Continuous production of plastics products

In most extrusion processes, several raw materials pass through a complex process chain. The key factor is that every single process step is optimally geared to the overall process. Only in this way is it possible to produce tailor-made, high-quality products in a stable, resource-saving, energy-efficient process.

Our scientific assistants research the entire extrusion process chain – from the initial compounding and the design of the screw, die and process, through to further processing and quality assurance. A central characteristic of our research activities is the integrative approach to all the process steps. This makes a decisive contribution to their relevance for practical application and the quality of our work.

We carry out research in the field of extrusion with the focus on the following aspects:

  • Compounding
  • Process simulation and die design
  • Analysis and optimisation of the processing processes

For our research work, we can call on an excellently equipped extrusion pilot plant.

Ongoing research projects in the field of extrusion

  • Graphpol – application of graphene in polymers and polymer composites
  • INNOVATIV Compound – further development of electrically and thermally conductive plastics compounds with functionalities for use in heat exchangers and fuel cells
  • Ultrasonic production of electronic circuits of extruded film composites
  • Development of a production process for physically foamed multi-layer blown films
  • Practice-oriented further development of a contact cooling process for greater efficiency in blown film extrusion
  • Use of tailor-made blowing agent mixtures based on CO2 for the substitution of alkanes in foam sheet extrusion
  • Development of a device, separate from the rest of the extrusion line, for carrying out chemical reactions, based on the example of the foam extrusion process
  • Development of a flame-retardant system for the sustainable cellulose acetate bioplastic for use in resource-saving foamed products
  • Customised production in profile extrusion
  • Cluster of Excellence: Forming of microstructures with variothermal temperature control
  • Simulative optimisation and generative production of static mixers for the extrusion of plastics
  • Efficient production of elastomeric blow-moulded parts through adapted, temperature-controlled die technology
  • Automatic optimisation of the geometry of extrusion blow-moulded plastic parts with stiffening elements based on a structural-mechanical calculation
  • Development of an easily retrofitted process for the profiling of the temperature of semi-finished products with the aim of increasing material efficiency in thermoforming
  • Simulative preform design with the lowest possible use of material and specified bottle properties by stretch blow moulding
  • Development and analysis of a material model based on the reptation theory for simulating the strain behaviour of PET at high strain rates

Martin Facklam, M.Sc.

Head of department Extrusion and Rubber Technology +49 241 80-28372

Do you have any questions on this topic? Please don't hesitate to call me or send me a message.

We develop solutions for the plastics industry

Extrusion is the most important process for the continuous production of semi-finished and finished products made of plastic. This can be seen, for example, from the quantities of raw materials processed by extrusion each year. The fields of application for this processing technology are extremely varied: Extruded products range from packaging in the food and consumer goods segment, through technical profiles for furniture and window frame production, to blow-moulded products for beverage containers and fuel tanks. Over and above this, extrusion technology is also used for the processing and compounding of thermoplastic materials.

The application-related research and development work carried out at IKV is characterised by the integrative approach for all process steps. Only in this way is it possible to produce tailor-made, high-quality products in a stable, resource-saving, energy-efficient process.

Frequently asked questions

Cooperation projects with our partners from industry often deal with several of the following subjects, for which we draw up customised solutions that can be directly implemented:

  • Material selection, suitable for extrusion
  • Development of functional compounds and production of compounds on a laboratory scale
  • Die and process design by simulation
  • Analysis of the influence of the processing process on the properties of the semi-finished product
  • Feasibility studies and evaluation of the processability
  • Evaluation of the further processing capability of semi-finished products
  • Determination of processing properties
  • Process development and analysis
  • Parameter studies and optimisation
  • Process selection

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