Overview of the plastics market: stable growth and new perspectives. Own business: production of plastic products

For the manufacture of plastic products, ready-made lines in technology or separate professional machines are used. For the production of plastic at home, special technology and molds are used.

Professional Plastic Production: Twin Screw Extruder

Professional equipment for the production of plastic products is a wide range of machines, through which large tubular films, plastic window profiles, plastic pipes, polymer sheet and slate.

The flat-slot device includes the following components:

extruder with filtration system;
pneumatic loaders;
inflation head with cooling device;
mechanism based calibration;
flat laying module;
rods for turning the horizontal direction;
winder;
pulling device.

The basis of the machine is the extruder. All additional components only complement the device. The principle of operation of the device is based on automation, controlled by a given program.

Devices for the production of plastic under pressure

Such equipment for the production of plastic products involves pouring the finished mass into special shapes where it is cooled down. The result is a finished product. Most of the plastic elements are produced on such machines. The technology makes it possible to create complex shapes that correspond to the right size, multi-color parts, hybrid, foam and others. The injection molding machine is designed for the production of various

Such a device is also used as equipment for the production of heat-insulating plastic products.

The design of the machine includes:

module for the preparation of raw materials;
a module that regulates the closing and opening of forms;
drive unit;
automated control unit.

Such a device has a high cost and contains many modern solutions.

Blow molding machines

This equipment for the production of products from thin walls is used for the manufacture of hollow containers. For example, they produce canisters, barrels, bottles up to 5 thousand liters.

The blowing device heats the material and shapes it by blowing. Often, this technique is combined with injection molding in a machine with a combined configuration. In this way, PET containers are made.

Extruded blow molding fixtures

This equipment for the production of plastic products, as well as rubber, performs the synthesis of blowing and extrusion. It can produce a wider range of products than blow molding devices: fuel tanks, bumpers, pallets, seats, barrels, buckets, toys, tomato and milk bottles, cosmetic bottles. All processes are carefully controlled by a microprocessor.

Equipment for the production of plastic and rubber products is divided according to:

from the configuration of the heads;
on the number of posts.

Device package

Equipment for the production of plastic products includes:

Thermoforming units

Such equipment for the production of plastic products is designed to produce products based on a film, the supply of which is carried out in a continuous mode. Material thickness and consistency may vary. With the help of this apparatus, products such as disposable containers, glasses based on paper or plastic are obtained.

The principle of operation of the device

The material is heated up to 140 Cº, the product is blown from the roll. Typically, a film with a thickness of 100 micrometers is used in the manufacture.

By type, such machines are divided into tape, rotary, revolving, single-position and multi-position. Units of revolving and rotary type are used for molding. The process takes place in automatic mode, manually or on the basis of semi-automatic.

Additional devices

In addition to the main units, in the process of manufacturing their plastic products, devices are used that greatly facilitate the work:

drying devices;
loaders;
mixers;
crushing devices;
conveyors;
flash collection devices.

Mini tools for plastic production

Mini equipment for the production of plastic products is used to obtain a product in small batches. As a rule, single or multiple forms are used. The weight of this device is 15 kg. It fits easily on the table sturdy construction. Therefore, such a device was called desktop. Some units come with their own small table.

Models with an electric drive and an automated clamping module are more compact. Such small machines are used to obtain experimental parts for new equipment.

Do-it-yourself semi-finished plastic products

Scrap plastic can be found everywhere. At home, old unnecessary things made of plastic are constantly collected. There are many bottles and packages outside. For those people who like to create something with their own hands, it may be an idea to use all this for the production of plastic products at home, to grind and melt the leftovers.

But it is not recommended for a novice master to resort to such actions, since each has its own characteristics, and the melting temperature for them is different. In addition, usually in factories and plants, parts are cast using specialized installations in which powerful pressure is maintained.

Even if you collect pieces of plastic and subject them to grinding and melting, bubbles will appear. best advice will purchase plastic in liquid form at a building materials store, which will be used to manufacture parts that are in no way inferior in quality to factory ones. Rubber can also serve as a replacement for plastic.

