What is Extrusion?
Extrusion is a precision manufacturing process used to create object with a fixed cross-sectional profile. Material is pushed or drawn through a die to form complex shapes, making this method ideal for applications requiring tight tolerances and excellent surface finishes. It is commonly used with metals, polymers, ceramics, and even food products, offering both versatility and high throughput.
Applications range from the production of pipes, tubes, window frames, and wires to components in aerospace, automotive, and construction industries. Extrusion is also widely used in medical tubing, foodstuffs, and consumer products where consistency, strength, and material integrity are essential.
Process Cooling in Extrusion
Cooling plays a critical role in extrusion, ensuring materials are properly solidified and machinery operates at optimal temperatures. Without controlled cooling, finished parts can warp, degrade, or fail to meet quality standards.
Process cooling supports:
Recirculating Chillers
Recirculating chillers are widely used in extrusion processes to deliver precise and consistent cooling. These systems circulate a temperature-controlled fluid through a closed-loop, helping to regulate the temperature of extrusion machinery and materials throughput production. By maintaining thermal stability, they play a critical role in protecting both the equipment and the quality of the extruded product.
One of the main advantages of recirculating chillers is their ability to deliver highly accurate temperature control, which is essential when working with sensitive materials. They also help to reduce thermal stress on components, support continuous operation, and often feature compact, energy-efficient designs – making them suitable for both large-scale and space-limited manufacturing environments.
Airblast Coolers
Airblast coolers remove heat from the extrusion process using ambient air as the cooling medium. These systems are particularly well-suited to applications where water use is restricted or minimising environmental impact is a priority. By avoiding the need for refrigerants, airblast coolers offer a simpler and more sustainable alternative for many extrusion setups.
They are cost-effective, energy-efficient, and require minimal maintenance, which makes them easy to install and operate. However, their performance is more dependant on ambient conditions, which can impact efficiency in hotter climates. In addition, their larger size and potential for increased noise levels should be considered when integrating them into a facility.
Water-to-Water Heat Exchangers
Water-to-water heat exchangers offer high-efficiency temperature control by transferring heat between two independent water circuits. This separation is especially beneficial in extrusion applications that require clean, closed-loop cooling, such as in food, medical, or high-precision manufacturing.
These systems are known for their excellent thermal efficiency and ability to reduce the risk of contamination between process and utility fluids. They are also highly flexible, adapting well to a wide range of materials and extrusion types. As part of a broader cooling strategy, water-to-water heat exchangers can help to maintain consistent product quality while contributing to operational efficiency.
Heat Transfer Fluids in Extrusion
The choice of heat transfer fluid directly affects thermal efficiency, system reliability, and safety across the extrusion process. Selecting the right fluid ensures optimal heat exchange, protects equipment from corrosion or degradation, and supports long-term operational stability.
When choosing a fluid, it’s important to consider thermal conductivity, stability under operating conditions, environmental impact, and compatibility with system materials such as seals, pipes, and heat exchangers. The right fluid not only boosts performance but also supports sustainability and maintenance efficiency.
Common options include:
Ideal for general-purpose cooling and freeze protection
Suitable for high-temperature applications
Designed for extreme temperature ranges or chemically sensitive environments.
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