EXTRUSION PROCESS

1. introduction
 It is a Multi-National Company (MNC). Its main plant is in Germany. In India it has plant in
Vadodara. The company name is Aluplast. The founder of the company is Manfred J Seitz has
started the company in year 1982 in Germany. In India the manager Director –Mr. Arun Sharma
has started the company in Vadodara in year 2015. Aluplast is a company which makes UN –
plasticized poly vinyl chloride (UPVC) Windows. This UPVC windows are very efficient now
days for homes, Flats, Buildings etc. Now days UPVC windows provide you with a complete
solution for your windows best advanced technologies than aluminum & wooden windows.

 I would explain about extrusion process in which how windows profile are made through this
process.
1. Procedure -
 In this process first we decide the material or it is in powder form which material is used
according wise. The material is made of PVC.
 Then we pass the material from the hopper Then It goes to the doser in which the material
is pass slow rpm and it goes to the barrel heating zone temperature by heating the material
which is in powder form to make it hard by heating.
 NOTE – Master Batch is a process only used for making color profile. In white profile we
did not used master batch process.
 Then from barrel heating zone it passes through die and die is different for different tool
id. Die function is to give the shape to the profile.
 Now after die process There are calibrators which are used to cool the temperature of the
profile. Then it pass through the water tank / tank plate in which there is water to cool the
profile at temperature of 13 – 14*C , there are vacuum which control the pressure of water
which is flowing and to give the profile a gloss finish.
 After this co extrusion process is there in which we provide gasket to the profile.
 After complete of gasket we provide a print code to the profile in which we get the details
of profile when it is made, by which tool id it is made etc.
 Then after printing it goes to the puller which give the path to move the profile forward.
 After this process key tape is provided on the profile to free from dust particles.
 After Product key tape then it provide a cutter in which a specific length is set to cut the
profile.
 The last process is tripping table in which it sense the length of the profile and it
automatically down the profile and after this process we check the quality process.
 In last packaging is done of the profile
 NOTE – when in first when we pass the material from die we use rope to give the path to
the profile.
 In the end this is the extrusion process how we make the profile for making windows.

2. Motivation
  In extrusion process I have seen in last month that scrap material is more and in this month
scrap material is less so improvement of scrab material is done to reduce the scrap material
some process parameters are changed and efficient skilled training is given to the works
that are operating the machine. By this wastage of material is less and we get the profile
in good conditions.
 In this process I have get the motivation that how the things work in real life. this process
helps to make profile for the windows that are used now days more instead of aluminum
and wooden profiles.

3. Literature Review
 In Extrusion process we provide support rollers to move the profile in proper path . It is done after
co – extrusion process. So the development done in extrusion process is providing the support
rollers.
 In this Extrusion process packing is done manually and now days steel rollers are provide for the
packing process . so heavy profile can move easily on steels rollers so second development is steel
rollers are provided.
 In Extrusion process day bin is used to kept the raw material now days by this proper suction of
material is done properly so development of day bin is done . By this process wastage of material
is less.

4. Objective of the work

 The main objective of work is to understand how the extrusion process is done. How the profile
are made for making the windows. In tool changing process in extrusion how it is done. In tool
changing process how I can reduced cycle time so tool changing process will not take more time.
And to understand each and every process in extrusion how it is works. In extrusion tool changing
process is very time taking and what problem facing when the process of extrusion is going on.
How we can overcome the problems. So this is my main objective to do work
 The second objective is to understand each and every process which is going in industry because
there is many process instead of extrusion (For eg – lamination process, fabrication process ,
quality check , packaging process) which would be understand and if I can do any improvement
in this process how to reduce wastes in industry. So the second objective is how can we reduce
wastes and do some kaizen work so wastage should be less in industry. These two points are main
objective of my work.