You will also need to purchase:

silicone;
large capacity;
lithol.

If you decide to make something out of plastic, then do the work indoors. closed type. Vapors from plastic are toxic.

We make a form

Equipment for the production of plastic products at home includes a master model, the basis of which can be anything.

Suitable for you:

plasticine;
gypsum;
tree;
paper and other materials.

The model of the part to be cast must be coated with lithol or other lubricant. After that, make a shape. Silicone is very popular. Everything is clear here, since working with such material is very simple and convenient.

Important nuances

Silicone is of two types: for pouring and coating.
Each type has its own elongation coefficient and degree of viscosity. As for the first indicator, silicone with an indicator of up to 200% is applicable for the manufacture of plastic.

We pay attention to the viscosity of the material

Pay attention to the viscosity index of the material. The lower it is, the more accurate the shape is.

This point is especially important if you are working with a material such as potting silicone. Also take into account the duration of polymerization. If you use casting silicone, then the master model should be placed in a flask (its base can be steel or bronze), and then poured with silicone.

The coating material is carefully applied with a brush. In this case, all irregularities are taken into account. The silicone must be allowed to cool, after which the master model is removed.

A flask is a container made of metal. It should be slightly larger than the master model.

casting parts

This process is directly dependent on the basis of the production of the part. Polyester-based resins and liquid-consistency plastics are attractive in that they do not melt. Their difference lies in the indicator and lifetime.

Step-by-step instruction

The casting mold is taken and thoroughly cleaned. It should not be wet or dirty. All residual materials left after preliminary work are removed.
If necessary, you can change the color of the composition. For this purpose, a drop of paint is added, but it should not be water-based (paint is incompatible with liquid plastic).
There is no need for degassing. Casting plastic at home from the very beginning provides for the short life of the substance. Bubbles of small products are removed manually after pouring.
All components are thoroughly mixed and poured into the template slowly in a thin stream. The pouring should be continued until the entire volume and some part of the channel for casting is filled with the mixture. After passing the degassing procedure, the volume of material will decrease and become required.
For a high quality plastic model, cool the template gradually. Follow all instructions carefully.

Russian has a huge production and consumer potential. Solid reserves of raw materials, combined with a constant growth in demand and relatively weak saturation of the industry, attract many large players from European and Asian countries to the country. Even in the current sector continues to develop dynamically.

Brief analysis of the global plastics market

Over the past half century, the international plastics market has grown steadily. The leader in terms of production today are -, South Korea, Singapore, Japan, etc. - which account for approximately 35-45%. In Europe and North America, somewhere around 20-25% is produced. As for equipment manufacturers, Germany unconditionally excels here, carrying out almost a quarter of all world exports.

In the coming years, we should expect even more development of the Asian plastics market. This is primarily due to the tightening of requirements for enterprises based in developed countries. The need to constantly raise the standards of the production process, especially in terms of ecology, leads to a serious decrease in profitability. In this regard, Western companies prefer to open representative offices in Asian countries, where the climate is much "warmer".

domestic plastics market

According to statistics, currently approximately 15% of industrial products are made from synthetic polymers. This figure is growing every year mainly due to an increase in demand for materials in construction. Given that the share of plastic elements and structures used in the construction of structures in Russia is several times lower than in many developed countries, the prospects here are truly enormous.

Consumer goods are also in demand in the domestic plastics market. Previously, they mainly attracted consumers with their low cost, today thanks to modern technologies Decent quality and environmental friendliness were added to this advantage. It is for household products and Construction Materials accounts for the lion's share of sales in the sector.

The share of imports in the industry is constantly decreasing. This is facilitated by both the national currency and the activation domestic manufacturers. certainly played into the hands of exporters. If they continue, then in the future Russian enterprises can almost completely replace foreign products. It will take much less time than in the vast majority of sectors of the economy.

