Professional Certification Portal for Single Screw Extrusion`

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A Professional Certification Portal from Routsis Training delivers essential eLearning to your entire workforce. Their newfound knowledge and skills translate directly into increased productivity and profitability for your company.

Your new “Cert Portal” comes pre-configured with our most effective online training courses. Employees start with the basics and quickly progress to intermediate and advanced topics; teaching them the skills they’ll need to consistently deliver quality products to your customers.

These preconfigured portals provide the most cost-effective way to train your entire workforce.

Single Screw Extrusion Fundamentals

Math for Extruders

This two-part online training program was created for all personnel within the extrusion industry who would like to expand or fine-tune their math skills.

Part 1

  • Whole Numbers, Negative Numbers and Decimals
  • Using a Calculator
  • Addition, Subtraction, Multiplication and Division
  • Rounding Numbers and Significant Figures
  • Formulas, Equations and Order of Operations

Part 2

  • Metric and Imperial Units
  • Length and Distance
  • Area, Volume & Flow
  • Weight, Mass and Force
  • Conversions
  • Understanding Percentages
  • Calculating Tolerances

Single Screw Extrusion

Our Single Screw Extrusion Series is designed to provide training for anyone working in a production environment. These programs use animation and actual production footage to demonstrate complex concepts. Important safety precautions are stressed throughout these training programs.

Tailored for Single Screw Extruders, these training courses provide specific information for all extruders from blown film to profile extrusion. Whether you use single stage or vented extruders, the information will relate to the equipment, materials, and processes operating at your facility.

This training series with help teach any employee on the concepts relating to the machine, material, process, quality, startup, shutdown, problem solving, material handling as well as the correct terminology associated with Single Screw Extrusion.

Part 1: The Extruder

  • Discusses the drive system of the extruder including the motor and gearbox
  • Introduces the material feed systems used in Single Screw Extrusion
  • Covers the entire screw and barrel assembly including screw design and venting
  • The die and adaptor are presented along with the extruder’s control system

Part 2: Plastic Materials

  • Introduces the plastics industry and the nature of plastic materials
  • Explains complex concepts such as melt viscosity and polymer flow
  • Provides detailed explanations of both shear and shear heating with plastics
  • Covers the behavior of both amorphous and semi-crystalline polymers
  • Gives an understanding of shrinkage, orientation, and degradation

Part 3: The Extrusion Process

  • Explains the mechanics of Single Screw material feeding and conveying
  • Melting processes for standard and barrier screw designs are covered in detail
  • Describes the commonly used types of dispersive and distributive mixing systems
  • Covers the pumping, shaping, cooling, and cutting of the extrudate
  • Cites important safety precautions for working around extrusion equipment

Part 4: Preventive and Corrective Actions

  • Covers common extrusion defects and their typical causes
  • Explains the importance of accurate process monitoring
  • Differentiates between open and closed loop process control systems
  • Ways to adjust the process and detect equipment problems are also covered

Part 5: Startup, Changeover and Shutdown

  • Provides common procedures to start-up and shut-down an extruder
  • Details both upstream and downstream changeovers
  • Die, material, and color change considerations are also covered
  • The importance of safety and cleanliness are stressed throughout this series

Part 6: Quality

  • Defines quality and its importance to the success of extrusion operations
  • Explains the concepts of quality assurance vs. quality control
  • Covers the form, fit, and functionality of the extruded product
  • Critical vs. non-critical extrudate defects are compared and contrasted
  • The importance of meeting the customer’s needs is stressed throughout the course

Part 7: Material Handling

  • Stresses the importance of proper material handling – from delivery to feedthroat
  • Covers various vacuum conveyance and hopper loader systems
  • The problems associated with not drying hygroscopic materials
  • Details ways to blend materials while avoiding material contamination

Part 8: Problem Solving and Troubleshooting

  • Focuses on getting the right answer in the shortest time
  • Easy to follow problem solving steps and rules are detailed
  • The importance of documentation and procedure

Level 1 Certification Training

Understanding Plastics

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.

  • The definition of plastics
  • Polymer classification
  • Material properties affected by processing
  • Proper material handling techniques
  • Processing characteristics of virgin and regrind

Material Drying Technology

Routsis Training’s two Material Drying Technology online courses provide participants with a better understanding of how different polymers are best dried and prepared for reliable processing. These courses show participants how proper plastics material handling and drying is critical to produce a consistent product and process. Course One reviews polymer basics, as well as both hygroscopic and non-hygroscopic polymers – to better convey the importance of properly drying water-sensitive materials.

Material Drying Technology, Course 1

  • Polymer Basics
  • Hygroscopic vs. Non-Hygroscopic Polymers
  • Hydrolysis
  • Purposes of Drying
  • Dewpoint
  • Dewpoint Measurement
  • Dewpoint Sensors
  • Drying Procedures

Material Drying Technology, Course 2

  • Hot Air Dryers
  • Compressed Air Dryers
  • Desiccant Dryers
  • Vacuum Dyers
  • Calculating Material Consumption
  • Calculating Residence Time
  • Calculating Dryer Capacity

Blueprint Reading

The six programs in our online blueprint reading training course develop workers’ abilities to accurately locate and interpret dimensions on engineering drawings. These training programs are based on ANSI standards and incorporate input from a broad industrial cross-section.

The primary audience is production and inspection personnel, supervisors, group leaders, set-up personnel, and anyone who wishes to read engineering drawings.

