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A silicone extruder machine is designed for making various types of products from silicone rubber by the extrusion process. Different types of silicone material can be extruded with these machines, including clarity silicone and colored silicone. Clarity silicone is a strong and transparent thermoplastic that can be thinly extruded into a flexible film. Factory or industrial-grade clarity silicone can be used as a food release agent when baked or cooked at high temperatures, around 450 degrees, and it will not affect food or cooking elements. Colored silicone can come in any matte or bright color and is used in products where color is an essential aspect of the final product. It can also be used for its ability to withstand extreme temperatures, aging, UV rays, and moisture. Specific types of colored silicone are used in electrical insulation and high-energy applications, such as making gaskets, seals, tubing, and other custom parts.
Some commonly made products using a silicone extruding machine include:
Kitchenware:
Custom silicone molds are made with non-stick silicone material used for baking, cooking, and freezing. Other products include baking mats, piping bags, and spatulas.
Medical Supplies:
High-temp silicone medical extrusion makes various medical and healthcare products, like catheters, drainage tubing, stents, seals, and gaskets.
Automotive Components:
Silicone rubber extrusion creates custom automotive parts like silicone hoses, seals, and gaskets that withstand high temperatures, pressures, and harsh automotive fluids.
Packaging Materials:
Flexible silicone extrusion produces custom straps, fenders, and pouches that can be used for packaging, carrying, and protecting fragile or easily broken items.
Electronics Manufacturing:
Liquid Silicone Rubber (LSR) injection molding extrudes processes options that are used in electronics so that components can remain operational in humid and wet conditions. Some other examples include custom silicone keypads and switches.
LED Light Fittings:
Optical silicone extrusion is commonly used to make LED light bulbs. The silicone lens will not yellow from aging like plastic will, and it can be made clear like glass.
Silicone extrusion machines usually have some key specifications that determine their performance and capabilities.
Production capacity
This is the amount of silicone product the machine can make in a given period, usually measured in kilograms per hour (kg/h) or pounds per hour (lb/h). The capacity can vary depending on the model and design of the machine. For example, a large silicone rubber extruder like the SJ-60 can produce around 150-200 kg/h.
Power
This refers to the amount of energy the machine uses to operate, usually measured in kilowatts (kW) or horsepower (HP). The power determines the motor's torque for driving the screw and pump. An example of power is 18.5kW for some models. Stronger power generally means higher capacity and better handling of materials.
Barrel diameter
The barrel diameter affects the volume of material that the extruder can hold and process at one time. It is usually measured in millimeters (mm) or inches. For instance, the barrel diameter for certain models of silicone extruders can be 60-120 mm. A larger barrel size enables higher capacity and greater flexibility to work with different materials.
Screw design
Silicone rubber extruding machines have special screws that are meant for specific applications. The screw design includes its length, shape, and modification features. Some extruders may have double screws or entailed screws for better mixing and distributing of materials like silica. For example, some screws may be longer than 3,000 mm.
Temperature control
The performance and quality of silicone products depend on precise temperature control while processing. Therefore, silicone extruder machines are equipped with units that monitor and modify the temperature of the barrel and die. This can ensure effective curing and dispersion of silica within the material. Temperature control systems can be electronic or digital and may have multiple zones.
For the optimal performance and longevity of silicone extrusion machines, it is very important to exercise regular maintenance procedures discussed below.
Clean regularly
Users should make an effort to wipe the machine clean after each use. This will help to remove any leftover glue or material. Periodically, they need to wash the entire equipment thoroughly to avoid any material buildup inside, which may block or damage the extruder.
Lubricate moving parts
Apply proper lubricating oil to the movable components of the silicone rubber extruder on a routine basis. This includes chains, gears, and bearings. Lubrication greatly reduces the wear and tear of extruders and prolongs their service life.