Growth points: equipment

There are a number of points, the improvement of which should significantly contribute to the development of the plastics market in Russia. First of all, this. Many large companies have already switched to full electric cars, which, compared with hydraulics, are characterized by higher productivity and accuracy, are easier to operate, and consume energy more economically. In addition, they are much more effective in the manufacture of "delicate" goods, such as medical ones.

The next factor is a change in the approach to equipment operation. The quality of the raw materials used should be carefully controlled, not chasing productivity by significantly reducing the cycle time, etc. Special attention should be given to the protection of molds. Modern electric and hybrid machines are equipped with sensor systems, through which you can control the operation of these expensive elements as accurately as possible.

In the context of the economic crisis, the majority of Russian players in the plastics market cannot afford to purchase new equipment. In the best position today are those who at one time purchased the basic units of a modular type, the design of which makes it possible to modernize them. According to experts, the future belongs to such a technique that can be improved.

Growth points: design and ecology

The modern consumer pays attention not only to the quality and functionality of the product, but also to its appearance. High plastics on the market contributed to the development of "artistic" casting methods - molding, multi-component, etc. In addition to classical technologies, "hybrid" production also gives good results in this direction, for example, a combination of compression and hydraulics.

In order to be able to supply our products to serious customers, it is necessary to have an appropriate environmental certificate. Every year, the requirements here are tightened, which must be taken into account when organizing the production process. The established standards must comply not only with the manufactured products, but also with the equipment involved in their manufacture.

If in the early seventies of the last century the world production of gas-filled plastic products accounted for 6-7% of the total production polymer products, now this figure, as knowledgeable people testify, exceeds 20-25%.

It is understandable, filling with gas reduces the consumption of polymer for the manufacture of an item. The state of the Ukrainian "polystyrene foam" industry was discussed relatively recently (see BUSINESS No. 18 of 06.05.02, pp. 19-22), since then little has changed on the market. The interviewed experts agree that the demand, for example, for polystyrene foam boards in Ukraine will grow in the coming years, which means that the organization of their production is a promising business. But on polystyrene boards the world has not converged like a wedge, you can produce a lot of things from foamed polymers and make good money on it.

Profitability
According to the surveyed operating manufacturers, the profitability of the production of products from foamed polymers can be 2-30%. The degree of profitability largely depends on what product is produced. The size of the initial investment also plays a significant role. To organize a truly highly profitable production, a lot of money is needed. For example, 100-150 thousand "conventional units" is an amount sufficient to organize the production of heat-insulating products.

For comparison
A disposable polystyrene cup weighs 3 g. The same cup made of polypropylene foam - 2.5 g. cups made of polystyrene and polypropylene foam are approximately the same.

State of the industry
In Ukraine, as well as in other countries - the former republics of the USSR, the production of products from gas-filled polymers has long been "in the paddock". The share of such in the total volume of manufactured plastic items is very small. A significant part of foam products is imported from abroad (see BUSINESS No. 18 of 06.05.02, pp. 19-22).

According to the information available to BUSINESS, now there are about 30 manufacturers of products from gas-filled polymers in all of Ukraine.

In particular, "UkrTermoBud" (Nikolaev), "Termoplast" (Kyiv), "Ros-Plast" (Belaya Tserkov, Kiev region).

Moreover, the majority of enterprises producing products from gas-filled plastics use “aged” equipment - either worn-out Soviet machines or restored imported equipment purchased recently.

What to do
According to the interviewed “polymer workers”, now it is best to engage in the production of various kinds of insulating gaskets, sheets and panels, pipes, cups, containers and packaging.

As you know, Ukraine has begun assembling TV sets from imported components. To protect finished TV from impacts, they use imported foam packaging, the cost of which is about $ 7. Why, one asks, to carry polystyrene from the same Japan? And then throw it in a landfill? However, organizing the production of packaging will cost more than one million dollars. The fact is that the mold of this package has to be constantly changed due to the change in the shape of the TVs. It may happen that the purchased mold will be used for a year, then the packaging manufacturer will have to buy a second, third, etc.

