This training package is designed to deliver comprehensive training to twin screw extrusion operators, technicians, supervisors, and managers. The courses in this package cover extruder operation, plastic materials, and math skills.
package includes:
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
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
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
Twin Screw Extrusion
Our Twin 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 Twin Screw Extruders, these training courses provide specific information for profile, pipe, or compounding extruders. Whether you use a co-rotating or counter rotating extruder, the information will relate to the equipment, materials, and processes operating at your facility.
This training series with help teach any employee on concepts relating to the machine, material, process, quality, startup, shutdown, problem solving, material handling as well as the correct terminology associated with Twin 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 Twin 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 Twin Screw material feeding and conveying
Melting processes for both programmed and fixed screw designs are covered
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
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.
Certification Exam for Twin Screw Extrusion Professionals
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 Twin Screw Extrusion. We also offer a Single Screw Extrusion version.
Who Should Consider Certification?
Machine operators, technicians, supervisors, engineers, managers… Anyone working in the extrusion industry should participate in our certification program. Managers should strongly consider offering this certification as a means of benchmarking — to ensure they have a confident and capable production team.
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, prior to retaking the exam.
Question Categories:
Extrusion Safety
Basic 5S & Housekeeping
Twin Screw Extrusion
The Extrusion Process
Product Quality & Troubleshooting
Plastics Material Basics
Material Handling
Basic Dimensions & Mathematics
How to Prepare for Certification:
Although preparatory training is not necessary to achieve certification, participation in Routsis’s structured training programs can greatly increase a candidate’s chances of successfully completing the examination.
We offer an online training package specifically geared toward helping individuals prepare for and pass this extrusion certification exam. For small and mid-sized companies, our Professional Certification Portals provide a convenient, cost-efficient way to train, benchmark, and certify your employees. Larger companies should consider our exclusive RightStart™ in-house training system.
