Author: Southern Heat

Maximizing Efficiency: Cooling Maintenance Tips for Plastic Extrusion Systems

Posted on by Southern Heat
Authored by: Isabel McCord

Maximizing Efficiency: Cooling Maintenance Tips for Plastic Extrusion Systems

Efficient cooling is essential to keeping your plastic extrusion line running smoothly. It ensures consistent product quality, prevents downtime, and reduces energy use. Core components like portable chillers, temperature control units (TCUs), and cooling towers manage the heat load—but only if they’re well-maintained. Routine maintenance and timely upgrades can dramatically improve system performance and lower operating costs.

Portable Chillers: Keep Your Cooling on Point

Portable chillers deliver targeted cooling to individual machines, helping maintain stable process temperatures. Well-maintained chillers support quality and prevent costly interruptions.

Maintenance Tips:

  • Check coolant levels regularly to avoid overheating.
  • Clean condenser coils to maintain heat exchange efficiency.
  • Monitor refrigerant levels to ensure reliable performance.
  • Inspect pumps for steady coolant circulation.

Why Upgrading Matters:
Older chillers often consume more energy and deliver less reliable cooling. Upgrading to energy-efficient models improves heat transfer, reduces strain on your machines, and lowers utility costs.

Temperature Control Units (TCUs): Fine-Tune the Heat

TCUs regulate heat in molds, barrels, and dies—making or breaking product consistency. A poorly performing TCU can increase scrap rates and energy waste.

Maintenance Tips:

  • Flush the system periodically to prevent mineral buildup.
  • Calibrate thermostats and sensors for accurate control.
  • Inspect pumps and hoses for leaks or damage.
  • Ensure proper insulation to minimize heat loss.

Why Upgrading Matters:
Modern TCUs feature digital controls for precision adjustments. Upgrading reduces temperature swings, boosts consistency, and cuts down on wasted energy.

Cooling Towers: Maximize Heat Rejection

Cooling towers remove excess heat from the system, keeping extrusion operations stable and efficient. Their performance heavily depends on regular upkeep.

Maintenance Tips:

  • Clean fill media and nozzles to ensure even water distribution.
  • Monitor water treatment to avoid scale, corrosion, or biological growth.
  • Inspect fans and motors for smooth operation.
  • Maintain proper water levels and flow rates for optimal performance.

Why Upgrading Matters:
Aging towers often underperform. Newer designs offer better materials, energy efficiency, and cooling capacity—leading to longer equipment life and lower maintenance costs.

Cooling Maintenance Checklist

Use this quick-reference guide to stay ahead of common cooling issues:

  1. Inspect Water Quality
    • Use filtered/treated water to prevent scale and corrosion.
    • Watch for algae, rust, or mineral deposits.
    • Test pH and conductivity monthly.
  2. Clean Cooling Channels
    • Flush lines routinely to remove buildup.
    • Use descaling agents if needed.
    • Try ultrasonic cleaning for tough-to-reach spots.
  3. Monitor Flow Rates
    • Install flow meters for accurate tracking.
    • Check hoses and pipes for blockages or slow flow.
    • Log flow trends to catch issues early.
  4. Inspect Chillers and Cooling Towers
    • Clean filters, coils, and fans.
    • Check refrigerant levels and leaks.
    • Lubricate fans and pumps regularly.
  5. Test Temperature Control Units (TCUs)
    • Compare inlet/outlet temperatures to expected values.
    • Calibrate controls and inspect heating elements.
    • Test alarms and safety features.
  6. Check for Leaks
    • Examine hoses, manifolds, and fittings for damage.
    • Replace worn parts immediately to maintain pressure and flow.
  7. Document and Schedule Everything
    • Keep detailed logs for each system component.
    • Create a schedule for daily, weekly, and monthly checks.

Expert Tips for Better Cooling System Health

  • Standardize hose sizes/fittings to simplify replacements.
  • Use color-coded or labeled lines to reduce errors.
  • If using air cooling, inspect blowers and air knives for dust or obstruction.
  • During shutdowns, drain and dry lines to prevent bacteria or corrosion.
  • Train operators to spot early warning signs like temperature spikes or slow cooling.

Why It Matters

Cooling system maintenance isn’t just about protecting your product—it directly impacts energy consumption, mold/tool longevity, and production speed. Neglected systems can lead to scrap, breakdowns, and costly downtime.

Think of maintenance as a small investment with big returns: lower scrap rates, fewer breakdowns, and longer machine life.

Wrap-Up: Partner with Southern Heat

Whether you run a high-speed extrusion line or a precision molding operation, proactive cooling system maintenance is key to staying competitive. Use this checklist as your go-to guide—and stick to it.