The market is also in demand for pallets, in which supermarket “raw cuts” are packed - all kinds of schnitzels, chops, chicken legs.

Naturally, it is worth thinking about the sale of such products not after, but before the creation of production.

Premises and permissions
To accommodate production, any room is suitable, the ceilings of which do not leak. As a rule, there are no special requirements for it. The exception is production in which the foaming process is carried out using pentane. Its explosive nature will provide a potential "foamer" with the opportunity to get acquainted with representatives of the State Supervision Service (in particular, boiler supervision) and the fire inspectorate. In the general case, it is necessary to comply with the requirements of SN 245-71 “Sanitary design standards industrial enterprises”, SNiP 2.04.0591U* “Heating, ventilation and air conditioning”, GOST 12.1.005-88 “Air working area”, GOST 12.4.011-89 SSBT “Means of protection for workers. General requirements and classification”, “Rules fire safety in Ukraine". Needless to say, it is best to look for premises for production location away from the “sleeping” areas of large cities, it is more expedient to locate somewhere in an industrial zone or on the outskirts of a settlement.

To place the line of areas, you will need nothing at all - from 40 sq.m to 200 sq.m. But a considerable warehouse may be required (after all, air will have to be stored in a certain sense - the products weigh little, and take up a lot of space). As such, you can use almost any room that provides protection for products from wind, moisture, dust, thieves, homeless people and other adverse factors. Granular polymers should be stored in a dry and, if possible, heated room: in this case, their surface absorbs less moisture, and the quality of any product will only benefit from this.

The “permissive” authorities include local executive authorities, a sanitary and epidemiological station, a fire inspectorate, local divisions of the State Supervision Service, thermal workers, “electricians”, a gas service, etc. The time and money spent on “permission” depend on the skill of the businessman. In favorable cases, 2-3 months and several thousand “killed raccoons” are enough.

Equipment
"Iron" can be found in different ways. In particular, some domestic enterprises have idle equipment, which, with proper dexterity, can be bought not too expensive and, using the services of specialists, modernized and put into working condition.

If you have money, it is better to buy something newer. There are many machine-building enterprises in the country that produce equipment for the creation of machines for polymer processing.

You can also buy imported equipment. One of the experts interviewed by BUSINESS expressed the opinion that, for example, the restored german equipment for the production of products from foamed polymers, in terms of quality, it approximately corresponds to the new equipment that can now be purchased in Ukraine. Of course, no one forbids buying new imported equipment, but ... Firstly, it can cost millions of dollars, and secondly, it is usually done under a very advance order.

Unfortunately, almost none of the Ukrainian manufacturers and suppliers of “iron” makes “ready-made” offers for the sale of equipment for the production of products from gas-filled plastics, most prefer to talk about each specific issue with a specific customer…

Regulations
Apparently, "underdevelopment" domestic production products made of gas-filled plastics causes an almost complete absence of the corresponding regulatory framework. According to the data available to BUSINESS, now only the standard for thermal insulation materials from gas-filled plastics used in construction - DSTU B V 2.7-8-94 "Polystyrene foam plates". Therefore, each manufacturer is brought to “start” the technical specifications for each manufactured product (group of products).

It is best to entrust the development and approval of technical specifications to the technologist who selected the equipment and will subsequently be engaged in the establishment of production. This procedure will “lighten” the wallet by about $ 1 thousand.

IN specifications for products that may come into contact with food products, and for some products used in construction, must be hygiene requirements. When the first batch of such products is released, the compliance of products with the stated requirements will be verified. This should be done by the sanitation department. Based on the results obtained, it can be argued that the equipment used is suitable for the production of, say, “food” products.

In order not to have problems on this ground throughout the year, a certificate of conformity for granular polymers and additives used in the production (ready mixes) is sufficient. sanitary standards. Then it will be necessary to conduct regular tests of products in terms of toxicity. Such a “pleasure” costs about 800 UAH.

