Process Engineering

With the equipment of our technical area, we are able to produce formulations of thermoplastic polymers, both commercial and experimental, with additives and fillers with different shape, size and chemical nature. We can work with granules, flakes, powders and liquids. Moreover, we produce polymeric blends, working with different polymers, from simple polyolefins to polyamides, polyurethanes, bio-based and biodegradable polymers, up to recycled materials. We manufacture small compound batches and samplings (up to 500 kg) through lab and pilot-scale twin screw co-rotating extruders, also pre-mixing granules and fillers by dry-blend, when necessary. Proplast is the right partner both to optimize new formulations to be placed on the market and to produce small batches of compounds.

Our consolidated experience in several types of polymeric materials allows us to perform sheet extrusion fine-tuning, producing samples with a nominal width of 200 mm and a thickness ranging from 200 micron and 1 mm. In collaboration with our R&D team, the optimization of processing parameters and their correction, if necessary, is performed with a careful monitoring based on customer’s requirements in order to maximize the quality of the product. A further strength of Proplast facilities is represented by the physical expansion of thermoplastic materials by supercritical CO2 through Promix technology. This process allows obtaining parts with a markedly reduced weight but with performances like unexpanded parts. Finally, Proplast is at disposal with its competences in testing materials like PVC using specific tools and technologies.

We have been supporting and optimizing processes parameters since ever, throughout mold testing and evaluation, and preparation of small sample batches to validate the development phase before passing to a production phase. Our technicians perform precise monitoring of injection molding parameters, together with dimensional and functional checks. Effective solutions for each kind of productive need are achieved combining the use of innovative technologies and the analysis of testing data. Several innovative manufacturing techniques are together gathered in Proplast’s facilities. This aspect represents a paramount opportunity for our customers due to the fact we can easily support them in enhancing physical, mechanical, and aesthetical properties of their products and, therefore, incrementing their productivity. Finally, we are able to produce pre-series samplings, offering to our customers a productive advantage if they need to test new products before commercializing them and building final moulds. Proplast, with its long experience and consolidated flexibility, is actually a reliable partner on the market to produce small batches (from 500 to 5000 pieces), using not only pilot mould built in our internal workshop but also with mould of the customers.

With our new vertical compression moulding machine (clamping force 40 tons), we can perform R&D activities on both materials and technology, exploiting the cooling and heating system of the mould during the process. Moreover, this kind of machine is equipped with a specific plastification system which can be used for compression moulding of rubbers.

With our pilot-scale thermoforming machine, we can produce small batches of thermoformed pieces, also using biocomposites. Thanks to the experience of our technicians, we are able to optimize processing parameters adapting them to different types of polymeric materials. Thermoformed components are compliant to customers’ features and requirements and their compliance can be evaluated with a complete chemical, physical and rheological characterization in our laboratories.

With the help of open source machines present at Proplast, we are able to combine the freedom of geometry (inherent in 3D printing) with the freedom of materials and their characteristics. High expertise in formulation development on polymeric materials is also applied to FDM technology to further expand the potential of 3D printing technology. We can therefore produce material samples and/or directly spools of wire for FDM with the characteristics required by the customer.