PRECIOUS PLASTIC Extruder Pro User manual

Machine Manual
Extruder Pro –Version 1.2
Feb 2022
Extruder Pro

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Contents
1.1 The Extruder Pro
1.2 Components
1.3 Specifications
2.0 Operation &
Maintenance
2.1 How the Extruder works
2.2 Operating the machine
2.3 Maintenance
3.0 Safety 3.1 - 3.10 Safety Instructions
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1.0 Introduction
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5.0 More 5.1 Online resources
5.2 Community power
5.3 Be part of it
5.4 Feedback & Support
5.5 Take it to the next level
6.0 Technical
Documents
6.1 List of recommended spares
6.2 Electrical control box
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4.0 Setup and
Decommisioning
4.1 Setup
4.2 Decommisioning
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The Extruder pro uses a screw to melt and pump plastic. It can be
used to make bricks, beams and profiles. It has an troughput of 10
–15 kg/hr depending on the type of plastic and the design of the
mold/die.
1.2 Components
1.1 The Extruder Pro
Barrel covers
Frame
1.0 Introduction
Motor
Reductor
Electronics
box
Hopper
Nozzle
Control
Panel VFD
Heating
control

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1.3 Specifications
Weight 110 kg
Dimensions (l x w x h) 1105x670x1460mm
Voltage 400 V, 3 phase
Total power consumption 4,8 kW
Motor Power 3,0 kW
Heating power 1,8 kW
Required amperage 16 A
Screw speed @ 50hz 227 rpm
Pressure
Rated up to 200 bar
Input Thermoplastics
Rate troughput 15 kg/hr
Screw diameter 30 mm
L/d screw 20:1
Maximum temperature 350ºC
Temperature regulation Yes
Heater type Band heater
Number of operators 1

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Note! Before operating the machine, make sure to read and
understand chapter 3.0 safety section in this manual!
The extruder pro uses heat combined with friction to melt plastic
granules or flakes at a high rate and pressure. The friction and
thereby heat is generated by means of a plasticizing screw. The
screw is able to pump the molten plastic (extrudate) at a high
pressure into moulds or dies to produce a large variety of products.
Do your research, read through different How-To’s and check out
the products on the Bazar before investing in mould that will fit
your needs best.
2.1 How the Extruder works
2.0 Operation & Maintenance
Image source: Overview of a plastic extrusion machine with the
plasticizing component... | Download Scientific Diagram
(researchgate.net)

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2.2 Operating the machine
Make sure to use properly designed molds and dies while operating
the extruder. Make sure to clean the sealing surfaces and thread of
the nozzle before installing the molds. Always use high
temperature ceramic or copper grease on the threads to prevent
seizing of the threaded connection. Make sure to fill the hopper
with plastic flakes or granules.
Startup
1. Plug in the Extruder in a 400V, 16A, 5 pole socket
2. check the emergency stop is released and switch on the
main power switch. (the heating PID controllers should
switch on)
3. Check the required temperatures to melt your type of plastic
and set the PID controllers to the desired temperatures.
4. Switch on the heating by operating the “heating on/off”
switch
5. Allow the temperatures to reach the set temperature. Wait
an additional 5 minutes after it reaches the temperatures to
make sure it’s fully heated evenly.
6. Switch on the VFD by operating the “VFD on/off” switch.
7. Set de desired motor speed using the turning knob on the
VFD control panel.
8. Switch the direction switch on the VFD on fwd.
9. Press “run” on the “VFD control” panel to start the motor

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2.2 Operating the machine
During operation
•Make sure to fill or dose the hopper with plastic during extrusion.
•Make sure not to leave the motor running without plastic to
prevent excessive wear.
•Adjust the throughput op plastic by adjusting the motor speed.
•If needed, stop the motor by pressing the red “stop” button on
the VFD control panel.
Shutdown
Before shutdown it’s good practice to flush the extruder with clean,
virgin polypropylene to remove any contaminants inside the barrel.
1. Allow the hopper to run empty and run the motor until the
flow of plastic stops.
2. Stop the motor by pressing the red “stop” button on the VFD
control panel.
3. Detach the mould or die.
4. With the motor stopped, switch off the “VFD on/off switch”
5. Switch off the heating using the “Heating on/off switch.
6. Allow the temperatures to cool down to a safe value (<
100°C)
7. Make sure to clean your workplace
8. Switch off the “main switch”.
The extruder is now clean, shut down and ready for the next
production