Of course, the technical specifications reflect the requirements for manufactured products, as well as methods for testing them. Typically, quality indicators such as dimensions, mass, density of the product, in some cases, strength indicators, thermal and electrical conductivity, etc. are checked. Each batch of products is subjected to acceptance tests.

It is hardly expedient to create your own laboratory capable of checking all indicators: these are the costs of premises, equipment, the salary of a laboratory assistant, accreditation of the laboratory itself, and much more. Experts believe that it is better to enter into long-term contracts for the necessary tests with organizations that have laboratories accredited to conduct such tests. An example of such an organization is the Kievmiskbud Institute. Acceptance testing of product samples taken from one batch of foam insulation will cost about 400 UAH.

Staff
To service the line will require from 2 to 10 people. Workers, most likely, will have to be taught “from scratch” (for very modest money, an equipment supplier can train). But you can also hire them for relatively little money - in Kyiv it can be $ 60-70 per month (in the provinces - even less). But it is better not to skimp on the salary of a technologist, mindful of the large shortage of those. In any case, as they explained to BUSINESS at operating enterprises, even $300-400 for a good technologist is not the limit.

Raw materials
Primary polymers

With raw materials for the production of products from gas-filled plastics, the situation in Ukraine is not very good. Now the country produces:

polyethylene (concern "Oriana", Kalush, Ivano-Frankivsk region);

polypropylene (JSC LiNOS, Lisichansk, Luhansk region);

polystyrene (JSC Stirol Concern, Gorlovka, Donetsk region).

Many polymers are imported into the country from abroad (from Russia, Belarus, France, Germany, Poland, Hungary, Czech Republic). According to the interviewed experts, now it is most expedient to establish the production of all kinds of little things made of polyethylene, polypropylene and polystyrene. These polymers are almost harmless, chemically neutral, and their cost is low. The foams obtained from them have a wide scope. Finally, these polymers are produced by powerful and stable enterprises.

You need to be very careful when buying polymers. No matter how good the equipment is, its use, most likely, will not allow obtaining products of the same quality from polymers of the same name from different manufacturers. To carry out "transitions" from one raw material to another, a serious reconfiguration of equipment and development of technology using a new polymer are needed. The best option is to constantly buy granular polymer from the same manufacturer. And one more thing: if the shelf life of granulated polyethylene and polypropylene intended for foaming is almost unlimited (if they are stored under proper conditions), then the shelf life of granulated polystyrene for a similar purpose is only six months. For this reason, one should not be especially greedy for a cheaper polymer that accidentally turns up.

Prices for granulated polymers are unstable - jumps of 10-20% are common. On average, one of the most commonly used polymers for the production of foam plastics - granular polyethylene - costs at least $ 1 thousand per 1 ton. Granular polypropylene is about 20 percent cheaper.

Secondary polymers
If the product does not have particularly stringent requirements (for example, it should not withstand high loads), then a secondary (that is, already used) polymer can be introduced into the composition of the initial mixture along with the primary one, but the share of “recycled materials” should not exceed 20 %.

Recycled polymers should not be used in cases where the product will come into contact with food. Recycled polymers are usually 20-30% cheaper than primary ones, if you wish, you can make them yourself if you have a special crusher (it will cost $ 200-5000 depending on the origin, type and productivity). Behind the "hill" secondary polymers, for example, are widely used in the production of insulating materials.

Additives
In addition to polymers, fillers such as wood flour, silicon oxides, titanium, carbon black, and graphite are sometimes added to foamed mixtures. This allows you to reduce the cost of products and/or give them the desired properties. For example, to reduce the mass of sheets used as facing or insulating materials.

As already noted, the production of products from gas-filled polymers is not complete without the use of various modifying additives. Now in fashion is the use of ready-made mixtures, which are introduced into the original composition in an amount of 0.5-3% of the total volume of raw materials. “ Ready mixes” are exclusively of foreign origin, they are managed by Ukrainian distributors. The cost of 1 kg of any of these mixtures is close to $6. It is not necessary to look for mixtures of modifying additives for every polymer: polystyrene intended for foaming already contains all the necessary additives.

