Neoplast

Thermoplastic Vulcanizates

Extrusion Guide
for Neoplast TPV
Contents

page

Introduction...........................1
Extruder...........................1
Screw...........................1
Barrel...........................1
Screen Pack & Breaker Plate...........................1
Venting...........................1

Extruder Dies...........................2
Profile Dies...........................2
Tube Dies...........................2
Sheet Dies...........................2
Die Land...........................2

Processing...........................2
Purging...........................2
Pre-drying...........................2
Temperature Profile...........................2
Screw Speed...........................3
Die Swell...........................3
Co-extrusion...........................3
Take-off ...........................3
Use of regrind...........................3
Colouring of Neoplast...........................3

Storage & Handling...........................3

Trouble Shooting...........................4

Introduction
Neoplast Thermoplastic Elastomer is a
dynamically vulcanised EPDM/PP alloy supplied
in the pelletised form. Neoplast replaces
conventional vulcanised rubbers as well as
flexible thermoplastics for a broad range of
automotive and non-automotive applications.
Neoplast exhibits unique features i.e. it provide
the feel & performance of a rubber yet
processing ease and economics of
thermoplastics.

Extruder
Neoplast can be processed on conventional
standard polyolefin extruder without any
modification. For extrusion of Neoplast, we
recommend single stage, three zone
polyolefin type metering screw with L/D
ratio of min 24:1 & compression ratio in the
range of 2.5 : 1 to 4 : 1 . Extruder with PID
temperature controller is preferred for
better control over flow/temperature.

To obtain high out put with adequate shear &

optimum melt homogeneity, we recommend
screw with L/D ratio of 30 : 1 ( Min 24 : 1).
Compression ratio should be 3:1. For softer
grades of Neoplast ( 145 M/E, 155 M/E) screw
with higher compression ratio is recommended.
The screw should be neither heated nor cooled.

Barrel
We recommend flame hardened 4140 steel
chrome plated screw with bi-metallic barrel
(Xaloy 306, Wesco 555 or equivalent is preferred)
this will allow processing other thermoplastic
also. We suggest grooved barrels since they
create a zone of compression and high shear at
the entrance in the extruder this will result in
decrement in viscosity and facilitate the
transportation of granules to the transition zone.

Screen Packs & Breaker Plate

We recommend single stage, three zone

polyolefin type metering screw. The best
screw for processing Neoplast consists of :

We recommend use of screen packs & breaker

plate while extruding Neoplast thermoplastic
elastomer as they create back pressure resulting
in homogeneous mix & flow of material, assist to
disperse colour concentrate, prevent damage of
die/extruded part as they work like sieve. Screen
pack should be placed at the exit of the screw
just prior to die adopter. Screen should be made
of stainless steel with 60/80/100 mesh screen.
You must have one coarse screen ( i.e. 20 mesh)
in order to support with your finer screen.

Feed zone. relatively short ( 25 % of total

screw length). Screw with deep feed
channel is preferred for consistent pumping
of Neoplast granules.

We recommend breaker plate made from

hardened steel/alloys with min CLTE material.
Breaker plate with thickness 9 to 18 mm with
holes of 1.5 to 2.5 mm diameter is preferred

Transition zone. about 25 % of total

screw length to ensure uniform melt.

Venting

Metering zone. about 50% of total screw

length to provide better shear mixing. Avoid
any decompression zone as this can results
in irregular output.

We recommend ventilation at the exit of the die.

This will help to escape air in barrel. A fume hood
located directly above the die will provide the
most effective ventilation.

Screw

Neoplast Extrusion Guide

Extrusion Dies

Processing

NeoplastThemoplastic elastomer material can

be used to produce any type of profile, shape,
tubing, sheet etc. Most common applications
are tube, sheet, profiles etc. These are several
basic types of extrusion dies. Profile & tubing
dies are designed oversized since Neoplast
having a low die swell characteristic.

Purging

Profile Dies
Generally profile dies are flat plate or
streamlined melt design. Due to the excellent
melt stability of Neoplast you can use flat plate
design for many application. Flat plate designs
are also less expensive than streamlined dies.
Streamlined dies are preferred for high volume
production.

Tube Dies
Using regular polyolefin die assembly you can
produce tubing from Neoplast. Die size should
be 3 to 5 % larger than the final size. Die land
from 10 to 20 mm are to be used. For tubes
having OD below than 5 mm use die land almost
two times of the OD.

Sheet Dies
Using standard polyolefin sheet die you can
produce sheet from Neoplast.
Make sure that heat distribution should be
uniform throughout the die.

To avoid contamination , the equipment should

be cleaned before processing Neoplast. Use of
high viscosity polyolefins will speed up the
purging process. Low MFI PP is suitable for
purging. Purge at a temperature of 200 C.
Before processing of Neoplast material cleaning
operation is most important if the equipment
has been used previously for PVC or Acetal.

Pre - drying
Neoplast, Thermoplastic Elastomer is slightly
hygroscopic. Effective moisture control ensure
high quality parts with an appealing surface
appearance. Moisture can cause poor melt
quality as well as voids, porosity, rough surface
and uneven appearance or silver streaking.
Neoplast is packed in 25 kgs. ( 55 lbs) bags with
a built-in moisture barrier. Neoplast requires
pre-drying for about 2 hours @ 85-90 C. In case
of extreme high humidity condition drying in
dehumidified air dryer is recommended for 4
hrs. @ 90 C.

