The Plastics Training Specialists

Single Screw Extrusion Technician


This package combines fourteen courses which directly relate to the job functions of those working at a typical extrusion facility. This training series with help teach any employee on the concepts relating to the machine, material, process, quality, startup, shutdown, problem solving, material handling as well as the correct terminology associated with Single Screw Extrusion.

Complete Single Screw Extrusion Series

Our Single Screw Extrusion Series is designed to provide training for anyone working in a production environment. These programs use animation and actual production footage to demonstrate complex concepts. Important safety precautions are stressed throughout these training programs

. Program 1: The Extruder

- Discusses the drive system of the extruder including the motor and gearbox
- Introduces the material feed systems used in Single Screw Extrusion
- Covers the entire screw and barrel assembly including screw design and venting
- The die and adaptor are presented along with the extruder’s control system

Program 2: Plastic Materials

- Introduces the plastics industry and the nature of plastic materials
- Explains complex concepts such as melt viscosity and polymer flow
- Provides detailed explanations of both shear and shear heating with plastics
- Covers the behavior of both amorphous and semi-crystalline polymers
- Gives an understanding of shrinkage, orientation, and degradation

Program 3: The Extrusion Process

- Explains the mechanics of Single Screw material feeding and conveying
- Melting processes for standard and barrier screw designs are covered in detail
- Describes the commonly used types of dispersive and distributive mixing systems
- Covers the pumping, shaping, cooling, and cutting of the extrudate
- Cites important safety precautions for working around extrusion equipment

Program 4: Preventive and Corrective Actions

- Covers common extrusion defects and their typical causes
- Explains the importance of accurate process monitoring
- Differentiates between open and closed loop process control systems
- Ways to adjust the process and detect equipment problems are also covered

Program 5: Startup, Changeover and Shutdown

- Provides common procedures to start-up and shut-down an extruder
- Details both upstream and downstream changeovers
- Die, material, and color change considerations are also covered
- The importance of safety and cleanliness are stressed throughout this series

Program 6: Quality

- Defines quality and its importance to the success of extrusion operations
- Explains the concepts of quality assurance vs. quality control
- Covers the form, fit, and functionality of the extruded product
- Critical vs. non-critical extrudate defects are compared and contrasted
- The importance of meeting the customer’s needs is stressed throughout the course

Program 7: Material Handling

- Stresses the importance of proper material handling – from delivery to feedthroat
- Covers various vacuum conveyance and hopper loader systems
- The problems associated with not drying hygroscopic materials
- Details ways to blend materials while avoiding material contamination

Program 8: Problem Solving and Troubleshooting

- Focuses on getting the right answer in the shortest time
- Easy to follow problem solving steps and rules are detailed
- The importance of documentation and procedure is stressed throughout the course

Math for Extruders: Program 1

This two-part training program was created for all personnel within the extrusion industry who would like to expand or fine tune their math skills.

- Whole Numbers, Negative Numbers and Decimals
- Using a Calculator
- Addition, Subtraction, Multiplication and Division
- Rounding Numbers and Significant Figures
- Formulas, Equations and Order of Operations

Math for Extruders: Program 2

- Metric and Imperial Units
- Length and Distance
- Area, Volume & Flow
- Weight, Mass and Force
- Conversions
- Understanding Percentages
- Calculating Tolerances

Understanding Plastics Training

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on part properties during processing.

- The definition of plastics
- Polymer classification
- Material properties affected by processing
- Proper material handling techniques
- Processing characteristics of virgin and regrind

Material Drying Technology, Course 1

These programs identify drying as a critical step when processing any plastic – and teach participants that proper preparation, handling, monitoring and controlling moisture levels results in higher quality parts, higher production yields and consistent processing. Material Drying Technology course two focuses on the operation and utilization of Hot Air Dryers, Compressed Air Dryers, Desiccant Dryers, and Vacuum Dyers in today’s production environments. Course two also teaches the participants how to Calculate Material Consumption, Residence Time, and Dryer Capacity.

- Polymer Basics
- Hygroscopic vs. Non-Hygroscopic Polymers
- Hydrolysis
- Purposes of Drying
- Dewpoint
- Dewpoint Measurement
- Dewpoint Sensors
- Drying Procedures

Material Drying Technology, Course 2

- Hot Air Dryers
- Compressed Air Dryers
- Desiccant Dryers
- Vacuum Dyers
- Calculating Material Consumption
- Calculating Residence Time
- Calculating Dryer Capacity

Plastic Part Design - Mechanical Behavior of Polymers

- The mechanical behavior of polymers
- Stress/strain curves
- Visco-elastic behavior of polymers
- Creep and stress relaxation