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Motor reductor maintenance
•Change the gearbox oil after the first run in period. This should
take place after 300 running hours or 3 months
•After the first oil change, check the following after 3000 running
hours or 6 months:
The oil quality
The oil level
Leakages of oil from the seals
•Replace the oil and bearing grease every 10000 running hours or
3 years
Note: recommended Oil volume in motor reductor = 0,75 l. Use
synthetic gearbox oil of any of these types:
•ISO VG220
•Shell Omala HD220
•Mobil SHC 630
Daily extruder maintenance (after use)
•Flush barrel after use with clean / virgin PP
Monthly extruder maintenance
•Check the function of the band heaters by switching them on for
about 30 seconds. The temperature of all heaters should
increase at an equal speed. Use (infrared) temperature gauges
to compare. Replace band heater if required.
•Check your emergency stop is still functional. If it is not, a
licensed electrician must install a replacement before further
use.
2.3 Maintenance

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Yearly
•Check the electronics box and inspect for signs of dust, liquids
or burn marks. Also ensure all wires are securely in place. If any
repair is required, seek a licenced electrician.
•Remove the barrel and inspect the extruder screw. Replace the
screw when required. Also check the condition of the inner
surfaces of the barrel. Replace barrel if wear looks excessive.
•Disassemble the bearing body and check the bearings for wear.
Replace the bearings and bearing shells if required. Regrease
the bearings with bearing grease after reassembly. Don’t overfill
the bearing body with grease to prevent the seals from popping
out of position. Check the shaft for smooth rotation after
reassembly and make sure no bearing play can be felt.
•Check tightness and condition of all screws and bolts.
Periodically
•Check website for hacks/updates. The community are
continuously developing hacks, modifications and techniques
which get shared on the internet, take a look to see what is
there that can help or inspire you!

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3.0 Safety
3.1 - General instructions
●The Extruder pro is designed to process thermoplastics
only. Processing other materials could introduce additional
hazards.
●It is recommended that the source and grade of the plastic
material is also known and does not contain any
contaminants (for example water or oil) that could introduce
additional risk.
●Batches of mixed plastics shall not be used with the
Extruder pro as they may possess different melting
temperatures - melting plastic at the incorrect temperature
may increase the risk of VOC emissions.
●Regular maintenance must be conducted at intervals
specified in 2.3 to ensure the system is working as intended.
●A monthly check of the electrical emergency stop shall be
conducted. Instructions on how to do this can be found in
section 2.3.
●If it is found that the emergency stop is no longer functional,
a licensed electrician must install a replacement before
continued use of the machine.

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●The following components have been designed or selected
for the safe operation of the machine. As such, they should
not be removed or replaced by components which are not
identical.
○Electronics box and its contents
○Extruder screw
○Covers
●The Extruder pro must not be modified in any way. Doing so
may introduce additional hazards.
●Always make sure to run the machine in a well ventilated
room (More info section 3.2)
●Always use the correct personal protection equipment as
indicated by the safety labels on the machine (More info
section 3.4)

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3.2 - Exhaust ventilation system
●During the plastic melting process, hazardous compounds
including volatile organic compounds (VOCs) are released.
●A ventilation system with an activated carbon filter or
other filter suitable for VOC filtration must be used in
conjunction with the Extruder pro at all times.
●It is recommended that an electrician wires the ventilation
unit such that it automatically initiates once the power to
the extruder pro is initiated.
●Consult the manufacturer guidelines of the filtration unit
for details about maintenance and filter replacement.
●A respirator suitable for VOCs should always be worn
when dealing with high volumes of plastic. Consult the
manufacturer guidelines for instructions on replacement
intervals of filters.
●It should be noted that melting thermoplastics above their
unique melting temperature is proven to emit a higher level
of VOCs and thus should be avoided. It is the user’s
responsibility to be informed on these melting
temperatures and avoid heating plastics above these
values.
●It should be noted that processing PS emits a higher level
of VOCs which are hazardous to health and additional
safety measures such as a VOC detector and additional
space filtration is recommended when processing this
materials
●Processing PVC can be highly hazardous and not advised
with this system.

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3.3 Movements of moulds
●Movements of moulds, particularly when releasing products
from hot moulds from the extruder, must be done with the
motor switched off and using proper heat resistant gloves or
suitable lifting tools.
●Direct contact and handling of the moulds when hot is not
advised.
●Don’t touch the molds or dies when the extruder is running.
●Never stand in front of the extruder nozzle with the extruder
running!
3.4 Personal protective equipment
●Heat proof gloves such as MIG welding gloves should be
used at all times while using the Extruder pro. These gloves
should extend to provide protection to the forearms as well.
●A work suit or coverall that covers arms and legs must be
worn while using the Extruder Pro
●Safety glasses or a face shield must be worn at all times in
the vicinity of the Extruder pro to protect from spontaneous
ejection of hot substances from the mould area or the
unlikely failure of moving parts.
Have a look at the chapter about safety in the Academy
to read more about fumes and safety gear.
community.preciousplastic.com/academy/plastic/safety

