Extrusion Module 1- Machine Setting

Dates: To be verified

Duration: 4 days

Location: 7 Centre Court, Blyry Business and Commercial Park, Athlone.

Accreditation: Plastics Extrusion

Full Fee: €1495 including course manual, certification, lunch and refreshments

Course code: QQI Code: 5N2625

Programme overview

The extrusion training delivered is a mix of both theory and practical. This course is designed to provide the learner with an in-depth understanding of exactly what is happening inside the extruder/tooling and on the extrusion line itself during the extrusion process so that they can effectively and efficiently troubleshoot the extrusion process.

This course is a 4-day course and day 4 needs to run separately a few weeks after the first three-day block in order to complete the certification on this course.

It is a very practical introduction to extrusion, the major focus of the course is to practice the correct techniques to set up the extrusion line correctly using the correct tooling, start and stop an extruder correctly and safely and avoid the common production issues such as degradation, ovality, concentricity issues, leaks from extrusion tooling, etc.
It will also enable the learner to understand the theory of what is happening in the extrusion process.

The extrusion training delivered is a mix of both theory and practical.
A comprehensive folder with all the theory is provided to all learners.
The folder is constantly being revised to reflect current industry best practices and/or if learners are finding it difficult to understand a particular concept.
The theory is typically classroom based but in order to effectively explain the theory, time may also be spent on the extrusion line actually showing the learners, etc what – where – why, etc.
Learners typically find some of the theory aspects easier to understand if they can actually see the “what – where – why” on the actual extrusion lines instead of being of purely classroom based.
The practical aspect involves using the theory previously learned and setting up and running actual tubing products and seeing the critical interactions of the extrusion process when different changes are made to the equipment and or to the operating conditions.
The practical aspect of the programme gives the learners greater insight into the extrusion process as they can see the process first hand.
There are practical skill demonstrations built into the practical side of the learning.
The trainer demonstrates how the task should be correctly performed and then the learners perform the task.

The training is a blend of the theory behind the various aspects of the extrusion process and practical hands-on learning on an extrusion line which allows the learner to put the theory into practice.

This combination of theory and hands-on learning has proved to be very effective in upskilling existing extrusion technicians and/or new technicians.

Safety Shoes – Required on this course

Learning outcomes

At the end of this course attendees will be able to:

  • Explain the safety considerations associated with extrusion tooling including heat electrical and chemical substance hazards
  • Explain how extruded component size can be controlled by process parameters such as air pressures, vacuum pressure, screw speed and haul off speed.
  • Explain basic Statistical Process Control (SPC) concepts such as average, standard deviation, range, process capability (Cp) and mean shift (CpK).
  • Create control charts to record drawing dimensions and monitor the extrusion process.
  • Remove and clean a screw from a single screw extruder
  • Remove a die from an extruder without compromising personal safety or risking tooling damage.
  • Handle extrusion die tooling to include labelling, assembly, disassembly, and damage avoidance using protective storage.
  • Demonstrate the effects on extruded component size of changes in process parameters such as air pressure, vacuum pressure, screw speed and haul off speed.
  • Perform extrusion tooling assembly giving due consideration to assembly sequence, tooling selection, tooling condition, torque levels, details of tool sealing surfaces and surfaces in contact with plastic melt.
  • Interpret production drawings to produce plastic extrusion components in accordance with design specifications

Who is this course for

This course is suitable for

  • Extrusion Operators
  • Technicians
  • Engineers who are currently working in the extrusion industry
  • or who are planning to work in extrusion and who have had no formal extrusion training,
  • or anyone who needs an understanding of the extrusion process. 

Course Content:

Section 1: The Melting process in single screw extruders
Section 2: Parts of the extruder
Section 3: Extruder Screws
Section 4: Melt Pressure and Melt Temperature
Section 5: Heating and Cooling the extruder
Section 6: Safety in extrusion
Section 7: Tooling
Section 8: Guill 712 Tooling  Assembly and Dis assembly Manual
Section 9: Extruder start up and shut down procedures.
Section 10: Extrusion Line Set up.
Section 11: Process Parameter Interactions & Impact of raw material properties on extrusion process.
Section 12: Statistical Process Control
Section 13: Monitoring the process parameters and troubleshooting procedure.
Section 14: Common Extrusion Problems.
Section 15: Troubleshooting hints

Trainer Profile

Padraic Lunn has worked since 1990 in the medical device extrusion industry in Ireland.  His company is the official representative for 6 specialist extrusion equipment companies for Ireland, UK and parts of Europe. These companies are recognized as market leaders for extrusion equipment used in the medical device industry worldwide.

Padraic Lunn also provides customized Extrusion Training programs which are based on a customer’s specific process requirements. These programs can be hands on or classroom based or a combination of both. Prior to compiling the customized training, time is spent observing the current process’s to evaluate work practices etc and this information is incorporated into the training to maximize effect.

See Padraic’ full profile here

 

Find out how to achieve a Major Award in Injection Moulding (Level 5)

This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications – see www.nfq.ie  and is a mandatory component of major award 5M3074 – Plastics Extrusion

Protection for Enrolled Learners Policy

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