Extrusion

Extrusion

Solutions for plastic extrusion processes

In extrusion processes, production continuity, flow stability, and final product uniformity depend on the balance between formulation, rheological behavior, and line operating conditions.

From dispersion management to the control of surface and functional properties, every variable directly impacts process quality, productivity, and efficiency.

Free Flow supports companies, R&D teams, and production departments in developing solutions formulated to enhance process stability, processability, and material performance across major extrusion technologies.

What is technology?

Film extrusion enables the continuous production of plastic films for packaging, industrial, and technical applications using blown or cast processes.

Material uniformity and line stability are essential to ensure consistent optical, mechanical, and functional properties.

Key challenges

  • Sharkskin and surface defects;
  • Bubble instability;
  • Thickness variations;
  • Non-uniform dispersion;
  • Slip and COF issues;
  • Gels and contaminations;
  • Thermal degradation.

How Free Flow provides support

We develop solutions aimed at:

  • Improve line stability;
  • Optimize the dispersion of color and additives;
  • Control surface properties and flow;
  • Reduce aesthetic imperfections;
  • Increase production continuity and quality consistency.

What is technology?

Tube extrusion is used for continuous production processes requiring geometric control, dimensional stability, and mechanical reliability.

Flow continuity and material thermal management directly influence final quality and performance.

Key challenges

  • Ovalization and geometric instability;
  • Dimensional variations;
  • Non-uniform dispersion;
  • Surface defects;
  • Flow rate instability;
  • Material degradation.

How Free Flow provides support

We support optimization activities designed to:

  • Improve process stability;
  • Increase product uniformity;
  • Optimize dispersion and coloration;
  • Reduce waste and production instability;
  • Improve line continuity.

What is technology?

Cable extrusion requires precise control over the coating and material uniformity to ensure production continuity, performance reliability, and compliance with the most stringent application requirements.

Process stability, material behavior during extrusion, and interaction with the various cable components directly influence surface quality, reliability, and final performance.

Key challenges

  • Surface defects;
  • Interaction with copper;
  • Insufficient dispersion;
  • Compliance with strict technical standards;
  • Die build-up;
  • Thermal degradation.

How Free Flow provides support

Our solutions contribute to:

  • Improve surface quality and uniformity;
  • Reduce die build-up phenomena;
  • Optimize the dispersion of pigments and additives;
  • Support the stability of the extrusion process;
  • Improve formulation compatibility in applications involving contact with copper;
  • Support specific regulatory and performance requirements;
  • Increase production continuity and quality reliability.

What is technology?

The extrusion of sheets and profiles enables the continuous production of components with controlled geometries and specific functional properties.

Flow stability, uniformity, and surface control are key factors in ensuring quality and repeatability.

Key challenges

  • Dimensional variations;
  • Surface defects;
  • Material instability;
  • Non-uniform dispersion;
  • Internal tensions;
  • Deformations and shrinkage.

How Free Flow provides support

We support companies and manufacturers in the development of formulations aimed at:

  • Improve surface quality;
  • Increase geometric stability;
  • Optimize material behavior;
  • Reduce process waste and defects;
  • Improve production uniformity.

What is technology?

The extrusion of raffia, monofilaments, and fibers requires high process stability and control over the material’s mechanical properties throughout all production stages.

Molecular orientation, uniformity, and dispersion directly influence strength, production continuity, and final quality.

Key challenges

  • Filament instability;
  • Variations in toughness;
  • Insufficient dispersion;
  • Line breaks;
  • Thermal degradation;
  • Color variations and surface properties.

How Free Flow provides support

We develop solutions formulated for:

  • Improve process stability;
  • Increase uniformity and dispersion;
  • Optimize aesthetic and functional properties;
  • Reduce breakages and production waste;
  • Support the operational continuity of the line.

Contact us

Do you have an application or a process-related issue?

Let’s discuss your extrusion process to jointly identify the solution best suited to your production and application requirements.