In addition to our CIM technology, Icoform offers advanced film and sheet extrusion capabilities. We process a wide range of thermoplastic materials to produce films and sheets in thicknesses from 1 mm to 8 mm. Our extrusion lines support up to five‑layer configurations, enabling the combination of different materials, the integration of recycled content, and the creation of products with tailored performance characteristics.
Extrusion Process for Polymeric Materials
Our extrusion process transforms high‑quality polymer compounds into precise, durable products through a controlled and efficient manufacturing workflow.
Feeding and Melting
The process begins with raw material—polymer pellets—being gravity‑fed from a top‑mounted hopper into the extruder barrel. Additives such as colorants and UV stabilizers can be blended with the resin beforehand to ensure consistent performance.
The pellets enter the barrel through the feed throat and come into contact with the rotating screw, which typically operates at speeds of up to 120 rpm. As the screw conveys the material forward, the pellets are gradually heated by multiple independently controlled PID heater zones. This temperature profile ensures uniform melting while preventing thermal degradation of the polymer. Additional heat is generated naturally through pressure and friction inside the barrel. If required, cooling fans or integrated water‑cooling jackets maintain the melt temperature within the defined limits.
Filtration and Flow Control
At the end of the barrel, the molten polymer passes through a screen pack that filters out contaminants. The screens are supported by a breaker plate, ensuring stable pressure and consistent melt quality.
Shaping Through the Die
After filtration, the melt enters the die. The die determines the final product geometry and is engineered to transition the polymer flow from a cylindrical shape to the required profile. Precise die design ensures even distribution of material and consistent product dimensions.
Cooling and Solidification
Once the material exits the die, it is cooled to solidify its final shape.
- On the CIM line, cooling is achieved by pulling the material through a cooling roll, which simultaneously acts as the mold for the grass or other three-dimensional structures.
- On the CP, the film and the sheet lines, cooling is performed using a combination of cooling rolls and air‑blowing fans.
This controlled cooling process ensures dimensional stability and high‑quality surface characteristics.