We do it all! When your design calls for Custom Plastics Extrusions, we can tackle the toughest jobs. We have been doing this for over 43 years! We are experts in Custom Plastics Extrusion.
Plastic Extrusion is a process in which very small pellets are fed into a machine with a rotating screw and a barrel that supplies heat. The small pellets (typically referred to as the “resin”) are slowly heated and melted to form the melt. The melt is then forced or squeezed through a die which forms the shape of the profile. The die may be in the form of a rod, pipe, hose, sheet, coating, film, tubes or as a custom profile.
The heat is then removed and the melt which was created by the melting of the pellets now takes the shape of the die as a permanent profile. The key to this process is that it is “continuous”.
Other plastic processes could make a profile but it would be much shorter than the lengths that are created through the creation of plastic extrusions.
The beauty of plastic extrusions is that the lengths can be extremely short (less than .250”) or they can be extremely long and/or spooled into lengths of 1,000 feet or more. The machine that is used to create Plastic extrusions can also do many different materials and colors.
There are many post extrusion processes that can be applied to plastic extrusions such as cutting to length, laminating, punching holes, embossing, and printing.
The size of extruders are generally based on the size of the screw. A 1-inch machine is relatively small and contains a screw that is 1 inch in diameter. These machines are typically used for medical products, R & D, and/or expensive materials. The output is generally low, around 50lbs/hr. On the other side of the spectrum, a 6-inch extruder has a screw diameter of 6 inches and is capable of putting out over 2,500 lbs/hr. The extruder in essence is generally a simple machine in which a screw turns, heat is applied and pellets are melted.
For over 4 decades, we have manufactured plastic extrusions, plastic extruded products, coextrusions, hollow profiles, recycled profiles, custom profiles, and more. We have the technical expertise on staff (even PhDs) that includes materials, profile design, Senior Processing Engineers, and a Sales Staff that can answer all of your questions immediately. We run every type of material that is commercially available and we can even have custom formulations produced.
We service every industry today and we are very proud of our customer base in providing custom plastic extrusions. Plastics are our business. Therefore, our manufactured plastic profiles in ABS, PVC Plastic, nylon, and polycarbonate are created by no less than industry specialists. There is absolutely no design too simple or too complicated for our team of experts to design or manufacture, which is why we offer custom materials and designs to meet your needs when it comes to custom plastic extrusions.
We offer many services that also complement our Thermoplastic custom plastic profiles. We can custom color any color that you provide us. We can apply pressure-sensitive tape on any design and, with many of the newer technology tapes. Here at Keller Products, you can expect specially designed screws during the manufacturing of pvc extrusions. The reason being for this engineering feat is in order to provide us the best melt with an ultimate degree of mixing for brilliant color dispersion. If you don’t already know, the ratio of the length of the screw to the diameter of the screw is typically conveyed as the L/D ratio. Thus, a low of 20/1 to 24 to 1. L/D’s ratios being a common length to diameter ratio can get as high as 30/1 here at Keller Products in order to get the best dispersion when it comes to color.
We have custom-made drilling stations that can be positioned to provide any type of design scenario for holes.
We can also provide custom laminations and would be happy to send you samples upon request. We currently have seven lamination stations that can handle many different types of custom plastic extrusions.
We offer custom packaging and are currently packaging an extruded profile product that is sold to a “Big Box” Company.
We have many customers we provide inventory management for and we stock their Custom Plastic Extrusions so they can pull any number of units and dropship them anywhere in the world. Keller Products is a versatile company that provides a number of capabilities and products backed by years of experience, allowing us to work with customers coming from various industries. We serve markets involving aerospace, consumer and retail, healthcare and medical, military, automotive, electrical, industrial, and recreational and sporting goods.
Keller Products runs all materials including, foamed profiles, elastomeric profiles, co-extruded profiles, and almost anything you can dream up. We even tackle the toughest designs with the more exotic materials. Be it simple, complex, hollow, coextruded, or embossed, our team of experts can customize it for you. In addition, our specialists understand that no two jobs are the same and we plan to keep it that way. This means that here at Keller Products we can offer you any number of products for your design needs.
We offer complete Engineering Design services and can even offer up 3D print prototypes, yes, even in Extrusion! With our focus on innovation, we can assist you in designing virtually any plastic profile and even develop new types.
We have been the leader in the latest extrusion technology and we pride ourselves in offering you a quick solution for your extrusion needs. We offer support in any decisions you make and provide assistance in addressing all designing and manufacturing issues. Keller Products is definitely more than just a leading plastic extrusion house because we also aim to be your business partner.
We deliver innovation. We guarantee Quality, Service, and Value Every Day!
How Much Does Plastic Extrusion Cost?
There is no short answer to the cost of customized plastic extrusions because of the different possibilities available for each project. Total cost is dependent on what your final product is, how much you need, and the process required for your plastics to be extruded. There are multiple processes and a wide range of custom plastic extrusions available that allow us to create products with different requirements. Not all companies utilize the same extruding processes either. Contact us for the best quote based on your custom plastic parts needs!
Why Keller Plastics Is The Best Custom Plastic Extrusion Company
Keller Plastics has tackled some of the most challenging requests for custom plastic extrusion and has risen to the challenge each time. We want to help you with your custom plastics project, regardless of the product type or how the plastic is extruded. We have serviced just about every industry with our custom plastic extrusion such as Aerospace, retail, medical, and automotive. We offer custom designs and materials to meet your needs as the leader in plastic extrusion.
Our engineers will design the final plastic product to meet your specs and we will customize the color of the parts you want during the custom plastic extrusion process. At Keller Plastics, we guarantee that you receive quality service and value. Call us today for a quote on your custom plastic extrusion project.