Southern Heat specializes in helping manufacturers modernize outdated cooling equipment with energy-efficient, high-performance solutions tailored to your operations.

Extend the Life of Your Band Heater: Pro Tips

Posted on by Southern Heat
Authored By: Isabel McCord

Heat Smarter, Not Harder: Tips for Extending the Life of Your Band Heater

Band heaters are essential to plastic extrusion and molding, working hard behind the scenes to keep things running smoothly. While they’re built to withstand intense heat, they’re not indestructible. A little care goes a long way in extending their lifespan, improving system efficiency, and avoiding costly downtime.

Here are some simple, effective tips to help your band heaters go the distance:

  1. Moisture Is the Enemy

Band heaters and moisture go together like oil and water—literally.
If a heater sits in a humid environment for too long, it can absorb enough moisture to blow out the moment it’s powered on. And we’re not just talking puddles—damp lead wires or insulation can also trap moisture.

💡 Pro Tip: If your heater’s been exposed to moisture, preheat it at a low temperature to safely dry it out before applying full power.

  1. Keep Oil Where It Belongs (Hint: Not on Your Heater)

Oils and other organic materials might seem harmless, but at high temperatures, they can carbonize and become conductive. That’s a major hazard for your heater.

Even if oil only touches the lead wires, it can be drawn inside the heater and cause failure.
Bottom line: Keep your heater clean, dry, and far from spills.

  1. Avoid Overheating—Your Heater Will Thank You

Band heaters thrive on balance. Run them too hot, and you’ll burn through their lifespan.

Here’s how to keep them in the sweet spot:

  • ✅ Ensure a snug fit. Gaps between the heater and barrel reduce efficiency and force the heater to overwork. Retighten the clamping strap after the initial heat-up for a better fit.
  • ⚡ Choose the right wattage. Bigger isn’t always better. Excessive wattage causes more frequent cycling and unnecessary heat—both of which wear out your heater.

🛠️ Quick Fix: Retighten the heater after its first use to improve heat transfer and longevity.

  1. Minimize the On-Off Marathon

Frequent cycling wears out your heater fast. Every time it powers on and off, the element wire oxidizes. Over time, this leads to thinning, cracking, and eventual failure.

Reduce unnecessary cycling by:

  • Using a well-calibrated temperature controller
  • Avoiding oversized heaters
  • Checking for sticking switches or faulty sensors

🎯 Consistent operation helps your heater last longer—and saves you from surprise breakdowns.

  1. Handle With Care

Band heaters may look tough, but they’re not built for rough treatment.

🚫 Don’t pull them by the lead wires.
🔧 If you’re working with post terminals, use two wrenches—one to hold the base, the other to tighten.

Also, minimize vibration or movement during use. Excessive jostling can damage internal components over time.

  1. Get the Specs Right

We know—it’s not the most exciting part. But choosing the right heater for your system makes all the difference.

Common mistakes to avoid:

  • Incorrect size or shape
  • Mismatched wattage or voltage
  • Poor sensor placement
  • Using the heater outside its intended application

Take time to spec it properly now, and you’ll save yourself headaches (and replacement costs) later.

Wrapping It Up (Before It Burns Out)

Your band heater doesn’t need constant attention, just the right kind. Avoid moisture, keep it clean, reduce cycling, handle it with care, and make sure you’ve got the right fit for the job. Do all that, and it’ll keep powering through—even when the plastic pellets start flying.

💬 Have questions or need help finding the perfect band heater? We’re just a message away.

Maximizing Efficiency with Advanced Power Controllers

Posted on by Southern Heat
Authored by Isabel McCord

Maximizing Efficiency with Advanced Power Controllers

Are Your Processes Running at Peak Efficiency?

In plastic manufacturing, precise heating control isn’t just a luxury—it’s essential for maintaining product quality, reducing waste, and optimizing energy use. Yet, many manufacturers still rely on basic mechanical relays for simple on/off switching, missing out on the advanced benefits that power controllers bring to the table.

The Key Benefits of Power Controllers in Plastic Manufacturing

✔ Precise Temperature Control – Fluctuations in temperature can lead to defects, increased scrap rates, and inconsistent product quality. Power controllers modulate power smoothly and accurately, delivering steady heat distribution for superior results.

✔ Eliminate Electrical Noise – Electrical interference and harmonic distortion can disrupt nearby equipment and create inefficiencies. Unlike SSRs, power controllers significantly reduce these issues, ensuring a cleaner and more reliable power supply.

