Extruder machinery

The extruder machine is made up of several key parts:

• Hopper – Feeds material into the barrel.
• Panel – The main control system, containing:
  • Master switch for the machine.
  • Temperature controls for heating elements.
  • Variation Frequency Drive (VFD) to control motor speed.
  • Panel cooler to prevent overheating.
• VFD (Variable Frequency Drive) – Adjusts motor speed based on the material in the barrel.
• Motor – Drives the gearbox, taking speed commands from the VFD.
• Gearbox – Controls the barrel’s movement and turns the screw inside.
• Barrel – Houses a single screw inside and has seven heating elements on the outside.

Modifications we made

Extruders do not always arrive fully ready for use, and adjustments may be needed to match specific requirements. Some of the modifications we made include:

• Upgrading the power cable for the heating elements.
• Adding a VFD to better control motor speed.
• Replacing three faulty analogue temperature controls.
• Changing three heating elements with higher wattage ones.
• Insulating the barrel with insulating wool to reduce energy loss and improve efficiency.

Making these adjustments helped us improve machine performance, energy efficiency, and overall output.

Extruder apparatus

In addition to the extruder machine, several technical components are needed for the extrusion process to run smoothly.

Key apparatus for extrusion

• Universal die – Connects the mould to the barrel. The die and the mould nozzle must fit perfectly together.
• Extrusion table – A platform that holds the mould during extrusion.
• Cooling system – Helps cool and harden the extruded plastic.
  • Cooling bath – A water tank where the hot mould is placed after extrusion.
  • Cooling medium – A pumped cooling system:
    • A motor pumps hot water to a second tank.
    • Water passes through cooling steps (like a car radiator) while a fan blows air to cool it down.
    • Gravity pulls cooled water back into the cooling bath.
• Demoulding table – Uses a hydraulic system (jack, pump, tank, and valve) to remove plastic lumber from the mould.

Other essential equipment

To support the extrusion process, other tools are needed, including:

• Hoist – Lifts heavy moulds.
• Welding machine – Used for metal fabrication.
• Drill press – Drills holes, mainly for mould-making and accessories.
• Hand grinder – Cuts and shapes metal components.
• Circular saw – Cuts plastic lumber and tubes.

These tools help ensure smooth operation, maintenance, and troubleshooting in the production facility.