PVC/PP/PE/PC/ABS Profile Extruder Extrusion Line

This extrusion line is suitable for the production of plastic profiles made of PVC/PP/PE/PC/ABS and other plastics, covering models from YF50 to YF300 with product widths of 50–300 mm. It adopts the JWS series energy-saving drive (e.g., 15/11 kW dual-power mode), water consumption of only 4–7 m³/h, and air consumption of 0.5–0.6 m³/min. Widely used in doors & windows, automotive trims, cable ducts, etc., it offers advantages such as fast material changeover, low energy consumption, and stable dimensions.

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Application

Advantages

Advantage	How parameters support this advantage
Energy-saving drive system	Dual power ratings (e.g., 15/11 kW on YF50) allow switching between high-torque and economy modes, saving up to 25% energy for thin-wall profiles.
Low utility consumption	Cooling water 4–7 m³/h (30–50% lower than industry average for same output); compressed air only 0.5–0.6 m³/min – can be supplied by a small 7.5 kW compressor.
Broad material flexibility	Screw design (JWS series) specifically optimized for PVC/PP/PE/PC/ABS – no need to change screws; only fine-tuning of temperature settings required.
Compact footprint for small width models	YF50 (max 50 mm) occupies only 6m x 1.8m, ideal for workshops or labs.
Scalable production capacity	From 50 mm to 300 mm width using the same control system – reduces training and spare parts inventory.

Practical advantage case study:
A British recycler processed post-industrial PP waste (MFI 3–8) on YF180. The 90/75 kW drive system could handle fluctuating viscosity without stoppages, while the 5 m³/h cooling water kept melt temperature below 200°C – preventing degradation. Output: 180 kg/h of recycled pallet profiles.

Process

We implement a 5-stage QC protocol to ensure each extrusion line meets CE and ISO 9001 standards.
Stage 1 – Incoming Components
Screw & barrel: 100% inspection of hardness (HRC 55–60) and chrome layer thickness (0.05–0.10 mm).
Heating bands: Resistance and insulation test (≥10 MΩ at 500V DC).
Gearbox: Noise check at full load (<78 dB) and vacuum test for oil leakage.
Stage 2 – Sub-assembly Testing
Extruder idle run: Run at 50% of max screw speed for 4 hours – measure vibration (≤2.5 mm/s).
Cooling system: Flow verification (4 m³/h ±5% for YF50/YF108) and pressure drop (≤0.3 bar across die head).
Stage 3 – Full Line Integration
Material trial run: Use standard rigid PVC (K value 65–68) to run 200 kg at rated speed. Record:
Output stability (±3% over 1 hour)
Profile dimensions (Cpk ≥1.33 per 10 samples)
Material changeover test: Switch from PVC to PP (using purging compound) – record time (<40 minutes on YF180).
Stage 4 – Final Factory Acceptance Test (FAT)
48-hour continuous run using customer-selected material (simulated).
Safety checks: Emergency stop distance (<50 mm), thermal circuit breakers, CE-certified guards.
Stage 5 – On-site Re-commissioning
Our engineers repeat FAT at customer's factory and train operators. Signed test report including actual profile samples.
QC outcome example:
A Vietnamese pipe producer purchased YF240. During FAT, we detected uneven cooling on the 240mm die – adjusted the water channel design, resulting in final product straightness improvement from 1.2 mm/m to 0.3 mm/m.

Parameters

Model	YF50	YF108	YF180	YF240	YF300
Max product width (mm)	50	108	180	240	300
Extruder model	JWS45	JWS50	JWS65	JWS90	JWS120
Drive power (kw)	15/11	22/18.5	30/22	55/45	90/75
Cooling water consumption (m³/h)	4	4	5	7	7
Compressed air consumption (m³/min)	0.5	0.6	0.6	0.6	0.6

Q1: Why does the YF180 list two drive power values (90/75 kW)?
A: The 75 kW setting is for high-torque, low-speed extrusion of heat-sensitive materials (e.g., rigid PVC). The 90 kW setting provides higher throughput for PP/PE. Switch via the VFD panel – never switch while running.

Q2: My compressed air supply is only 0.5 m³/min. Can I run YF108?
A: Yes, YF108 requires 0.6 m³/min, but most customers oversize their compressor. If your supply is only 0.5 m³/min, you can still run at up to 85% of max line speed. For full speed, add a 200L air receiver tank or upgrade the compressor. We recommend a safety margin – use 0.8–1.0 m³/min.

Q3: Can I produce 300mm wide profiles on YF240?
A: No – the maximum width per model is hardware-limited by die width and calibration table size. YF240 max = 240 mm. To produce 300 mm, choose YF300, or run dual-strand extrusion (two 150 mm profiles side-by-side) on YF240 with a custom die.

Q4: How often should the cooling water be replaced?
A: Closed-loop system: check conductivity monthly – replace if >500 µS/cm. Open-loop (tap water): use a 200-mesh filter and descale every 3 months. The required flow rate (4–7 m³/h) is moderate; many customers use a small cooling tower.

Q5: Can the same screw extrude both ABS and PC?
A: Yes, but with limitations. The JWS series has a compression ratio of 2.5:1 – suitable for ABS (easy) and PC (requires higher temperature, 260–280°C). For frequent PC/ABS blend changeovers, we recommend a nitrided screw (standard on JWS90/120). Avoid running glass-filled PC – use a special wear-resistant screw.

Q6: My YF50 output is very low (only 8 kg/h). What's wrong?
A: Check:
Material feeding: Is pellet bridging in the hopper?
Screen pack: Clogged? Replace with 40/60/40 mesh.
Back pressure: Too high? Open die restrictor valve 1/4 turn.
Drive power setting: You may be in 11 kW economy mode – switch to 15 kW.
Screw speed: Target 40–70 rpm for PVC, 80–120 rpm for PE.
Case study: A Kenyan customer had the same problem – it turned out they were running high-viscosity PE material in 11 kW mode. After switching to 15 kW and raising screw speed from 45 rpm to 95 rpm, output jumped to 19 kg/h.