✔ Improved Process Stability – Consistency is key in plastic manufacturing. Power controllers use advanced algorithms to maintain stable operating conditions, reducing variations in material properties and improving overall product uniformity.

✔ Lower Electricity Costs – Energy waste can quickly add up. Power controllers optimize power usage, reducing unnecessary energy consumption while prolonging the lifespan of heating elements—leading to substantial cost savings over time.

Featured Power Control Solutions: 

Crydom Series 1 Solid-State Relays

Unlike mechanical relays, solid-state relays (SSRs) have no moving parts, allowing them to turn on and off faster while offering longer service lives. Using semiconductors for activation, these SSRs resist disturbances from environmental factors like shock, vibration, and electronic noise.

  • AC or DC control
  • Series 1 product family
  • SCR output
  • Life expectancy: 1 billion operations
  • Panel mount
  • Zero Cross switching standard

GFX4 Power Controller

The GFX4 is a four-loop power controller designed for efficient electrical power management. Combining multiple technologies in a compact unit, it reduces space and cabling costs while offering precise control and diagnostics.

  • Integrated controller and solid-state relays
  • Built-in current transformers and optional fuse holders
  • Analog and digital inputs/outputs
  • Standard digital communication interfaces
  • Autonomous four-loop control with real-time diagnostics

Watlow DIN-A-MITE A Power Controller

The DIN-A-MITE® A power switching device is engineered for precision and reliability. It offers single-phase zero-cross switching up to 25 amperes at 600VAC, integrating a built-in heat sink and termination system for optimal performance. Mercury-free and safety-certified, it ensures stable and efficient power management.

  • Variable time base
  • 4-20mA process control or VAC/VDC input contactor versions available
  • 200KA short circuit current rating (SCCR) tested up to 480VAC
  • DIN-rail and back panel mounting

 Tips for Choosing the Right Power Controller

If you’re new to power controllers, here are some key considerations to help you choose the best solution for your manufacturing process:

🔹 Understand Your Load Requirements – Different heaters require different power ratings. Ensure the power controller you select can handle the voltage and current your heating system demands.

🔹 Look for Built-in Safety Features – Overload protection, short-circuit detection, and overheating safeguards can prevent costly damage to your equipment and ensure safe operation. 🔹 Integration with Existing Systems – Ensure your power controller can easily integrate with your current temperature control system, whether it’s PLC-based or standalone.

Common Mistakes to Avoid

❌ Ignoring Heat Dissipation Needs – Power controllers generate heat. Ensure proper ventilation and cooling to prevent performance issues.

❌ Selecting an Undersized Controller – A power controller that isn’t rated for your load will lead to failures and inefficiencies.

❌ Overlooking Maintenance – Regularly inspect connections, cooling elements, and system integration to maximize the lifespan and efficiency of your controller.

Optimize Your Heating Control with Southern Heat

At Southern Heat, we offer a comprehensive range of power management solutions, from solid-state relays to advanced power controllers designed to meet the unique needs of plastic manufacturers. Whether you’re looking to enhance efficiency, cut costs, or improve product consistency, our experts are here to help.

Take control of your heating processes today—contact us for more information!

📱 770-607-4501
✉️ sales@southernheatcorp.com

RTDs vs. Thermocouples: Choosing the Right One

Posted on by Southern Heat
Authored by Isabel McCord

RTDs vs. Thermocouples: Choosing the Right Temperature Sensor for Plastics Processing

In the world of plastics manufacturing, precision is everything. From extrusion to injection molding, maintaining the right temperature at every stage is crucial for product quality and operational efficiency. This is where temperature sensors like Resistance Temperature Detectors (RTDs) and Thermocouples come into play.

These sensors ensure your equipment runs smoothly and your products meet the highest standards. But which one is best for your application? Let’s break it down.

RTDs and Thermocouples: A Quick Intro

RTDs (Resistance Temperature Detectors)

RTDs work by measuring how a material’s electrical resistance changes with temperature. Typically made from platinum, nickel, or copper, they’re known for their accuracy and stability. In plastics processing, these qualities are invaluable for maintaining tight control over heating zones.

Thermocouples

Thermocouples, on the other hand, measure temperature using the Seebeck effect—a voltage generated at the junction of two dissimilar metals when there’s a temperature difference. They’re rugged, cost-effective, and capable of handling extreme conditions, making them versatile for many plastics applications.

