PVC Extrusion

Polyvinyl Chloride (PVC) is one of the most widely used plastics in the world, for this reason Bausano specialized also in PVC extruders. PVC extrusion is the process where a PVC material is forced through a die in order to create a fixed and shaped form or product.

PVC extrusion generally needs a Twin Screw extruder because of the harsh condition of PVC processing. The melt temperature of PVC is around 170-200°C. PVC is a thermoplastic made of 57% chlorine and 43% carbon. Polyvinyl chloride is obtained from the polymerisation of vinyl chloride monomer and is then added with other substances, such as stabilizers and lubricants, to give it specific physical and mechanical characteristics that improve its performance and are necessary for the many applications that can be extruded with the polymer and with Bausano extrusion lines.

PVC consumption is only lower than that of polyethylene and polypropylene, because of its many characteristics. PVC has become more utilized in the extrusion sector and in its applications because of its many advantages respect to wood, metal and other materials.

PVC Advantages

General PVC advantages are:

Durability
Easy to install
Cost-effectiveness
Nontoxic material
Fire resistance
Versatility

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PVC Categories and Applications

PVC can also be divided in various under categories like rigid PVC and flexible PVC. Rigid Polyvinyl Chloride is a material that provides a good balance of stiffness impact resistance and UV stability. For this reason it is most used in construction for pipe and in window & doors profile applications.

Rigid PVC is also often used as a replacement for metal and wood thanks to its properties. Flexible PVC becomes flexible thanks to the addition of a that plasticizer makes it much more flexible. Flexible PVC is much softer and more amenable to bending than its rigid counterpart. Flexible PVC is commonly used in the creation of electrical wire insulation. Many residential and commercial builders also use flexible PVC to create flooring.

In general PVC has many applications:

Pipe extrusion for construction sector
Profiles for window and doors
Electrical cable industry
Healthcare sector

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Bausano custom PVC extrusion

With Bausano E-GO Single Screw Extruders or MD Twin-screw extruders, various PVC products can be produced, and different types of additives are used depending on the product:

Fillers, usually mineral particles that can have the dual function of improving certain properties and making PVC more economically competitive.
Plasticizers, where flexibility is desired in the final product
Stabilizers, to prevent and counteract ageing and thermal degradation of the product
Lubricants, to facilitate processing.
Pigments, to give the desired color to the final product.

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Compounds and Additives

Before analysing the various fields of application for PVC, it is worth saying a few words about an intermediate product, compounds. PVC can be found on the market either in the form of a resin with additives (dry blend) or in the form of pellets, i.e., compounds. The latter, obtained by processing the dry blend in a special Bausano extruder, can be used to produce a very wide range of products.

Bausano especially produces Extrusion lines for PVC pipes, profiles, pellets, and medical tubes & bags. The compounding process can also be useful to improve the quality of recycled PVC by allowing an "upgrading" process of post-consumer PVC that leads to the marketing of a higher quality recyclate.

Thanks to qualities such as:

Strength and lightness
Ease of transport and installation
Durability
Versatility
Environmental friendliness and convenience

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Examples of Custom PVC Extrusion Applications

Bausano Extrusion lines are highly customizable and so suitable for a material like PVC that is used in many applications with high flexibility in the end product.

Bausano Extruders for PVC are commonly used in a wide range of applications and sectors, like:

Construction sector

From transporting drinking water to drainage solutions, to advanced irrigation and firefighting systems. This popularity is due to a unique combination of properties: safety, durability/cost-efficiency, environmental performance and recyclability. PVC pipes have a much lower failure rate than other materials. Compared to others, PVC pipes are also the most economical choice throughout their life cycle. This includes the costs of purchasing pipes, installation, maintenance, and decommissioning.

Bausano has a wide range of extruders that can be applied for PVC pipe production like Bausano MD 158 Twin screw extruder. For example, with this PVC extruder it is possible to extrude up to 800mm PVC pipes.

Examples of Custom PVC Extrusion Applications

Plastic Window Profiles had an increase in
demand over the years because of the many
advantages it offers respect to other materials,
like aluminum or wood.

Window profiles

PVC is suitable for window profiles, cladding, flooring and wall coverings. In addition, PVC does not require frequent painting and does not corrode like iron and wood. In particular, the parameters to consider for a PVC window frame are:

Insulation values and heating costs that make this type of frame the one with the highest energy saving potential.
PVC profiles are less expensive, allowing suppliers and customers to save money compared to aluminium. PVC windows are exceptionally durable and long-lasting. Frames made of PVC pellets are extremely resistant to weather conditions. With a Bausano MD 75 nextmover Extruder, we made an extrusion line for Rigid PVC window profiles.

Examples of Custom PVC Extrusion Applications

Floors and decking profiles are one of the many
PVC and Bausano Extruder combination.

Floors and decking

Bausano PVC Extruders are also commonly used for floors and decking in hospitals, sports clubs, kitchens and all other public buildings where a high level of hygiene and safety is required. PVC floors are waterproof, fire resistant and easy to clean. Like any other PVC application, they can be customized with a wide variety of colours and shapes. Focusing on wall coverings, they are designed with high thermal insulation and exceptional weather performance, with good UV resistance and at the same time are also useful for renovating older houses.

Examples of Custom PVC Extrusion Applications

Protection of power lines, cable for
telecommunications or data transmission is more
than ever critical nowadays, and PVC is the right
choice.

Electric cable industry

PVC is not a conductor and is therefore an insulating material, which is excellent for all electrical applications such as cables and conduits. Utilising the thermal efficiency of PVC, cables can withstand high/low temperatures and have flame retardant properties.

PVC cables do not harden and do not break over time: they are used in many applications, from telecommunications to thermal blankets.

In addition, PVC is extremely safe. It has been extensively researched and tested to meet all international health and safety requirements. It is entirely non-toxic and is considered on a par with other thermoplastics in terms of environmental impact.

Examples of Custom PVC Extrusion Applications

The healthcare sector has high standards for this
reason PVC has the right characteristics.

Healthcare sector

PVC has become the best choice when it comes to healthcare, not only for medical bags and tubes that you can produce with the MD Bausano Twin-screw extruder series, but also for wall coverings and hospital interior floors. Thanks to its physical and technical characteristics (chemical resistance, low maintenance), PVC accounts for 40% of the plastic medical devices used in hospitals and is now the most popular material for pre-sterilised single-use medical applications.

To make the vinyl softer and more flexible, plasticisers need to be added, but these are subject to pre- and post-assessment procedures and are included in the European Pharmacopoeia. In addition, PVC can be easily sterilised by methods such as steam, EtO, Gamma and Beta radiation, making it safe.

For a material like PVC and its high flexibility you need an equally highly customizable Bausano Extruder.

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