE otherwise Low-Density Polyethylene is not tolerant to very high temperatures.
iii. High-Density Polyethylene
When looking for a plastic Resin with strength, rigidity, and heat resistance, then look no further. HDPE offers all that under its umbrella.
iv. Thermoplastic Polyurethane
Thermoplastic Polyurethane is ideal for application in areas that need elastic and soft material. Its properties can work well in such areas. On top of that, Thermoplastic Polyurethane also shows high tensile strength and the ability to withstand high temperatures. This Resin has received lots of praise since it is easy to use, reducing time wastage and reducing production costs.
Crystalline resin has a specific melting temperature when heated, unlike the Amorphous Resin. They also show strong intermolecular forces holding the molecules together. They include;
Acetal is a great choice and fits well in applications that need a material with dimensional stability and friction resistance. At the same time, you can use Acetal products in areas with a lot of moisture and heat. The material has a low moisture absorption rate and a heat distortion property. Other outstanding properties include; heat resistance, chemical hesitance, hardness, and anti-wear property.
This kind of Resin has remarkable properties such as chemical resistance, heat resistance, hardness, dimensional stability, etc. Its products portray excellent performance, especially in places where glass is required. The price of acrylic is meager and makes it an excellent material for fixed-budget production.
iii. Polypropylene (PP)
Polypropylene is the most used Resin globally. It tops the list of most used materials. Being in that position is no mean joke. Polypropylene has insane properties that make it the best choice over other types of Resin. High melting point, stress resistance, electrical resistance, hardness, chemical hesitance, and high elasticity are some of Polypropylene’s selling properties. To attain the best results during extrusion, you must include fillers in the mixture. That gives the end product more strength and hardness.
iv. Polyamide (Nylon)
It is well-known for its mighty strength, hardness, chemical, electrical resistance, and wear resistance. Works well in rugged and unforgiving environments without struggling.
FAQs About Plastic Sheet Extrusion Line Resins
What Is The Best Material To Begin With In An Extrusion Process?
The choice of material depends on the application of the final product. The is no set type of material you have to begin within a plastic sheet extrusion line. Therefore, to get further information about the Resin, you must liaise with your supplier. The supplier has to guide on the type of material to pick. That is with consideration to the product you need to be manufactured.
How Plastic Resin is Made?
Resin is a naturally occurring compound found in plants. To meet the global needs came the introduction of synthetic Resin. The manufacturing process entails; heating compounds with hydrocarbons. That will lead to the breakdown of large molecules into ethylene or propylene. A plastic Resin is not only one material but a group of other materials with given properties that can produce the desired product.
Securing Resin/materials for your plastic sheet extrusion line can be a hefty task, especially if you are doing it without knowledge and experience. This publication best fits anyone having trouble selecting and picking the suitable Resin for extrusion. You are guaranteed a smooth experience when shopping for the perfect Resin. Only when you apply all the vital tips and the types of Resin above. On top of that, you also need to have the perfect machinery to carry out the extrusion. That is now where we swing in as FANLYPLAS. We are an established supplier and manufacturer of quality Plastic extrusion lines and ancillary machinery. Selecting the best Resin for extrusion is a plus for production. However, purchasing quality and reliable Plastic extrusion lines are vital. Try us today. We won’t disappoint at all!!