Where RTDs Shine in Plastics

RTDs are the go-to choice when precision and stability are key. Here are a few scenarios where they excel:

  • Extrusion Processes: Maintaining consistent temperatures in the barrel and die is critical for achieving uniform melt quality. RTDs provide the precision needed to monitor and control these zones effectively.
  • Injection Molding Machines: In applications where accuracy is paramount—such as when processing high-performance plastics—RTDs help ensure precise temperature control in heating bands and molds.
  • Calibration and Quality Assurance: RTDs are ideal for calibrating equipment and verifying temperature consistency, helping manufacturers meet strict quality standards.

Where Thermocouples Steal the Spotlight

Thermocouples are tough, fast, and built to handle a variety of environments. In plastics manufacturing, they’re often used for:

  • High-Temperature Extrusion: When working with materials like polycarbonate or PEEK, which require high processing temperatures, thermocouples can handle the heat.
  • Thermoforming: These sensors provide rapid response times, making them perfect for applications where sheet heating must be monitored closely and adjusted in real-time.
  • Cost-Sensitive Operations: For applications like recycling or lower-end material processing, thermocouples offer a budget-friendly option without compromising reliability.

RTDs vs. Thermocouples in Plastics: Key Differences

Here’s how these sensors stack up for the plastics industry:

Feature RTDs Thermocouples
Accuracy High—perfect for tight tolerances Moderate—great for general applications
Temperature Range Moderate—suitable for most plastics Wide—handles extreme temps with ease
Response Time Slower but steady Faster for dynamic processes
Durability Stable overtime in controlled settings Rugged and ready for tough environments
Cost Higher upfront investment Cost-effective for broader use

How Southern Heat Corporation Supports Plastics Professionals

At Southern Heat Corporation, we understand the unique challenges of the plastics industry. Whether you’re molding, extruding, or thermoforming, our range of RTDs and thermocouples is designed to meet your needs.

Here’s How We Help:

  • Expert Recommendations: Unsure whether you need an RTD or a thermocouple? Our team can assess your specific process and recommend the right solution.
  • High-Performance Sensors: We supply durable, accurate sensors that stand up to the demands of plastics processing.
  • Customized Solutions: Need a specialized setup for your extrusion line or injection molding machine? We’ve got you covered.

We’ve worked with plastics manufacturers across the industry, providing temperature solutions that enhance efficiency, product quality, and operational reliability.

Making the Right Choice

So, which sensor should you choose for your plastic application? It depends on your specific process:

  • Choose RTDs if you need high precision, stability, and long-term reliability in controlled environments.
  • Choose Thermocouples if you’re working with extreme temperatures, rapid heating changes, or budget-sensitive projects.

Whichever you choose, Southern Heat Corp is here to ensure you get the best performance and value from your temperature sensors.

Ready to Optimize Your Process?

Whether you’re upgrading your equipment or starting a new project, temperature control is the foundation of success. Contact Southern Heat Corporation and Extruder Supplies today and let us help you choose the right temperature sensors to keep your plastics operation running smoothly.

Ungrounded vs Grounded Thermocouples: Choosing the Right One

Posted on by Southern Heat
Authored by Isabel McCord

Ungrounded vs. Grounded Thermocouples: Choosing the Right Option for Your Application

When it comes to measuring temperature in industrial applications, thermocouples are a go-to choice. However, not all thermocouples are created equal. The decision between ungrounded and grounded thermocouples can have a significant impact on the efficiency and accuracy of your processes. Let’s break it down by exploring the reasons for using each type, their common applications in the plastic industry, and any restrictions they might have.

  1. Why Use Ungrounded vs. Grounded Thermocouples?
  • Ungrounded Thermocouples: The junction is insulated from the metal sheath in ungrounded thermocouples. This design minimizes electrical interference, making them ideal for environments with high levels of electromagnetic noise. If your system involves sensitive electronic equipment or high-frequency signals, ungrounded thermocouples are the better choice. They also provide longer life in corrosive or oxidative environments due to the protective insulation.
  • Grounded Thermocouples: Grounded thermocouples have the junction in direct contact with the metal sheath, providing faster response times. This design is perfect for applications requiring immediate temperature readings. Grounded thermocouples excel in dynamic environments with rapid temperature changes, ensuring precise real-time monitoring.

Learn how to test the difference! 

