Key course information
- Course learning format: IN-PERSON COURSE
- More course dates: See below or click 'Register'
- Pricing: click 'Register' to preview
- Course duration: Two Days
- Location: Shropshire, UK
- Interactive learning face-to-face with expert tutors
- Electronic course notes
- Gain CPD Credits: Smithers training is IOM3 Quality Assured and counts towards professional development.
To book, click Register and choose a session
Looking for an alternative format?
Upcoming in-person course dates
| Select a session when registering | |
|---|---|
| 13 - 14 May 2026 | |
| 16 - 17 November 2026 | |
Course overview
In modern plastics manufacturing, production inefficiencies, quality issues, and material waste can quickly erode profitability. This course is designed to help you take control of the extrusion process, make informed decisions, and minimise costly errors.
Delivered in the classroom by industry experts, Exploring Plastics Extrusion provides a practical understanding of how to optimise single screw extrusion - from material behaviour and machine operation to downstream processing.
The course concentrates on the single screw extrusion process, with supporting modules covering compounding, rheology, and key application areas such as pipe, film, sheet, cable, and PVC profiles. Participants will gain the insight needed to troubleshoot effectively, improve consistency, and enhance overall process efficiency.
Learning outcomes
By the end of this course, you will be able to:- Spot and solve common extrusion faults before they escalate into downtime
- Improve product quality and consistency across runs
- Scale up R&D projects with confidence
- Make informed choices on equipment purchases
- Improve communication with suppliers, customers, and internal teams
- Understand how different polymers behave during extrusion - and why
Course content
The Basic Extrusion Process- What are we trying to achieve? Densification, Mixing, Compounding, Reinforcement, Reactive Processing, or the production of a particular shape.
- Feeding, Melting, and Pumping processes in single and twin screw machines, and the energy balance of the process.
- Understand the influence of rheology on the extrusion process.
- Aspects of design, choice and purchase of equipment.
- Different types of twin screw, their uses and compounding optimisation
- Various mixing techniques exist, add on mixing heads, barrier screws and modular kneading elements.
- Sizing of a machine from laboratory trials, scale-up, and choice of equipment.
- Compound, pipe, film, sheet, cable sheathing, profiles.
- Fault finding and practical solutions to common problems including:
- Probable causes of surging, melt fracture, etc.
- Difficulties encountered in handling rework, materials, feeding systems etc.
Who should attend
This course is ideal for professionals involved in the processing, quality control or technical management of extrusion operations.
It will be particularly valuable for:
- Process and production engineers who want to optimise extrusion performance and troubleshoot issues effectively.
- Technical managers and quality personnel responsible for ensuring consistent product standards and process reliability.
- Customer and technical service staff who need a deeper understanding of extrusion processes to support clients and resolve technical queries.
- Sales and purchasing professionals involved in specifying, selling or buying extrusion equipment and materials.
Meet your expert tutor
Jonathan Lea – Plastics Consultant, Extrusion Specialist
Jonathan Lea is a plastics consultant and extrusion specialist with extensive experience in polymer processing, equipment design and production optimisation. He combines deep process knowledge with a practical understanding of customer needs. Jonathan helps organisations improve extrusion performance, troubleshoot issues and develop more efficient manufacturing solutions..
What our delegates say about the course
“Very helpful and highly knowledgeable.”
Gerard Eaton (Hozelock)
“A very useful guide to how extrusion machines work.”
Mike Baillon (Stretch Polytech)
Contact us or download a brochure
Reach out to the training team now - ask about this course or discuss your training goals.
Prefer training tailored to your business?
Smithers also delivers custom and in-company training designed around your products, materials and processes. Get practical, targeted content delivered online or on-site by the same experts who run our public courses.