Processing Temperatures
A typical melt temperature profile for Neoplast
is between 180 - 200 C. Balanced melt
temperature will give good aesthetics to the
product. We recommend following temperature
profile for extrusion of Neoplast.

Die Land
Die land length are different for profiles, tubes
& sheets applications. Generally for profile die
land should be in the range of 2 to 5 times of
the wall thickness and for tubes die lands of 10
to 20 mm are typically used. For less than 5 mm
OD tube, die land should be two times of OD.

Neoplast Extrusion Guide

Screw Speed

Use of Regrind

Screw speed helps to control the shear rate.

Minimum screw speed is 20 rpm, which be can
increased up to 200 rpm. Care should be taken
while increasing screw speed more than 150
rpm, since this can generate excessive melt
temperature.

Neoplast Thermoplastic elastomer has an

excellent melt stability. All scrap generated
during processing can be recycled. You can
regrind & reprocess clean runners & sprue or
rejected products with virtually no loss of
material properties. Neoplast can be reprocessed
up to five times with no significant change in
properties. You can use 100 % regrind material
for first time, but we recommend 20-30 %
regrind with virgin material since the viscosity of
Neoplast slightly decreases after reprocessing. It
is recommended to blend a constant level of
regrind with the virgin material during
production. Always dry all regrind material
before processing & make sure that regrind takes
a little longer drying than virgin material.

Die Swell
Most of TPE gives less die swell compared to
conventional thermoset rubbers. Neoplast gives
die swell value from 3 to 5 %. Due to the low die
swell characteristic of Neoplast tubing & profile
die should be 3 to 5 % oversize than required
shape. You can adjust dimension by using draw
down technique. You must confirm die swell
before finalising design of die using prototype
flat plate die.

Co-extrusion
Neoplast can be co extruded.double, triple or
multiple extrusion are possible using Neoplast.
Neoplast can be co-extruded on itself, or any
other hard/soft compatible material. You can
produce large varieties using different colour
combination of Neoplast material. In coextrusion, both materials are joined under
pressure within the die to achieve permanent
melt bond. The die land should be minimum of
10.0 mm long for better adhesion.
Neoplast is easily bondable with Polyolefins &
TPEs. For non compatible plastics you can use
adhesive to achieve good bonding.

Take-off
Generally belt puller is most popular take off
technique for tube & profiles. A precision belt
puller is preferred to control draw drawn of
Neoplast profiles. Long belt min. 50 cm long is
advisable for small precision profile. We
recommend closed face sponge rubber belt to
achieve good grip.
Neoplast Extrusion Guide

Colouring of Neoplast
NeoplastThermoplastic elastomer can be
coloured to your choice. Natural colour Neoplast
can be coloured by addition of a suitable colour
masterbatches or solid or liquid colour
concentrate. Polypropylene based masterbatches
are best compatible. LDPE based master batch
are also suitable. Addition of Master batch may
lead to slight increase in hardness. We
recommend 1 to 5 % loading of master batches
by weight.

Storage & Handling

Neoplast is supplied in pelletised forms packed in
25 kgs.(55 lbs) with an in built moisture barrier.
The storage condition of Neoplast is important
since Neoplast granules will pick up moisture
from atmosphere to a slight degree.
Neoplast bags should be stored in sealed
undamaged condition, in a cool & non humid
environment. Bags should be opened just before
use. If entire contents from the bag are not
consumed , the bags should be closed securely
and stored in a cool & dry place.
3

Trouble Shooting
Problem : Improper wall thickness distribution
Remedy :
1. Adjust gap in the die assembly properly.
2. Adjust speed of take off equipment
3. Adjust RPM of machine
4. Check heaters of die
Problem : Inside rough surface
Remedy :
1. Adjust temperature of barrel so as to melt polymer completely.
2. Pre-dry the material thoroughly
3. Check die mandrel
4. Increase temp. of die assembly.
Problem : Out side rough surface
Remedy :
1. Increase temp. of barrel
2. Use proper sizing sleeve
3. Pre-dry the material thoroughly
4. Check die assembly
5. Check breaker plate & screen packs
Problem : Lack of gloss on surface
Remedy :
1. Increase temp. of barrel & die
2. Check surface of die core & die ring for smoothness.
3. Check sizing sleeve for smooth surface.
Problem : Porosity
Remedy :
1. Pre-dry the material for longer time
2. Use vented barrels
3. Adjust temperature of barrel

Neoplast Extrusion Guide

ZYLOG PLASTALLOYS PVT. LTD.

Sovereign Annexe, Lane # 4,
Kalyaninagar, Pune 411006, Maharashtra, INDIA.
Tel: +91 20 2665 0219 Fax: +91 20 2665 0220

These are typical property values, derived from representative samples & is intended to provide only general idea on our products and it possible uses, without any obligation. User should
therefore not construe this information as guaranteeing any specific properties for end use desired, without prior testing & evaluation. Values may differ elsewhere. The information in this
document relates only to the enclosed materials and not in combination with any other product or materials. We consider the information to be reliable on the date compiled, but we do not
represent, warrant, or otherwise guarantee, expressly or impliedly, the suitability of this product for a specific purpose, unless specified. The user is solely responsible for all determinations
regarding any use of material or product and any process in its areas of interest. Zylog expressly disclaims liability for any loss, damage, or injury directly or indirectly suffered or incurred as
a result of or related to anyone using or relying on any of the information in this document.

Format F/D&D/11, R0., Revised on 19/08/2011