  1. Most Commonly Used in the Plastic Industry

Maintaining consistent temperatures is critical for quality and efficiency in the plastic industry. Both ungrounded and grounded thermocouples have their place:

  • Ungrounded Thermocouples: These are commonly used in processes like plastic extrusion where electrical interference from other machinery could impact accuracy. By reducing noise, they ensure more reliable readings for controlled heating.
  • Grounded Thermocouples: Injection molding operations often use grounded thermocouples due to their rapid response times. In these applications, precise monitoring of quickly changing temperatures during the injection and cooling phases is essential for producing high-quality products.
  1. Restrictions to Consider

Each type of thermocouple has limitations that should guide your decision:

  • Ungrounded Thermocouples:
    • Slower response times compared to grounded thermocouples.
    • May be more expensive due to the added insulation.
    • Careful handling to avoid compromising the insulation.
  • Grounded Thermocouples:
    • Susceptible to electrical noise, which can distort readings in environments with significant interference.
    • Not ideal for corrosive or high-moisture environments, as the exposed junction can degrade faster.
    • Can create ground loops in systems with multiple grounding points, leading to measurement errors.

Making the Right Choice

Understanding the differences between ungrounded and grounded thermocouples is key to optimizing your processes. Consider your operational environment, the need for response time, and the potential for interference when making your decision. Whether you’re monitoring extrusion temperatures or ensuring precision in injection molding, the right thermocouple can make all the difference.

How Southern Heat Corp Can Help

At Southern Heat Corp, we specialize in providing top-quality thermocouples tailored to the needs of the plastic industry. From extrusion to injection molding, our team understands the unique challenges you face in maintaining precise temperature control. Here’s how we can support your operations:

  • Expert Guidance: Not sure whether an ungrounded or grounded thermocouple is best for your application? Our Sales Engineers can help you assess your requirements and select the right solution.
  • Custom Solutions: We offer a wide range of MRO and capital equipment designed to meet the specific demands of plastic extrusion, injection molding, and other processes.
  • Reliable Products: Our thermocouples are built to withstand the harsh conditions of industrial environments, ensuring long-lasting performance and minimal downtime. Shop Southern Heat Thermocouples! 
  • Dedicated Support: From installation tips to ongoing maintenance advice, we’re here to help you get the most out of your temperature measurement equipment.

Need help finding the perfect thermocouple for your application? Contact our team at Southern Heat Corporation for expert advice and solutions designed to keep your plastic operations running smoothly.

ISEC evo: Transforming Plastic Recycling with Pure Loop

Posted on by Southern Heat
Authored by Isabel McCord

Pure loop: Revolutionizing Plastic Recycling with the ISEC evo

At Southern Heat Corp, we are committed to supporting innovation in plastic recycling. Our partnership with Pure Loop allows us to bring the revolutionary ISEC evo Plastic Pelletizing Machine to businesses across the Southeast. As the preferred seller in Alabama, Georgia, Mississippi, North Carolina, South Carolina, and Tennessee, we are proud to offer this game-changing solution to our customers.

The Advantages of the ISEC evo

The ISEC evo is more than just a recycling machine—it’s a powerful tool for efficiency, sustainability, and profitability. Here are some of its key benefits:

  • High Throughput: Efficiently recycle large volumes of plastic in less time.
  • User-Friendly Design: Designed for ease of use, regardless of your team’s level of recycling expertise.
  • Cost-Effective Solution: Maximize your return on investment with an affordable and efficient system.
  • Versatility: Capable of processing a wide range of plastics to suit various recycling needs.
  • Exceptional Support: Pure Loop’s holding company, EREMA Group, ensures customers benefit from world-class service. Their experienced customer service team is ready to provide expert assistance whenever needed.
  • Trial Centers: Evaluate the ISEC evo firsthand at one of Pure Loop’s dedicated trial centers located here in the USA before making your purchase.

Part of Southern Heat Corp’s Capital Equipment Line

The ISEC evo is a key part of Southern Heat Corp’s Capital Equipment line. This comprehensive lineup offers innovative solutions designed to meet the evolving needs of businesses in plastic recycling and beyond. View our Capital Equipment line card here.

Empowering Businesses with Sustainable Solutions

Our collaboration with Pure Loop is about more than delivering state-of-the-art technology. The ISEC evo helps businesses:

  • Reduce Environmental Impact: Divert plastic waste from landfills and contribute to a more sustainable future.
  • Increase Profitability: Generate revenue streams from recycled materials and reduce reliance on virgin plastics.
  • Enhance Brand Image: Demonstrate a commitment to environmental responsibility and sustainability.

Southern Heat Corp: Your Partner in Recycling

At Southern Heat Corp, we believe in the power of innovation to address environmental challenges. By partnering with Pure Loop we can provide businesses with the tools, technology, and expert support they need to succeed in recycling.

Contact Us Today

If you’re ready to explore how the ISEC evo can transform your recycling operations, reach out to us today!

