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Marriott Austin Downtown
August 18-19, 2026
Presented by Gardner Business Media
Day 1: Tuesday, August 18th
Breakfast 7:30 am - 8:30 am
8:30 am - 9:00 am
Design of Highly Streamlined Extruder Screw to Minimize Formation of Gels and Black Specks
Speakers: Chris Rauwendaal | Rauwendaal Extrusion Engineering Inc.
Co-Author: Ned Uzelac | Performance Feed Screw Inc.
Defects such as gels and black specks are common challenges in sheet and film extrusion. The problem is more pronounced in film extrusion because small defects are highly visible in thin film. This presentation will describe the development of a highly streamlined extruder screw for single screw extruders and explain the principles behind it. This screw is called the Zero-Gels screw. A patent application for the Zero-Gels screw is pending. Detailed results of testing the Zero-Gels screw in blown film extrusion will be presented. Also, results of 3D CFD simulations of the Zero-Gels screw will be presented and compared to actual extrusion test results.
9:00 am - 9:30 am
Handling of Sheet and Film Regrind in your Process: Material Handling and Storage
Speakers: Joseph Dziedic | ACS Group
Producing quality color runs, economically, with minimal downtime is difficult to achieve. Stocking hundreds of custom colors to meet customer demands is expensive, causes raw material waste and takes up considerable valuable warehouse space.
9:30 am - 10:00 am
Cast Film Die Design Principles
Speakers: Sam Iuliano | Nordson EDI
Extrusion die systems for cast film include modern flow distribution channels, based on polymer rheology, which provide uniform distribution, flow streamlining, and coextrusion stability. Discussion topics include the basics of flow distribution channels, materials of construction, automatic lip adjustment systems, deckling systems, and coextrusion feedblocks.
Break 10:00 am - 10:30 am
10:30 am - 11:00 am
Troubleshooting Common Issues in Film Coextrusion
Speakers: Karen Xiao | Macro Engineering Inc.
Attendees will gain practical insights into designing for future capacity expansion while minimizing capital costs.
11:00 am - 11:30 am
Technical Benefits of Adding a Melt Gear Pump and Static Mixer to a Sheet Extrusion Line
Speakers: Joseph Mitchell | PSI Polymer Systems
The PLC or DCS represents the most critical and complex element of any control upgrade, serving as the central processor for machine coordination, interlocks, safety, and communications. As extruders become more sophisticated, control software has evolved to include advanced diagnostics, tighter process control, and seamless integration with plant-wide systems.
11:30 am - 12:00 pm
Machine Direction Orientation of Polymeric Films
Speakers: Steve Post | Windmoeller & Hoelscher
The orientation of polymeric films dates back to the 1930s when German scientist I.G. Farben oriented polystyrene film to make a stable, low-loss dielectric capacitor film. Subsequent decades saw developments in oriented polyamide fibers for stockings and parachutes during WWII. In the 1950s it was found that machine-
direction oriented films could be used for heat shrinkable sleeves. The big breakout for oriented polymers came in 1955 when E.I. Dupont commercialized their Mylar or biaxially oriented PET film. Ten years later, Showa Polymers in Japan introduced the first biaxially oriented polypropylene. Mono-oriented films were still used, but more for niche applications. Their big breakthrough came in the early twenty teens when the flexible packaging market began to look for BOPET replacements to make recyclable laminates or so-called mono-material packages. Since that time, more than two hundred MDOs have been installed globally. The presentation focuses on the physics behind the orientation of polymers, machinery design for different materials and how to optimize properties and control the process. Data is presented showing improvements to physical properties as well as the gaps that remain for creating a pure mono-material package.
