Custom PC Extrusion Line Manufacturer & Exporter

Polycarbonate is highly hygroscopic and susceptible to hydrolysis at processing temperatures exceeding 280°C. If raw PC resin with even minimal moisture content is fed into the extruder, the polymer chains cleave, causing a drop in molecular weight. This degradation leads to cosmetic defects like bubbles and silver streaks, and seriously undermines the impact strength of the final sheet. Therefore, GWELL incorporates dehumidifying desiccant dryers that achieve dew points below -40°C, drying the material at 120°C for 4 hours before processing.

For PC sheet and board extrusion, a single screw with a length-to-diameter (L/D) ratio between 30:1 and 35:1 is typical. Because PC has high melt viscosity, a specialized barrier screw design is utilized. This design includes mixing sections (such as Maddock mixers) to ensure color homogenizing and uniform melt temperature distribution without causing high shear stress that could degrade the polymer.

Optical clarity depends directly on the surface finish and temperature control of the three-roll calender. GWELL rolls are manufactured from high-grade alloy steel, super-mirror chrome-plated, and polished to a surface roughness of Ra ≤ 0.01 μm. In addition, we utilize independent internal water/oil circulation systems for each roll, enabling temperature adjustments within ±0.5°C to avoid stress-induced birefringence.

Yes. Outdoor PC sheets require a thin UV protective layer (typically 50 μm of high-concentration UV-absorber PC compound) on one or both sides to prevent yellowing over time. Our lines integrate a secondary co-extruder (typically a 50mm single screw) along with a multi-manifold co-extrusion feedblock from industry leaders like JC-Times. This ensures a consistent, micro-thin UV layer across the entire width of the sheet.

Our automation systems feature integrated PLC modules (primarily Siemens S7-1500 series) with secure remote internet gateways. If technical troubleshooting is required, GWELL's software engineering team can remotely analyze the system configuration, sensor logs, and extrusion parameter settings. This remote capability allows us to optimize control loop gains and resolve issues without needing to travel on-site.

To reduce material scrap during startup, GWELL utilizes precise melt pump controls, automated sheet tracking, and closed-loop thickness gauges. Real-time feedback from the beta-gauge thickness scanner automatically adjusts the die lip bolt temperatures or calender gap, minimizing the time required to achieve target specifications.