Preparing for the New Year: Boost Your Production

Posted on by Southern Heat
Authored by Isabel McCord

Preparing for the New Year: Boost Your Production Efficiency with Upgrades, Dynapurge, and Spare Parts

As the new year approaches, it’s the perfect time to optimize your plastic operations for peak performance. By investing in upgrades, improving equipment reliability, and preparing for increased demand, you can set your production up for success. Here’s how:

  1. Upgrade Your Heating Solutions

Efficient heating is at the heart of every extrusion process. Modern heaters, such as advanced band and cartridge heaters, provide better heat transfer, energy efficiency, and durability. Upgrading your heating solutions ensures precise temperature control, reduces downtime, and enhances the overall quality of your output.

  1. Upgrade Temperature Sensors and Pressure Controllers

Accurate temperature and pressure readings are essential for consistent results. Self-indicating thermocouples and solid 10 plugs are excellent upgrades that can help prevent defects, improve safety, and optimize productivity.

  1. Upgrade to an Air-Cooled Shroud System Over Water-Cooled Shroud System

Looking for a cleaner, more efficient cooling solution? Transition to an air-cooled shroud system to eliminate water-related maintenance issues while improving heat dissipation. Air-cooled systems are easier to maintain, environmentally friendly, and deliver consistent cooling performance, keeping your operations running smoothly.

Check out our blog- Water to Air: A Cool Conversion for Plastic Extruders

  1. Stock Up on Replacement Parts

Minimize unplanned downtime by keeping critical replacement parts on hand:

  • Heater Bands and Thermocouples: Ensure consistent operation and accurate monitoring.
  • Rupture Plugs: Maintain safety by regularly replacing these essential components.
  • Melt Pressure Transducers
  • Wire, Jacks, Plugs, Adapters, etc.

Partnering with Southern Heat Corporation gives you access to high-quality, compatible parts that keep your production line moving without delays.

  1. Invest in Advanced Control Systems

Take your operations to the next level with advanced control systems integrating data monitoring, process automation, and remote access capabilities. These systems enable you to:

  • Monitor temperature, pressure, and flow in real time.
  • Automate adjustments for consistent performance.
  • Reduce manual intervention and human error.

With smarter controls, you can improve efficiency, reduce waste, and gain greater flexibility in your production process.

  1. Incorporate Dynapurge for Optimal Cleaning

Dynapurge, the industry-leading purging compound, is used several times a year and more than once between jobs to keep equipment clean and optimized. It removes residue, contaminants, and buildup from your equipment, extending its lifespan and improving performance. A cleaner machine reduces the risk of contamination, minimizes defects, lowers maintenance costs, and ensures smooth operations during peak production seasons.

Make the New Year Your Best Yet

From upgrading heating and control systems to cleaning with Dynapurge and stocking replacement parts, these proactive steps will position your operations for maximum success.

Southern Heat Corporation is here to help you implement these solutions with high-quality products and expert guidance.

Contact us today to start preparing for a productive and efficient new year!

Winter-Proof Extrusion Operations

Posted on by Southern Heat
Authored by Isabel McCord

Tips & Tricks to Winter-Proof Your Extrusion Operations with Southern Heat Corp

As winter approaches, it’s not just the temperature that drops—efficiency and production quality can also take a hit if your equipment isn’t properly prepared. Southern Heat Corp is here to help you keep your extrusion operations running smoothly all winter. From preventing equipment malfunctions to avoiding costly repairs, these winter-proofing tips will ensure your production stays on track, even in the coldest months.

  1. Prepare Early with the Right Freeze Protection Products

Don’t wait until the first frost! Get ahead by installing freeze-protection products in the warmer months, making it easier to access key areas of your setup and avoid emergency downtime. Southern Heat Corp offers a comprehensive range of solutions, including:

  • Drum Heaters to maintain material flow and prevent blockages caused by thickened pellets.
  • Heating Tapes for pipes, hoses, and valves—your winter-proof answer to freezing and blockages.
  • Insulation Jackets to reduce heat loss and improve energy efficiency.
  • Heated Hoses and Tubing for maintaining precise material temperatures throughout your entire system.

By being proactive, you not only prevent winter disruptions but also gain a chance to plan and prepare, ensuring all installations are correct and efficient.

  1. Keep Materials Flowing with Drum Heaters

Winter weather can cause melted pellets to thicken, slowing down production. Southern Heat Corp’s drum heaters are the perfect solution. They wrap around your barrels, maintaining a consistent temperature to keep materials fluid and production steady. With our adjustable models, you get complete control over the heat settings, allowing you to handle winter temperatures without a hitch.