Technology
The most common gas-filled plastics include polyethylene foam, polypropylene foam, polyethylene terephthalate foam, polystyrene foam, polyurethane foam, polyvinyl chloride foam, and phenolic foam. Each of these materials has properties that define its areas of application.

The technology for producing gas-filled plastics consists in preparing a composition, introducing a gas phase into a polymer medium (most often by foaming), giving the foamed mass the necessary shape, and then fixing it.

Sometimes this same composition is poured into a mold, and then foamed. In the process of preparing the composition, the ingredients of the plastic mass or rubber mixture are combined (oligomers, polymers, hardeners, catalysts, plasticizers, dyes, stabilizers, fillers, blowing agents, etc.).

To introduce the gas phase into the polymer medium, various tricks are used: mechanical foaming, introduction of gas under pressure into the composition, saturation of the compositions with low-boiling liquids, which turn into steam when heated ...

One or another method of introducing the gas phase is used depending on which polymer is being processed and what they want to get from it. For the manufacture of gas-filled plastics, each of the listed methods usually uses “its own” equipment. But now there are machines more versatile, suitable for various processes.

By processing different polymers and using different techniques, it is possible to obtain gas-filled plastics with different properties. For example, flexible polyurethane foam (the most famous variety is foam rubber) is used in the production of upholstered furniture, clothes, soles for shoes, brushes, carpets, sponges, for packing breakable products, as a heat and soundproofing material. Rigid polyurethane foam can be used as a heat and electrical insulating, packaging material, for filling hollow structures in automobile, aircraft and shipbuilding, for protecting structures and equipment from vibration, moisture, mold, and corrosion.

Made of polyethylene having a density of about 920 kg/cu. m, you can get a gas-filled polymer with a density of 10-60 kg/cu.m. (highly foamed) to 400-500 kg/cu.m. or more (low-foamed). For other polymers, the entire “number” has the same order. From highly foamed materials it is possible to produce heat and sound insulating, as well as packaging materials(of course, if high strength is not needed). Low-foamed polyethylene and polypropylene are good materials for the manufacture of sheets, panels, pipes, insulating gaskets, etc. Products made of polypropylene (including foamed) have higher strength and thermal stability compared to products made of polyethylene.

Gas-filled plastics are divided into foam plastics (with closed pores) and foam plastics (with open communicating pores). Foam plastics are more common than foam plastics.

Depending on the elastic characteristics, gas-filled plastics (or foamed polymers) are conditionally divided into rigid, semi-rigid and elastic. You can get them from almost any polymer. Gas-filled plastics have a low apparent density (20-280 kg/m3) and high heat, sound, hydro and electrical insulation characteristics.

The scope of foamed polymers is endless. They can be used to make packaging, thermal insulation for building structures or refrigerators, filters for gases and liquids, rollers and cushions for furniture, protective pads for helmets and helmets, buoys, life buoys.

Vladimir Alexandrov.

Questions, error messages or typos in this article, please leave in

In the early 1970s, the global production of plastic products accounted for no more than 7% of the total production of polymer products, but now this figure exceeds 25%. There is a great demand for this species products, so you can earn not bad in this area.

The profitability of the production of plastic products can reach up to 30%. The level of profitability depends on the product that is produced. The size of the initial investment also plays a big role.

Premises, workshop for the production of plastic products, plastic

In order to accommodate the production of plastic products, you need a room with standard communications. There are usually no special requirements. The exception is those productions where the foaming process takes place using pentane. It is important not to forget that the premises for production must be selected away from the "sleeping" areas of large cities, it is best to be located on the outskirts of a settlement or in an industrial zone. It will take only 40 - 200 sq.m. to place the line of areas. But the warehouse may need to be very large (since you will have to store “air” - the products do not weigh much, but they take up quite a lot of space).

