PC Diffuser Profile Extrusion Line
+25% Output Efficlency
-15% Energy Consumption
99.6% Stable Operation Rate
Why our plastic profile extruder stands out
- Specialized High-Precision Single Screw Extruder: Engineered with a dedicated high-L/D ratio (typically 30:1 or 32:1) single screw design.
- Micro-Precision Vacuum Calibration Table: Our heavy-duty stainless steel vacuum calibration table offers multi-axis 3D micro-adjustments, high-stability vacuum water rings, and precise sizing plates.
- Optical-Grade Die Head & Tooling: The extrusion die is crafted from premium German-standard die steel, with internal flow channels hard-chrome plated and mirror-polished.
- Seamless Downstream Integration: Fully synchronized production via an intuitive central PLC control panel.
Parameter
| NO | PC Extruder model | Motor power(kw) |
|---|---|---|
| 1 | SJ45 | 11 |
| 2 | SJ50 | 11 |
| 3 | SJ55 | 15 |
| 4 | SJ65 | 15/18.5 |
Core Advantages
Extruder
Anti-Yellowing Screw Profile: The dedicated single screw geometry minimizes mechanical friction and localized shear heat. This preserves the optical clarity of the PC resin and prevents yellowing.
Dehumidifying Vacuum Dryer: Standardized with a premium honeycomb dehumidifier to dry materials to a strict dew point below $-40^\circ\text{C}$. This completely eliminates silver streaks, bubbles, and structural hydrolysis.
Strict Temperature Management: Micro-precision PID controllers paired with ceramic heaters and cooling blowers govern the barrel zones. This ensures stable melt viscosity and uniform profile shaping.
High-Torque Synchronized Drive: Equipped with a heavy-duty thrust distribution gearbox and stable motor system. This guarantees consistent material feeding and pulse-free extrusion under high pressures.
Mould
Premium German Steel Build: The complete die assembly is forged from high-grade German DIN-standard tool steel. This ensures excellent structural stability and resists thermal deformation during long production runs.
Mirror-Polished Flow Channels: All internal polymer-facing channels are hard-chrome plated and polished to a mirror finish. This eliminates material stagnation points and prevents surface streaks on the lampshade.
Streamlined Co-Extrusion Design: Engineered with precise modular distribution blocks to feed multiple layers smoothly. It allows perfect melt-bonding for co-extruded dual-color or frosted/clear striped PC profiles.
Quick-Change Tooling System: Designed with modular die plates and mandrels for streamlined dismantling and cleaning. This cuts operator changeover time drastically and minimizes product scrap during restarts.
Vacuum Calibrator
3D Micro-Positioning Bed: The stainless steel table features precision handwheels for exact longitudinal, lateral, and vertical adjustments. This allows perfect, rigid alignment with the die exit for complex geometries.
Independent Vacuum Circuits: Equipped with high-vacuum water-ring pumps and a digital manifold. It delivers smooth, un-fluctuating negative pressure to lock in tight-tolerance locking clips.
Anti-Corrosion Stainless Structure: The entire frame, water tank, and internal plumbing are constructed from high-grade SS304. This prevents water scaling and guarantees a lifetime of rust-free operation.
Optimized High-Pressure Spray: Positioned with fine multi-angle water nozzles for uniform and rapid thermal cooling. This prevents post-extrusion warping and locks in high-speed profile stability.
Haul Off
Optical-Grade Rubber Tracks: Fitted with custom-formulated, high-friction soft rubber pads that grip firmly. This pulls the delicate PC profile smoothly without causing scratches or indentations.
Precision Servo Speed Controls: Driven by a digital servo motor linked directly via a central PLC encoder. It eliminates micro-speed fluctuations to prevent stretch marks on the running profile.
Pneumatic Balanced Clamping: Utilizes dual-cylinder pneumatic regulators to apply even pressure across the lampshade profile. This prevents structural crushing on thin-walled or hollow LED diffusers.
Centralized Speed Synchronization: The linear traction velocity is fully interlocked with the extruder screw speed through the PLC. This allows automatic adjustments during start-up or speed ramps.
Cutter
Chipless Flying-Knife Cutting: Uses an automated, high-speed pneumatically driven heated knife blade that cuts instantly. This generates zero chips and zero dust, maintaining a high-standard cleanroom environment.
Slick, Square Cut-Ends: The knife motion is perfectly synced with the line speed via a high-precision slider block. It provides flawless, square cut ends that are ready for immediate end-cap assembly.
Digital Encoder Length-Counter: Features an integrated optical length-measuring wheel connected directly to the digital panel. This allows operators to set custom profile lengths with millimeter-level cutting accuracy.
Wear-Resistant Blade Guide: The blade housing uses hardened linear guide rails for ultra-smooth vertical movement. This extends the service life of the cutting tool and ensures repeat accuracy.
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FAQ
Why do you use a Single Screw Extruder instead of a Twin-Screw Extruder for PC lampshades?
Polycarbonate (PC) is an amorphous engineering plastic with high melt viscosity and excellent optical properties. Twin-screw extruders exert intense mechanical shear, which can easily overheat PC molecules, causing the material to degrade, turn yellow, or lose its optical clarity. A high-L/D ratio Single Screw Extruder provides gentle, progressive melting and highly stable pressure without excessive shear, making it the absolute industry standard for preserving the transparency and gloss of optical profiles.
Why is a dehumidifying dryer mandatory for PC lampshade extrusion?
PC is highly sensitive to moisture. Even a tiny trace of moisture absorbed by raw PC pellets will cause hydrolysis inside the hot barrel. This manifests as silver streaks, bubbles, brittleness, and poor light transmission in the finished lampshade. MIDTECH always supplies a high-end honeycomb matrix dehumidifying dryer to ensure the raw materials are thoroughly dried to an optimal dew point before entering the single screw.
How does the line handle dual-color or co-extruded PC profiles (e.g., half-clear, half-frosted)?
What causes dimensions to shift on PC profiles, and how does MIDTECH prevent it?
PC has a high shrinkage rate and hardens quickly upon cooling. Minor fluctuations in vacuum pressure or traction speed will cause the tight-fitting clips or wall thicknesses to go out of tolerance. MIDTECH solves this by:
- Utilizing VFD and servo motors for flawless haul-off speed consistency.
- Integrating independent, non-pulsing vacuum circuits on the calibration table.
- Offering precision 3D micro-adjustable tables to lock the geometry exactly as it exits the die.