  1. Protect Pipes, Hoses, and Valves with Heating Tapes

Winter is notorious for freezing and clogging pipes, hoses, and valves, which can cause costly disruptions. Think of heating tapes as a thermal scarf for your extrusion lines. They wrap around trouble spots to prevent freezing and keep your system running smoothly. Southern Heat Corp’s heating tapes offer precision warmth, perfect for preheating materials before they hit the extruder or maintaining temperatures during production.

  1. Save on Energy Costs with Insulation Jackets

Heating is crucial, but retaining heat is just as important. Our thermal insulation jackets are designed to keep extruder barrels and molds at optimal temperatures, reducing heat loss and lowering energy consumption. This not only keeps your operations running efficiently but also saves you money in the long run.

  1. Ensure Uniform Temperature with Heated Hoses and Tubing

Maintaining consistent temperatures throughout your extrusion system is critical, especially in winter. Heated hoses and tubing provide reliable warmth, ensuring materials flow smoothly from start to finish. Southern Heat Corp’s heated hoses and tubing prevent temperature drops, reducing the risk of clogs, freezing, or inconsistencies in your end product.

How Southern Heat Corp Can Help You This Winter

At Southern Heat Corp, we know winter poses unique challenges to the plastic extrusion industry. Here’s how we can support you:

  • Expert Advice: Our sales engineers will assess your operations and recommend the best products to keep production running smoothly.
  • On-Site Assistance: From product selection to installation, we provide hands-on support to ensure a seamless setup.
  • Comprehensive Product Line: Whether it’s drum heaters, heating tapes, insulation jackets, heated hoses and tubing, or other freeze protection solutions, we have what you need to keep your extrusion process warm and efficient.

Don’t wait until winter slows you down—reach out to Southern Heat Corp today! Our team is ready to help you stay ahead of the cold and maintain production quality all season long.

Extruder Performance: Key Products and Maintenance Tips

Posted on by Southern Heat
Authored by Isabel McCord

Enhancing Extruder Performance: Key Products and Maintenance Tips

Optimizing your plastic extruder’s performance is essential for efficiency and reliability. By using the right components and following a robust maintenance schedule, you can improve your extrusion process while minimizing downtime. Here are the essential products and maintenance practices to consider.

Key Products for Extruder Efficiency

Heater Bands:

  • Ceramic Heater Bands: Offering excellent heat transfer and durability, ceramic heater bands ensure uniform and reliable heating in critical extrusion zones. Their robust design also reduces the likelihood of heat loss, promoting energy efficiency.
  • Maxiband Heaters: Designed as Heat and Cool, Heat Only, or Cool Only. The channels in the extruded aluminum track are precisely sized to accept a .315-diameter tubular heating element and provide an excellent heat sink for rapid heat transfer and good temperature uniformity.

Sensors:

  • Thermocouples: Precise temperature monitoring is essential for maintaining optimal extrusion conditions. Thermocouples deliver accurate, real-time temperature readings, enabling fine control over the heating process.
  • Pressure Sensors: These sensors monitor material flow, helping to detect blockages or inconsistencies in material feed. By addressing pressure fluctuations early, you can avoid material waste and equipment strain.

Additional Products:

  • Extruder Screws: High-quality screws optimize material flow, improving efficiency and product quality.
  • Cooling Systems: Effective cooling systems help regulate the temperature of extruded materials, preventing warping, deformation, or other quality issues caused by overheating.

Best Practices for Maintenance

  1. Regular Cleaning
    Prevent buildup with Dyna-Purge to maintain smooth operation and reduce costly downtime. Dyna-Purge is an effective cleaning agent that clears residue on the first pass, Dyna-Purge minimizes downtime and reduces plastic scraps. Its ready-to-use formula requires no soaking or mixing and works at the machine’s normal temperature and speed, ensuring no hidden costs. Safe for both operators and equipment, it is heat-stable, non-abrasive, and environmentally compliant.
  2. Temperature Control
    Maintaining proper temperature settings is key to producing consistent material quality. Ensure that temperatures are neither too high nor too low to prevent material degradation or production defects.
  3. Lubrication
    Following the manufacturer’s lubrication guidelines is essential for reducing friction, wear, and tear on moving parts. Proper lubrication helps extend the lifespan of your extruder.
  4. Routine Inspections
    Regularly inspect your extruder for unusual sounds, vibrations, or other warning signs of mechanical issues. Addressing potential problems early prevents costly repairs and production delays.
  5. Proper Shutdown
    Adhere to recommended shutdown procedures to protect your extruder and ensure smooth restarts.

Conclusion  

Using the right components, such as heater bands, sensors, and Dyna-Purge, paired with regular maintenance, will ensure optimal performance of your extruder. Regular cleaning, lubrication, and inspections help minimize downtime and keep your extrusion process running smoothly.