We Specialize In Custom Plastic Profile Extrusions
With over four years in the custom plastic extrusions industry, Keller Plastics has been a leader in custom extruded plastics production. We have acquired a broad and solid client base through unrivaled custom plastic extrusions workmanship and exceptional customer service.
Keller Plastics is an experienced custom plastic profiles manufacturer and supplier of custom extruded plastic products among numerous sectors in various industries. We offer a wide range of services, including:
Rapid Prototyping and 3-D Printing
Free Design Engineering
Coextrusion Manufacturing
Fabrication Manufacturing
Embossing/Lamination Manufacturing
Color Matching
Injection Molding Manufacturing
Punching/Notching and Packaging Manufacturing
Custom and Recycled Plastic Manufacturing
We offer a comprehensive range of stock custom extruded plastic profiles and channels that are ready to use as is or customized to your particular specifications. With several custom plastic extrusion production lines and numerous co-extrusion lines, Keller Plastics is more than capable of supplying any order size, from small prototype samples to large productions.
Keller Plastics is a team of extensively trained and experienced custom plastic extrusions experts. Since our establishment over 40 years ago, our clients have always had confidence in our ability, knowledge, and experience to match or exceed their need for custom plastic extrusions.
To maintain our unrivaled quality of craft and impeccable reputation, we only use the most advanced custom plastic extrusions equipment. Additionally, our team of specialists all have the necessary technical custom plastic extrusions expertise to design and manufacture your product to your precise requirements.
On top of superior workmanship, Keller Plastic also prides itself on excellent customer service and satisfaction. At Keller Plastics, we have the extrusion solution for all your custom extruded plastic needs. We have always been and always will be committed to providing superior quality, and we ensure you’ll be impressed with the end product.
Trusted Manufacturer For Custom Extruded Plastic
Regardless if you’re at the idea stage of your custom plastic extrusions project or are seeking better solutions for your existing custom extrusions needs, you can rest assured Keller Plastics is the help you need. Here are a few custom plastic extrusions services we offer:
⦁ Plastic Extrusion Design Engineering: Our engineers at Keller Plastics can help you design your part and ensure a highly durable end product.
⦁ Plastic Extrusion Tooling: Keller Plastic is equipped with a cutting-edge tool room with numerous axis wire EDM and CNC machining centers to ensure your dies are to your precise requirements.
⦁ Co-Extrusion and Tri-Extrusion: Keller Plastics provides multi-colored plastic extrusions and a broad range of dual and tri-extruded products.
⦁ Plastic Extrusion Fabrication: A few secondary fabrication processes that Keller Plastics provides include de-burring, punching, routering, drilling, and product assembly.
Keller Plastics has been an industry leader in custom plastic extrusions for over 40 years delivering unmatched quality and value. We offer an extensive range of plastic extrusions capabilities with expert engineering and design services to meet your custom extruded plastic needs at competitive prices. Don’t hesitate to contact Keller Plastics for all your plastic extrusions needs to customization!
Diverse Applications of Custom Plastic Extrusion
Custom plastic extrusion is a foundational manufacturing technique across many industries, offering unparalleled versatility in product development. Through this process, Keller Plastics crafts an extensive range of custom-designed profiles, each tailored to meet specific industry standards and client specifications. Our commitment to quality and innovation enables us to transform a simple concept into a functional, high-quality product with precision and efficiency.
Industrial and Construction Applications
Custom plastic extrusion is instrumental in the industrial and construction sectors, providing essential components that contribute to the functionality and integrity of various structures and systems.
- PVC Pipes and Conduits: Specifically designed for electrical and plumbing systems, these extrusions offer superior durability against corrosion and chemical exposure, ensuring long-term reliability in infrastructure.
- Window and Door Frames: Crafted for enhanced insulation properties, these profiles contribute to energy efficiency while offering resistance against weathering, supporting sustainable building practices.
- Insulation Materials: Tailored for both thermal and acoustic insulation, these materials play a crucial role in creating energy-efficient and comfortable living and working environments.
The applications within industrial and construction settings underscore the significance of custom plastic extrusions in developing components that meet rigorous standards for safety, sustainability, and durability.
Automotive and Medical Components
In the automotive and medical industries, custom plastic extruded profiles are essential for manufacturing components in precision that meet exact specifications for functionality, safety, and regulatory compliance.
- Automotive Trims and Seals: These extruded parts are critical for sealing and finishing elements in vehicles, offering protection against environmental elements and contributing to the vehicle’s overall aesthetic and noise reduction capabilities.
- Medical Tubing: This includes specialized tubing for dialysis, intravenous lines, and catheters, where precision, biocompatibility, and flexibility are paramount. Custom extruded medical tubing ensures safe and effective delivery of medical treatments.
Keller Plastics’ proficiency in creating automotive and medical components through custom plastic extrusion profiles highlight our commitment to quality and safety, addressing the stringent demands of these high-stakes fields.
Consumer Products and Recreational Items
The versatility of custom plastic extrusion extends into consumer products and recreational items, where innovation meets daily life in functional and enjoyable ways.
- Sports Equipment Parts: Including components for bicycles, helmets, and fitness machines, these parts benefit from the durability and lightweight properties of custom-extruded plastics, enhancing the safety and performance of sports equipment.
- Home and Garden Products: From durable fencing posts and deck railings to flexible garden hoses, custom plastic extrusion produces various home improvement products that combine practicality with aesthetic appeal, enriching home and garden spaces.
Through these diverse applications, Keller Plastics demonstrates the extensive capabilities of custom plastic extrusion in producing specialized, high-quality products that serve essential roles in everyday life and industry-specific applications.
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