Lunch 12:00 pm - 1:00 pm
1:00 pm - 1:30 pm
Optimization of Sheet and Film Dies Using Flow Simulation Software
Speakers: Mahesh Gupta | Plastics Flow LLC
Designing dies for sheet and film extrusion presents the primary challenge of achieving a uniform velocity distribution at the die exit, which is crucial for minimizing thickness variation in the extruded product. For multilayer coextruded sheets and films, there is an additional challenge of maintaining a consistent layer thickness
across the extruded polymer. In sheet and cast film extrusion, a flat die with a coat-hanger-shaped manifold is commonly employed. The manifold ensures uniform velocity at the exit by effectively distributing the polymer across the die. Blown films, on the other hand, are extruded using a spiral mandrel annular die. The spiral groove in the mandrel overlaps multiple melt streams, eliminating weld lines and promoting circumferential flow uniformity. Flow simulation software, capable of accurately predicting velocity, pressure, temperature distributions, and layer structures in extruded sheets and films, serves as a powerful tool for designers of both coat-hanger and spiral mandrel dies. Unlike profile extrusion dies, which are highly customized, the geometries of coat-hanger and spiral-mandrel dies are well-established in the literature and can be easily parameterized using 3D CAD software like SolidWorks or Autodesk Inventor. As a result, die optimization software, which can automatically determine optimal values of the geometric parameters, can significantly accelerate die development for sheet and film extrusion. This presentation will discuss key design parameters for coat-hanger manifold and spiral mandrel dies. The polyXtrue software is utilized to accurately predict the velocity, pressure, temperature, and layer structure in the dies. Furthermore, die geometries for both coat-hanger manifold sheet dies and spiral mandrel blown film dies are optimized using the optiXtrue software. Results from these flow simulations and die optimizations will be presented and analyzed
1:30 pm - 2:00 pm
The Molecular Homogenizer: Deterministic Elongational Mixing in a Single-Screw Metering Section
Speakers: Keith Luker | Randcastle Extrusion Systems
Deterministic elongational flow has evaded conventional single-screw extruder designs, which are dominated by shear-controlled transport and compression-driven mechanisms. This paper describes a single-screw metering architecture that produces primarily elongational deformation through
geometry rather than compression. The architecture employs three channels (C1, C2, C3) and two shear anchors (SA1, SA2) that supply and remove material in a controlled manner. The resulting flow is deterministic, primarily elongational, and overall trilongational, combining axial and rotational components. When multiple metering elements are used in sequence, recombination and reorientation between elements introduce multiplicity, enabling cumulative elongational deformation. The flow architecture, mechanisms, and appropriate applications for this type of mixing are described. With this elongational architecture, the single screw advances from high pressure pump to a high pressure compounder.
2:00 pm - 2:30 pm
Driving Extrusion System Innovation: Powertrain Optimization for High-Performance Sheet Systems
Speakers: Tom Limbrunner | PTI Processing Technologies International
As sheet extrusion lines face increasing demands for higher throughput, broader material flexibility, and improved energy efficiency, traditional "one-size-fits-all" powertrain designs are becoming obsolete. This presentation explores innovative, data-driven approaches to optimizing the
extruder powertrain—specifically focusing on the critical, interdependent relationships between motor base speed, gearbox ratios, and maximum required production rates. We will analyze how to properly match drive components to avoid limiting line output, ensuring the system operates optimally across a diverse range of polymers. Key topics include maximizing screw rpm flexibility through advanced motor selection, calculating optimal reduction ratios to balance torque and speed requirements, and leveraging vector-duty motors for extended range capabilities.
Break 2:30 pm - 3:00 pm
3:00 pm - 3:30 pm
Driving Productivity with Motor & VFD Solutions
Speakers: Darryl Rouselle | ABB
Subtopics:
- Unlocking = Efficiency
– VFD & Motor Integration *Motor trend
– PM, RMsyn, etc * Integration
– grounding, DV/DT
- Reliability & Safety * VFD feature advancement Regen/ULH, zero speed holding torque, silicon carbide(?), etc *Industrial communication
– option card, embedded, OPC U* Safety
– STO, safety module, SIP/Profisafe
- VFD and Motor Innovation * Integration with controller & HMI * Pre-engineered solution
3:30 pm - 4:00 pm
Troubleshooting Gels in Single Screw Extrusion and Film processes
Speakers: James Odom | Graham Engineering Company
An all too common issue that extrusion and film manufacturing face at some time period is issues with “gel” defects. These can be described as any small defect that distorts a film product visually and affects the performance and runnability of a
process. Eliminating these defects can be challenging, expensive and time consuming since significant scrap can be produced in a short period of time. Sources vary and include, but are not limited to contaminants, carbon, unmelted resin, high molecular weight material that isn’t crosslinked, and highly oxidized materials. Sources for these defects can originate from the resin manufacturer and from the process. Normally a system set up proper filtration produces a very clean product that can be maintained with proper maintenance. The focus of this presentation will cover first level countermeasures for this problem and more extensive solutions.