The Role of Temperature and Pressure in Extrusion

Posted on by Southern Heat
Authored by Isabel McCord

Plastic extrusion is a pivotal process in the manufacturing of various plastic products, from pipes and sheets to complex profiles and films. The efficiency and quality of the extrusion process largely depend on two critical factors: temperature and pressure. Managing these parameters effectively ensures the production of high-quality plastic products, minimizes waste, and enhances overall operational efficiency.

Imagine plastic extrusion as a finely tuned engine—temperature and pressure are the heat and torque that keep everything running smoothly. Just like in a high-performance machine, getting the balance right between these two factors is what drives quality and efficiency. Mismanage either, and you’re left with sputtering output, wasted resources, and a lot of headaches.

The Importance of Temperature in Plastic Extrusion

Temperature is the heat under the hood that makes everything run. Too hot, and you risk overheating; too cold, and nothing moves. In extrusion, maintaining the right temperature ensures that your polymer flows like a well-oiled machine, ready to be shaped into the perfect product.

  1. Optimal Melt Temperature: Each type of plastic has an optimal melt temperature range. Maintaining the correct temperature ensures that the polymer flows smoothly through the extruder, reducing the risk of defects like bubbles, uneven thickness, or incomplete filling of molds. Just like engines require different grades of fuel, polyethylene needs lower heat compared to polycarbonate, so the temperature settings for extrusion need to be carefully calibrated.
  2. Zoning and Gradients: Think of your extruder as a multi-stage turbocharger, with each heating zone playing its part in boosting the melt. These zones help in gradually melting the plastic, ensuring a consistent flow. The right temperature gradient across these zones ensures smooth acceleration without thermal degradation or incomplete melting—just like keeping your turbo running at peak efficiency.

Products for Temperature Control:Fixed Thermocouple

  • Temperature Sensors: These are the gauges on your dashboard, giving you real-time data to keep everything in check. Whether it’s a thermocouple or an RTD, precise sensors are essential to avoid any redlining.
  • Heaters: Depending on the material and application, different types of heaters, such as infrared heaters, cartridge heaters, or band heaters, are used to achieve and maintain the desired temperature. These components are your spark plugs—reliable and efficient, ensuring that your extrusion process fires on all cylinders.

The Role of Pressure in Plastic Extrusion

If temperature is the heat, pressure is the torque. It’s the force that pushes your product through the die, shaping it with precision. Without the right pressure, your operation stalls out, but with too much, you risk blowing a gasket.

  1. Die Pressure: Think of this as the gear ratio—too low, and your product won’t take shape; too high, and it swells out of control. Precision here ensures your product is dense and dimensionally accurate, just like shifting gears at the perfect RPM.
  2. Back Pressure: Back pressure is the resistance encountered by the plastic as it moves through the screw and towards the die. Back pressure is like tuning your exhaust system—necessary for optimal performance, but too much can create unwanted strain. Managed properly, it ensures your plastic is uniformly melted and mixed, delivering consistent results without overloading your extruder.

Products for Pressure Control:Rupture Disks

  • Pressure Controllers: These are like torque converters, ensuring smooth and controlled power transfer throughout the process. Advanced pressure controllers keep your extrusion line running efficiently, preventing hiccups and stalls. These controllers often work in conjunction with pressure sensors to provide real-time feedback, ensuring optimal pressure conditions throughout the process.
  • Rupture Plugs: These safety devices are your pressure relief valves, stepping in when things get too intense. They protect your equipment by providing a controlled release, keeping everything running smoothly under the hood.

Balancing Temperature and Pressure for Optimal Extrusion

Achieving the perfect balance between temperature and pressure is crucial for the success of the plastic extrusion process. Get the balance right, and you’ll hit that sweet spot where quality, efficiency, and performance come together. If the temperature is too low, you’ll need more pressure to maintain flow, like having to downshift on a steep incline. Conversely, too much heat or pressure can lead to breakdowns, much like overworking an engine. By utilizing precise temperature sensors, reliable heaters, advanced pressure controllers, and safety devices like rupture plugs, manufacturers can optimize their extrusion processes, reduce downtime, and produce high-quality plastic products that meet industry standards.

 

Southern Heat Corporation offers a comprehensive range of products designed to meet the exacting demands of plastic extrusion. From top-notch temperature sensors to robust pressure controllers and rupture plugs, our solutions are engineered to help you achieve unparalleled control and consistency in your extrusion operations.

For more information on our products and how they can enhance your extrusion process, contact Southern Heat Corporation today.