Check and adjust
Perform regular inspections and adjustments of crucial parts like pressure gauges, temperature controllers, and valves. Examine them to ensure that they are working properly and have no issues. Make needed adjustments and repairs so that the silicone rubber extruder continues to have stable and reliable operating conditions.
There are many application scenarios of silicone extrusion machines in different industries.
Construction Industry:
In the construction industry, silicone extruders are often used to form silicone gaskets and seals used in waterproofing, glazing, curtain wall, and window sealing initiatives. The ability of the extruded material to maintain flexibility whilst forming a seal is worth noting.
Automotive Industry:
Silicone materials extruded in the automotive industry can be made into gaskets, seals, and hoses. Importantly, these components are capable of withstanding extreme temperatures and are highly resilient, making silicone the most preferred material.
Electronics Industry:
Silicone materials used in the electronics industry are often used to make keypads, switch mats, and insulating components. This is because silicone is reliable in ensuring electrical insulation and is able to resist high temperatures.
Medical and Healthcare:
Medical-grade silicone extruders are applicable in creating catheters, tubing, seals, and gaskets for medical devices. The reason is that silicone is a biocompatible material, making it suitable for use in healthcare products.
Consumer Goods:
Silicone consumer goods are much more popular due to their durability and heat resistance. Items ranging from kitchenware to baby products and personal care to outdoor gear are popular applications where the product extruded directly is silicone.
Consider the following tips when choosing a silicone extrusion machine:
Determine Product Demand
First, ascertain the level of demand the business is experiencing. Currently, what the market needs in terms of product will go a long way toward influencing the type of silicone extrusion equipment necessary to fulfill economic and demand requirements.
Assess the Materials Used in the Machine
The caliber of silicone used to make the machine is crucial. Select equipment with high-quality raw materials, particularly the feeding plate and blade, since they interact with the material to ensure even feeding and effective mixing.
Choose an Extruder with Flexible Speed Control
Select an elastic speed regulation device to change the feeding speed based on various requirements since silicone material has a good viscosity.
Ease of Maintenance
It's equally crucial to provide after-sales services and equipment maintenance simplicity. A device's maintenance needs are a factor in productivity. It will benefit the business to select devices that are easy to maintain since it will save time and increase production.
Assess the Machines' Compatibility
The production line's components must be compatible with those of other devices. Therefore, check to see if the silicone machine chosen works together with the other production line components to guarantee seamless integration. This ultimately helps rise efficiency.
Negotiate the Warranty
Since machines are a significant investment, negotiate the warranty terms when determining the silicone extrusion machine supplier. A long warranty period demonstrates confidence in the product's quality. Consider the terms and make sure they cover essential parts.
Check the Energy Rating
The energy use of the equipment has a direct impact on production expenses. When selecting a silicone extrusion machine, look at the energy rating. Despite having a greater initial cost, choosing one with lower energy consumption might result in long-term cost savings.
Q1 Are all silicone extruders compatible with standard-sized silicone baking mats?
No, most silicone baking mats are designed to work with silicone cooking extruders. Be sure to check the measurements and specifications before purchasing an extruder to ensure that it will be compatible with the baking mat that is being used.
Q2 Are handheld silicone extruders worth it?
For home bakers, a handheld or manual silicone extruder is an affordable option that is certainly worth it. It will allow the user to create even and consistent silicone strips without spending a fortune on a more industrialized model. In fact, many home bakers choose a handheld model simply because it is more practical, easier to operate, and more affordable than a large industrial silicone extruder. However, for commercial settings, a handheld model may not be suitable as it cannot be used to mass-produce silicone strips.
Q3 Are there any alternatives to silicone extruders?
Yes, there are several alternatives to silicone extruders that can be used to create silicone products. For example, a pipette or syringe can be used to layer silicone into molds. Some people prefer to use a vacuum pump and custom-made molds to produce silicone parts. Another option that some manufacturers prefer is CNC machining. However, none of these methods are ideal for product mass production like the silicone extruder can be.
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