In this capacity, you can use almost any room that provides protection for products from moisture, wind, dust, homeless people, thieves and other adverse factors. It is necessary to store granulated polymers in a dry and, if possible, heated room: in this case, their surface will absorb less moisture, and the quality of any product will improve even more. Institutions from which it is necessary to obtain permission to organize the production of plastic products include a sanitary and epidemiological station, local executive authorities, local departments of the State Supervision of Labor Protection, fire inspection, thermal workers, gas service and electricians. The costs of material resources and time for obtaining permits will depend on the skill of the owner. In favorable cases, 2-3 months is enough.

Equipment for the production of plastic products, plastic

Techniques for the production of plastic products can be found varied. At some enterprises, there are idle equipment, which, with proper dexterity, can be purchased quite cheaply and, with the help of specialists, modernize it and bring it into working condition. If you have enough material resources, it is better to purchase new technology. In our country, there are a large number of machine-building organizations that produce equipment for the manufacture of machines for plastic processing. You can also purchase imported equipment.

Basic equipment:

vacuum forming equipment,
thread cutting machine plastic pipes,
thermoplastic casting machines,
plastic packaging production equipment

Everything will depend on what product will be produced.

Raw materials for plastic products

With raw materials for the production of plastic products is quite difficult. Whatever good equipment, its use will not allow to obtain products of the same quality from similar plastic from different manufacturers. To move from one raw material to another, a serious reconfiguration of equipment and development of technology using new plastic is necessary. Most the best option- constantly buy plastic from one manufacturer.

Up to 10 people will be needed to service the plastic products production line. Workers will probably have to be taught from scratch. You will also have to hire a technologist for a lot of money.

Technological process for the production of plastic products

The technology for producing plastic consists in organizing the composition, introducing the gas phase into a special polymer medium (usually due to foaming), giving this foamed mass desired shape with its fixation. Sometimes this composition can be poured into a mold, and then foamed. In the process of creating a composition, ingredients or plastic mass are combined.

To introduce the gas phase into the polymer medium, several methods can be used: introduction of gas under pressure into the composition, mechanical foaming, saturation of the compositions with low-boiling liquids that turn into steam when heated. The method of introducing the gas phase is used depending on which plastic will be processed and what they want to get from it. By recycling a variety of plastics and using a variety of techniques, it is possible to obtain gas-filled plastics that will have different properties.

Plastic products have higher thermal stability and strength compared to polyethylene products. Gas-filled plastics are divided into foam plastics (with open pores) and foam plastics (with closed pores). are a more common product than foam plastics.

Gradually, plastic is replacing more expensive and difficult to process natural materials. Plastic products are in great demand, but few people think about the technology of manufacturing familiar and convenient items.

Types of plastics and raw materials

In the production of polymer products, the following types of plastics are used:

polyvinyl chloride;
polyethylene;
polypropylene;
polyethylene of high, low pressure;
polystyrene;
polyethylene terephthalate.

One of the features of the production of plastic products is the selection of raw materials. Even the best equipment needs to be reconfigured when changing manufacturers source material. Otherwise, the quality of the finished product will change.

Production technology

Receiving any types of plastic products is carried out according to a single algorithm:

creation of a certain chemical composition;
gas is introduced into the polymer medium (in the manufacture of foam plastics and foam plastics);
giving the resulting mass the required configuration (casting);
fixing the final form.

At the first stage, various ingredients are mixed until a plastic substance is obtained. Next, the gas phase is introduced into the polymer using one of the methods: mechanical foaming, the introduction of fast-boiling substances that evaporate when heated, or the injection of gas directly under pressure. The production method depends on the type of product and the type of polymer.

There are several methods for the production of plastic products:

vacuum forming - from sheets of plastic under various pressures, the necessary forms are obtained;
compression molding - inside the mold, the workpiece is compressed, excess material is squeezed out through the slots;
compression molding - the amount of material required during production is poured into the mold, the halves of the mold come together and the product is squeezed out;
casting (casting) - the plastic mass is converted into liquid state and poured into molds corresponding to future products. Most of the items are produced in this way: dishes, stationery, etc.;
blowing - the heated mass is fed into the mold, which is clogged and filled with air. The polymer is distributed evenly over the inner surfaces of the mold;
extrusion - the mass is softened and forced through a matrix that creates the necessary shape;
thermoforming;
encapsulation;
layer molding.

