In the dynamic plastics extrusion industry, where precision and productivity are key, flat die extrusion is an indispensable technique for transforming thermoplastic materials into sheets or foils of precise size and quality.
BG Plast is a pioneer in this field and offers innovative calendering solutions tailored to the diverse needs of thermoplastic materials processing.
The technical and constructional goodness of the calender is the key to improving product quality, streamlining production processes, and maximizing operational efficiency in the manufacture of thermoplastic sheets and foils.
From virgin or post-consumer recycled raw material to foils and sheets of all kinds
The calender according to BG Plast
BG Plast, a leader in plastics processing technology, prides itself on designing specialized calenders with different geometries to accommodate a wide range of materials, including PP, PE, PS, ABS, PETG, PVC, PC, PMMA, PET, HDPE, LDPE, TPU, and WPC. Through accurate pressure and temperature control, our calenders ensure unparalleled uniformity and consistency of extruded products, setting a benchmark for industry standards. Our commitment to continuous improvement fuels advances in productivity and quality, ensuring optimal performance in response to market demands. BG Plast’s calendering technology improves product quality and production processes and also maximizes operational efficiency, making it an indispensable asset in the world of thermoplastic extrusion, where precision and efficiency are indispensable.
BG Plast 45° calender for PET, PP, PS sheets
How the process of die cast extrusion takes place
The process of flat die extrusion takes place in a sequence of perfectly organized operations, each of which is essential to achieve certain product specifications.
It begins with careful weighing and mixing of raw materials, using special gravimetric feeders, to ensure the formation of a homogeneous polymer blend. This mixture is then introduced into an extruder, either single-screw or twin-screw depending on the materials, where it is gradually brought to melt and then filtered using special screen changers (continuous flow or automatically cleaned). The melt is then pushed into the extrusion head to come out in the form of a molten sheet with width and thickness similar to those of the final product. The latter then enters the calender to be calibrated and cooled.
There are different configurations of calenders depending on the type of polymer to be processed: BG Plast offers calenders with vertical rolls, inclined at 45° or with rolls arranged horizontally. These rolls, heated at controlled temperatures, exert pressure on the material, gradually compressing it to the desired thickness, thanks to the space the rolls have between them. With BG Plast’s calenders, which allow precision electro-mechanical control over the opening and closing of the rolls, product thicknesses between 0.2 and 40 mm can be guaranteed, depending on the material.
After the compression stage, the extruded material enters a series of surface processing and cooling stages. Here it passes through dedicated rollers designed to impart specific surface finishes and textures, improving both aesthetic appearance and functional properties. At the same time, the material is gradually cooled to stabilize its structure and prevent deformation. This cooling process is essential to maintain dimensional stability and ensure uniformity of the extruded product.
Once the material has been completely cooled, it is wound onto rolls or cut into sheets, ready for further processing or for use in various applications.
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Innovation fuels progress: calendering technology for plastic extrusion
Advances in calendering systems are growing the industry, with investments in automation, process control and material handling systems continuously improving productivity, efficiency and output quality. With the integration of advanced sensors and monitoring systems, perfect control of thickness, surface finish and defect detection is achieved, ensuring the reliability and consistency of calendering processes.
BG Plast, with its commitment to innovation and excellence, employs state-of-the-art technology and expertise to design and manufacture extrusion lines for thermoplastic materials to perform each step of the calendering process with precision and efficiency. This dedication to quality and attention to detail sets BG Plast apart, enabling us to provide calenders that meet the most stringent industry standards. From improving product quality to optimizing production efficiency, BG Plast calenders offer multiple benefits that lead companies toward success in today’s increasingly competitive marketplace.
Trust the professionals: contact us for your next project.
From consulting to understand the customer’s needs to post-installation support for calendering systems, BG Plast is always at its customers’ side