5. Target Specifications
 When starting extrusion process we have to give the proper soaking time
 The lumps are coming when process is going . so to reduced the lumps proper load should be
reached by the machine so less lumps would come. So wastage of material is less.
 In puller unit the pads are provided that should be clean & the surface of pads should be smooth
not rough.
 Degassing chamber should be properly clean so the bubbles will not form inside the profile.
 The heat exchanger is provided to control the temperature of the machine. The temperature should
not reach more than 35 to 45*c. if it is more than 45*c it will effect the profile and the machine
will automatically stop.
  In cutter unit the blade should not be broken. if it is broken then the length which is set in control
panel it would not cut properly. So blade should be proper
 The profile should be made properly so the quality check is done . In quality check degassing
problem should not be there, scratches should not be there, profile should not bend , gasket is
properly fitted or not this all are target specification

6. Functional partitioning of project

 Extrusion process divided into two parts –
 Extrusion is a primary process
1. Up stream :-
a) Extruder
2. Down stream :-
a) Calibrator table
b) Polar unit
c) Cutter unit
d) Tripping table
 Co Extrusion process which is used for providing the gasket to the profile. It is a secondary
process
 Printing process
 Product key tape
 Quality check
 Packaging process –
1. Domestic packaging
2. Export packaging

7. Methodology
 Assumption made are –
1. Soaking time of 2 hours is given
2. Material which using is properly check which material is used
3. Gasket process soaking time of 1 hour is given
4. Puller pads are properly clean.

 When running the extrusion process if we touch the puller unit in between it produced the
mushroom profile and we have to start the program again this should be check properly.

 [ Extrusion process start-> Raw material -> Hopper -> Doser -> barrel temp. zone -> Feed
Zone-> Compression zone-> Melting zone-> Die process-> Calibrator-> Water tank / Tank
plate-> Co Extrusion process is done for providing gaskets to the profile-> Printing code->
Puller unit->Product Key tape is provided for dust proof-> Cutter unit-> Tripping table->
Quality check-> Packaging is done -> Extrusion process end ].

 Every process should be properly done if any problem occur in between it will effect all the
process :-

1. The scratch line should not be there on profile.

 2. The gloss percentage of profile should be 25 to 50 %
3. Degassing problem should not be there like bubbles should not seen inside the profile.
4. All the measurement should be done properly.

8. Tools required
 This extrusion m/c tools required hand gloves, plastic hammer, measuring tape, vernier caliper.
 Tools are – 1. Allen key – T & L Type
2. Spanner
3. Melted Hammer
4. Gloves
5. Brass Pin
6. Plyer
7.Miter saw

9. Conclusions
 In the end I would like to say that Extrusion process is a vast process to understand .by this
process I get the knowledge how the profile are made . there are different tool id and different
die are used to produce different profiles . only two and three track does not requires gasket
process because this sliding windows and doors are made and all other die requires the gasket
process because they are made in sash / frame they are used to make casement windows , French
windows etc. In extrusion process I understand the problem that are faced & what is the
procedure of extrusion process and proper quality check is also done so we get the good profiles
. In the end this process help me to understand all the extrusion process.

10. Project Work Schedule

(a) Jan 2018: Status – 31st JAN,2018, I have introduction with the people working in the
company and basic introduction of all the m/c , introduction about the quality check
process and basic idea of packing

(b) Feb 2018: Status –

 1 to 15 FEB 2018, I have done extrusion process whole study and how m/c works in this
process quality check is done after every 2 hours. Reading should be taken when profile is
okay. how tools changing process is done, In water tank how plates are adjust accordingly to
move the profile, how gasket are provided to the profile, how puller, cutter and tripping unit
are done in extrusion process.

 15 to 27 FEB 2018, I have done Fabrication unit, how windows are made by using different
 m/c. and I have made a sample casement window for understanding each m/c process in
fabrication unit.

(c) Mar 2018: Status –

 1 to 11 MAR 2018 I have learned

how the tool changing process is
done. In this process how different
die are changed and how the cleaning
of the tools is done.

(a) Apr 2018: Status –

 NIL

(b) May 2018: Status –

 NIL

12. Technical References