Extrusion
Production of highly filled sheets
The extrusion process enables the cost-effective and continuous production of highly filled sheets in which a high proportion of functional mineral or other solid fillers is incorporated into a thermoplastic polymer matrix. The process combines a high functional filler content with industrial scalability and reproducible sheet quality.
During the process, the polymer, fillers, and, where required, additives are precisely dosed and fed into an extruder. Under controlled temperature, shear, and residence time, the polymer is plasticized and the solid phase is dispersed as homogeneously as possible throughout the polymer melt. This processing stage is particularly critical at high filler levels: as the proportion of solids increases, viscosity and torque typically rise, placing greater demands on dispersion and stable process control.
The homogenized, highly filled melt is then continuously formed into a thin sheet through a flat die. Die design, pressure distribution, and flow behavior play a key role in ensuring uniform basis weight and sheet thickness across the entire production width.
After leaving the die, the sheet is calibrated, cooled, and solidified using temperature-controlled rollers. The sheet thickness, surface finish, and other properties can be precisely adjusted by controlling the roller gap, take-off speed, and temperature. The sheet can then be continuously wound or fed directly into subsequent processing steps such as coating, lamination, bonding, or converting.
Technical and economic benefits
The key advantage of extrusion lies in the combination of continuous production, high throughput, and precise process control. Compared with batch production processes, large quantities of sheet material can be produced with consistent properties and a relatively high degree of automation.
With our state-of-the-art extrusion line, HAPPICH has the technology to manufacture highly filled sheets efficiently, precisely, and reproducibly.
- High filler content: Processing of demanding formulations with high proportions of functional fillers.
- Homogeneous material quality: Controlled compounding and uniform distribution of components within the polymer matrix.
- Precise sheet production: Defined sheet properties through precisely controlled and stable process conditions.
- High flexibility: Material composition and sheet properties can be specifically tailored to different applications and customer requirements.
- Reproducible quality: Modern equipment and process technology ensure consistently high quality standards.
- Efficient series production: The continuous extrusion process combines high productivity with cost-effective scalability.
- Expertise from a single source: From customized material solutions to industrially manufactured sheets.
We combine modern extrusion technology with materials and process expertise – delivering customized heavy-layer solutions that combine functionality and cost-effectiveness.