Course 1: Introduction to Engineering Drawings

  • Explains the purpose of an engineering drawing
  • Distinguish between a detail drawing and an assembly drawing
  • Interpret the drawing scale
  • Explains the purpose of dimensions and tolerances

Course 2: Multiview Drawings

  • The six principal views of a third-angle projection
  • Identify the ISO symbols for third-angle and first-angle projections
  • Auxiliary views, partial views, and enlarged views
  • Determine which line takes precedence over another

Course 3: Sectional Views

  • Determine which portion of the part is shown in section
  • Explain the purpose of section lines and identify the ways in which they are used
  • Identify and interpret the common drafting conventions applied to sectional views

Course 4: Dimensions and Tolerances, Part 1

  • Identify the size and/or location for a given part feature
  • Correctly calculate the tolerance specified for a given part feature

Course 5: Dimensions and Tolerances, Part 2

  • Locate and interpret dimensions specified by chain, baseline and direct dimensioning methods
  • Identify a datum feature and explain its purpose
  • Explain how maximum material condition (MMC) and least material condition (LMC) apply to internal and external features
  • Calculate allowance
  • Identify a surface finish specification

Course 6: Part Feature Specifications

  • Identifies twelve of the most common part features on a drawing
  • How to correctly interpret part specifications

Mechanical Behavior of Polymers

This course details the mechanical properties and behaviors of plastic materials.

  • The mechanical behavior of polymers
  • Stress/strain curves
  • Visco-elastic behavior of polymers
  • Creep and stress relaxation

The 5S System

5S is a critical component of Lean Manufacturing. The 5S system is used by successful manufacturing facilities worldwide. It consists of 5 simple and concise steps – Sorting, Straightening, Sweeping, Standardizing, and Sustaining – that can help your facility reduce clutter and waste and, ultimately, increase efficiency and productivity.

Production SkillSet™

Our online 5S training courses are built on Routsis Training’s exclusive SkillSet™ model. These courses combine clear online training videos and hands-on worksheets. This approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort of their own production environment.

Each unique training course is a blend of the following components:

  • BACKGROUND:
    Your technicians understand the goal of each Production SkillSet™
  • PURPOSE:
    Technicians learn specifically how each Production SkillSet™ applies to their job
  • EQUIPMENT:
    Items are detailed to ensure techs have the tools they need to succeed
  • PROCEDURE:
    Each step is demonstrated so your techs can proceed with confidence
  • WORKSHEET:
    Contains all the information your techs need to succeed with each SkillSet™

Step 1: Sorting

In the 5S System, the Sorting step’s goal is to eliminate all unnecessary items from the immediate workplace. This is done by sorting the workplace to determine what to keep, what to toss, and what to store. This helps prevent clutter from interfering with everyday production activities.

Step 2: Straightening

At the end of the Straightening step, everything in the workplace is neatly organized; resulting in a more convenient and more efficient workplace.

Step 3: Sweeping

In the Sweeping step, the best method for cleaning each selected area in the workplace is determined. A reasonable cleaning schedule should also be determined to ensure the workplace remains efficient, clean and organized.

Step 4: Standardizing

The goal of the Standardizing step is to achieve consistency. A similar appearance and layout should be applied to all workstations whenever possible. This step is often performed after a similar workplace or area within the plant has already been straightened.

Step 5: Sustaining

The purpose of the Sustaining step is maintenance. This is achieved by a review of the workplace and the existing Sorting and Straightening documentation – to ensure the workplace is efficient and up-to-date. This helps identify necessary materials or equipment that have been added to the workplace but have not yet been incorporated into the 5S documentation.

Single Screw Extrusion Professional Certification Exam

Routsis Training’s globally recognized Professional Certification demonstrates a broad-spectrum understanding of the extrusion industry.

In order to attain certification, candidates must have a working knowledge of extrusion safety, machinery, processing, materials, and quality — and demonstrate a solid understanding of current industry best practices. This edition of the certification exam focuses on Single Screw Extrusion. We also offer a Twin Screw Extrusion version.

Who Should Consider Certification:

Anyone working in the extrusion industry should consider participating in our Certification for Extrusion Professionals. For individuals, this certification can help advance their careers and industry standing. Companies should strongly consider offering this certification exam to their employees. A certified workforce gives managers confidence that their team will be able to rise to the challenges of a modern manufacturing environment.

How to Get Certified:

This comprehensive exam is conducted entirely online. The test takes approximately 1.5 hours to complete — with a time limit of 3 hours. Upon completion of the exam, participants are immediately notified whether they’ve passed or not, via email.

Those who attain a passing score will receive their certificate. Those who do not pass receive a detailed report indicating areas in which further improvement is needed.

Question Categories:

  • Extrusion Safety
  • Basic 5S & Housekeeping
  • Single Screw Extrusion
  • The Extrusion Process
  • Product Quality & Troubleshooting
  • Material Handling & Drying
  • Plastics Material Basics
  • Basic Dimensions & Mathematics

How to Prepare for Certification:

Although preparation training is not necessary to achieve certification, participation in Routsis’s structured Extrusion training can greatly increase a candidate’s chances of successfully completing the examination. Most of our corporate customers use Routsis Training’s exclusive RightStart™ in-house employee development system. For individuals and small companies, we offer an online training package specifically geared toward preparing for and attaining certification.