In today’s competitive marketplace, manufacturing company’s future strongly depends on its ability to reduce rejection or improve its production yield.  Without reasonable productivity and good quality products, nothing will happen.

Principle of Plastic Film Extrusion course focused on technical skill and techniques to create long lasting technical knowledge and awareness for individual production relevant personnel as well as for the company collective.

This course covers the film extrusion process flow, extrusion equipments, extrusion safety, processing conditions through to film extrusion with lectures and presentation. In addition, polymeric rheology, polymeric behaviour, polymeric structure and, characteristics and properties are discussed. Some testing needs to be conducted at receiving and outgoing of film extruded is mentioned. Participant will understand the concept of film extrusion and avoid problems.

TARGET GROUP

This course will benefit to Production / Quality Assurance / Quality Control / Engineering / Maintenance / Purchasing / R&D / Technical Service sections’ Engineer / Executive / Supervisor / Technician / Line-Leader and those staffs who working within the extrusion process.

OBJECTIVES

The two-day intensive technical skill training and development program will be highly participative and focused on the real issues and challenges we face as plastic film extrusion person.

As a result of attending this course, delegates will be able to:

• Understand the basic concept of extrusion process.
• Having safety conscious during operating extrusion machinery.
• Knowing the elements of extrusion equipment.
• Understand plastic behavior during film extrusion.
• Able to optimize processing condition.
• Understand polymeric characteristic, structure and properties.
• Knowing the quality control criteria and testing method of film extrusion’s raw material used as well as finished product.

TRAINING METHODOLOGY

Classroom and practical

TRAINING PROGRAM OUTLINE

Session 1:    Extrusion Process
This session discussed the film extrusion process flow from raw material receiving, blending, drying, feeding to extruder, extrusion process, solidification, dimensional control, secondary operations, inspection, packing and shipping.

• Raw material supply.
• Raw material blending, mixing and drying.
• Feeding polymer to the extruder.
• Extrusion process, solidification and dimensional control.
• Secondary operations.
• Inspection, packing and shipping.

Session 2:    Extrusion Safety
This session discussed the safety hazard around the extruder and during extrusion operation. Personal protection equipments and the safe ways of handling the extruder are mentioned.

• Hazard associated with an extruder.
• Personal protective equipments.
• Proper training.
• Inspection and housekeeping.
• Material safety.

Session 3:    Extrusion Equipment   
This session discuss the five major equipment components construction and its function.

• Drive system.
• Feed system.
• Screw, barrel and heaters system.
• Head and die assembly.
• Control system.

Session 4:    Plastic Behavior in the Extruder
This session discussed the behaviour of polymer in the extruder. Some common problems faced at this part of the extruder are discussed.

• Feed zone.
• Polymer melting and plastication.
• Melt conveying.
• Mixing.

Session 5:    Processing Conditions
This session discussed the understanding of handling extruder and proper procedures during operation of the extruder, this is important for the production floor staffs to understand and always adhere to.  

• Extruder temperature profiles.
• Extruder or production runs setup.
• Start up.
• Steady-state operation.
• Shutdown and product changes.

 Session 6:    Polymer Overview and Definition
This session discussed the resin symbols for recycling purpose, what plastic made of. Different type of polymers, polymer formation, molecular weight and copolymers.

• Resin symbols.                
• Polymer formation.
• What plastic made of?            
• Molecular weight.
• Thermoplastic and thermoset.        
• Copolymers.

Session 7:    Polymer Structure
This session discussed the structure of polymer and comparison of properties between different types of polymer structure.

• Amorphous polymers.
• Semi crystalline polymers.
• Comparison of semi crystalline & amorphous polymers.

Session 8:    Polymer Rheology
This session discussed the rheology of LDPE and LLDPE as mentioned below. The advantages and disadvantages of these rheologies are mentioned and compared.

• Definition of shear.                
• Shear viscosity.        
• Extensional shear.                
• Strain-hardening.

Session 9:    Testing Properties
This session discussed properties of polymer and its testing methods.

• Density.                    
• Tensile strength.
• Bulk density.                
• Elongation.
• Melt flow index.                
• Thermal properties and etc.