Equipment for the production of plastic products

For the manufacture of products from various kinds plastics are used ready technological lines or individual machines.

Extruders

A large group of machines that produce: sleeve and sheet films, window profiles, pipes, polymer sheet, plastic slate, foamed profiles.

The flat-slot installation includes the following set of elements:

extruder with filtration system;
pneumoloaders;
blowing head with a cooler;
calibration mechanism;
pulling device and rotary horizontal rods;
flat laying module;
winder.

The main device of the machine is an extruder, all additional mechanisms make up the extrusion line. Production works in automatic mode, controlled by the program.

Injection molding machines

Plastic injection molding machines. The prepared mass is poured into molds and cooled, a finished piece product is obtained. 75% of all plastic products on the planet produced on such machines. Technology makes it possible to create products complex shapes, exactly corresponding required dimensions, reinforced, hollow, products made of several colors of plastic, hybrid, foam and others. The injection molding machine can work with any kind of plastics.

The design of the machine contains:

material preparation module;
module for closing and opening forms;
drive unit;
automatic control unit.

Plastic injection molding equipment is expensive and contains many innovative solutions. By design, injection molding machines are divided into:

two- and one-worm, worm-piston and piston;
with one or more plasticizing units;
with separate or combined plasticization;
according to the number of form closure nodes: single-position or multi-position;
electrical, hydromechanical, electromechanical.

blow molding machines

They are used for the production of hollow containers with thin walls, for example, cans, barrels, bottles with a capacity of up to 5 thousand liters. The blow molding machine heats the material and molds it by blowing. Often the blow molding method is combined with injection molding in a single injection blow molding machine. In this way, PET containers are produced.

Extrusion blow molding machines

Combine blow molding and extrusion technologies, so they can produce a wider range of products than blow molding machines: fuel tanks, bumpers, pallets, seats, buckets, barrels, toys, ketchup and milk bottles, bottles for cosmetics. All processes are controlled by a microprocessor. Machines are classified:

by type of heads;
by the number of posts;
by the number of streams.

The device of the machine includes:

an extruder in which the raw material is converted into a soft homogeneous mass;
the extrusion head is located at the exit of the extruder, the mass passes through it. The head can be multi- or single-strand, angular or straight-through. The mass passing through the extrusion head forms a sleeve or tubular billet;
the blowing part is the main unit of the machine, compressed air is supplied here (through a needle, nipple or mandrel), the mold is brought in and closed, the workpiece is cooled, the mold is opened and the product is removed. Here the weld is cleaned.

The extrusion blow molding machine is equipped with a compressor and a cooler.

Thermoforming machines

This equipment is for making products from film fed continuously. Film thickness and composition may vary. The main products are plastic and paper food disposable containers, glasses.

The principle of operation of the thermoforming machine: the material is heated to 140 degrees Celsius, the product is blown out of the roll. Typically, a film with a thickness of 100 micrometers is used in production.

Thermoforming machines can be tape, rotary, turret, multi- or single-station. In addition to molding, tape machine products are cut and sealed. Turret and rotary are more suitable for molding. The process is controlled automatically, manually or semi-automatically.

Optional equipment

In addition to the main mechanisms in the production of plastic products, devices are used that facilitate the process:

dryers;
loaders;
mixers;
crushers;
conveyors;
conveyors;
flash fees.

Mini plastic injection molding machines

This is a kind of desktop mini-machine for the production of small parts in small batches. Single or multiple forms are used. The weight of the mini-machine is about 15 kg, it can be easily placed on any strong table, which is why it is called desktop. Some mini models come with a desktop. More compact mini-models with electric drive and automatic clamping module. Such desktop mini-machines are used to make experimental parts for new equipment.