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3.6 Moulds
●Only use molds which are specifically designed for the
extruder pro and are capable of handling high pressures.
3.7 Ancillary equipment
●The Extruder pro is not designed to be used in conjunction
with any other equipment than what is provided.
●Ancillary equipment shall not be mounted to the existing
frame.
●Any additional equipment used may introduce additional
risk which is not the responsibility of Precious Plastic.
3.8 Work-space hazards
●Make sure the extruder pro is standing level on a strong
surface during operation. Always make sure to have 80 cm
or room all around the machine during operation.
●It is recommended that an additional risk assessment
specific to your space is completed to identify and control
risks posed by the Extruder pro in your specific context.
Note that tripping and slipping hazards can have more
severe consequences when dealing with hot equipment.

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3.9 Information for emergency situations
●The Extruder pro can reach temperatures of up to 350ºC
and so as such, poses a serious risk of fire if there are no
steps taken to reduce this risk.
●It is recommended that an individual risk assessment is
undertaken for each specific workspace. As part of this
assessment, a fire extinguisher shall be located near the
machine.
●It is recommended that all operators shall regularly
undergo an induction on the emergency procedure
associated with their specific space.
●It is advised that only PP and HDPE are used without
further installation of extraction to the space. If, however,
a hazardous plastic is accidentally used with the machine,
an evacuation procedure shall be initiated. This consists of
disconnecting power to the machine and all persons within
the space being removed until the fumes have cleared.

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3.10 Safety Labels
Safety stickers on the Extruder frame
1. Hand Crush: Indicates an area of hazard due to crushing
2. Burn Hazard: Indicates a hazardous hot surface
3. Lifting Point: Indicates lifting points for handling
4. Wear Eye Protection: Indicates that eye protection is
required when using this particular machine
5. Wear Respirator: Indicated that a respirator is required
when using this particular machine
Safety stickers on electronics control box
6. Emergency stop: Signifies the emergency stop button for
cutting power to machine in case of emergency
7. Electrocution: Indicates hazards due to live parts
8. Do not switch: Do not disconnect during operation
9. Read manual: Read manual before using equipment
10. Electrical equipment: Authorised personnel only
11. Disconnect power: Disconnect power for service
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4.0 Setup and Decommisioning
●Complete assembly of the machine is out the scope of this
manual.
●The Extruder Pro machine frame van be fitted with either
adjustable machine feet or castor wheels to level the
machine and optionally make it mobile. The feet of the
machine frame is designed wit a slot suitable for M8 Thread
to fit these parts.
●Make sure to leave at least 0,5m of space all around the
machine for safety purposes.
●Molds and dies can be mounted to the extruder nozzle using
a nozzle profile as shown below. Always use high
temperature ceramic grease on the threads to prevent
seizing of the threads. The face also indicated with the
“keep sharp” header seals the insert to the extruder nozzle.
4.1 Setup

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●The Extruder Pro 3kW version requires a power input of
380-400 Vac with a 16A supply. The machine comes with a
5P male plug.
●Only run the machine in well ventilated rooms, use suction
devices with filtration to remove fumes while extruding.
●Make sure to remove the rubber seal on the deairation plug
on the motor gearbox. This allows the gearbox to “breath”
while running
●Be aware of smoke and fumes from the barrel during first
heat up because of oil and grease residue from
manufacturing.
4.1 Decommisioning
●Make sure the machine is cooled down
●Switch of the main switch and disconnect the extruder from
the power supply
●Clean the machine from any residual plastics or other debris
●Dismantle the product in accordance with all the precautions
imposed by the laws in force in the country of use. If
required before demolishing request an inspection by the
relevant authorities and relative report
●Proceed with disassembly of the individual
components/parts and group them together
●according to the materials they are made of: (steel, stainless
steel, aluminum, electrical parts, electronic parts).
●Clean all the disassembled parts.
●Dispose off / scrap the separated, segregated individual
parts /materials in compliance with the laws in force in the
country of use.

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Getting started can be overwhelming. Plastic recycling is a big
topic and there is a lot to learn. We do our best to create online
tools to help you find more information, resources and people to
connect with:
Website
Our website explains everything around the project, from the
history and mission, to machines, the community around it and
which options are there to start recycling.
www.preciousplastic.com
Academy
The Academy is where you'll find video tutorials, tips, drawings and
much more on topics like plastic, machines, product design,
business and so on.
community.preciousplastic.com/academy
Map
There is a custom map to connect the Precious Plastic Universe.
Find recycling spaces near you to push local plastic recycling in
your area.
community.preciousplastic.com/map
5.1 Online resources
5.0 More