4:00 pm - 4:30 pm
AI Automation for Short Run Color Sheet Extrusion Processing
Speakers: Douglas Brownfield | Ampacet Corporation
Sheet extrusion manufacturers are facing the challenges of JIT orders which require shorter runs. Producing quality color runs, economically, with minimal downtime is difficult to achieve. Stocking hundreds of custom colors to meet customer demands is expensive, causes raw material waste and takes up considerable valuable warehouse space. Using powder pigments to formulate colors is labor intensive and causes inconsistencies in color due to improper manual weighing. Making
adjustments during production using powder pigment batches causes downtime and lost production. Using pelletized mono pigments vs. powder pigments can offer lower manufacturing cost while enhancing quality due to greater uptime. AI equipment automation now exists that allows automated, accurate color weighing & blending without labor using a small palette of pelletized mono pigments or single pigment dispersions. Make color adjustments and corrections in-line and in real-time.
Takeaways:
1. Discuss the challenges of maintaining a profitable sheet extrusion manufacturing operation with customers growing demands of smaller lots.
2. New AI manufacturing technologies that eliminate labor and lowers production cost associated with running small lot color sheet runs.
3. Create a manufacturing competitive advantage using AI automation.
4:30 pm - 5:00 pm
The Importance of Upgrading Controls on Twin-Screw Extruders
Speakers: Al Bailey | ENTEK Manufacturing LLC
As extrusion equipment across the industry continues to age, obsolete control systems are increasingly limiting reliability, maintainability, and process capability. While mechanical components often remain serviceable for decades, legacy PLCs, DCS platforms, drives, and HMIs face hardware discontinuation, unsupported software, and growing cybersecurity risks. This presentation exists to help processors, engineers, and maintenance teams understand when control systems become a liability—and how targeted upgrades can restore performance while extending equipment life.
Day 2: Wednesday, August 19th
Breakfast 7:30 am - 8:30 am
8:30 am - 9:00 am
9:00 am - 9:30 am
Troubleshooting and Optimizing Sheet and Film Extrusion Operations Using an Advanced Real Time Monitoring System
Speakers: John Christinao | Davis Standard LLC
Trouble shooting extrusion system problems will be presented using an advanced continuous monitoring system. The presentation will focus on identifying and correcting extrusion issues including product quality, extruder performance and equipment problems.The presentation will show how digital transformation tools using cloud-based analytics can help you leverage your real time production data to help guide trouble shooting and improving decision -making regarding predictive and preventative maintenance.
9:30 am - 10:00 am
Coextrusion Troubleshooting: Case Studies
Speakers: Christine Ronaghan | Cloeren Incorporated
This discussion will present several real life challenges in cast film / sheet coextrusion along with troubleshooting techniques and remedies for each.
Break 10:00 am - 10:30 am
10:30 am - 11:00 am
Managing Melt Temperature, Pressure and Viscosity in a Twin Screw Extruder Integrated into a Film/Sheet System
Speakers: Charlie Martin | Leistritz Extrusion
Using pelletized mono pigments vs. powder pigments can offer lower manufacturing cost while enhancing quality due to greater uptime.
11:00 am - 11:30 am
Application of Automation Practices in Film Extrusion
Speakers: Kelly Chalmers | Applied Manufacturing
Traditional automation practices are rooted in rule-based systems, predefined instructions, and deeply embedded, rigid programming designed for high-volume, repetitive tasks. These practices focus on consistency and speed, often integrating directly into backend systems rather than mimicking user interfaces. Conventional automation integration can bring many valuable aspects to plastics manufacturing environments. But there are other times
when challenges specific to this industry require different strategies in how and when automation is best applied to manufacturing processes. This session will cover key considerations in plastics automation, including product variability, system flexibility, and the need to maintain safe and effective manual interaction. Topics will include approaches such as autonomous mobile robots (AMRs), integrated inspection, and flexible handling systems that can adapt to a wide range of roll formats. It will also explore how we can plan to leverage the developing AI capabilities into future automation strategy. By considering automation as it applies to the needs of the process, manufacturers can improve consistency, optimize interactions with manual operations, and better support the performance of high-speed equipment.
11:30 am - 12:00 pm
You May Not Need New Sheet Equipment
Speakers: Mike Mitchell | Extrusion Systems
Don’t spend millions on new sheet equipment, lets maximize the productivity of your existing lines. A professional evaluation of your existing equipment can pinpoint the causes of lost productivity and make recommendations to get your line back to or exceed like new productivity.
Lunch 12:00 pm - 1:00 pm
1:00 pm - 1:30 pm
Temperature and Pressure Control in Single Screw Extruders
Speakers: Ryan Pearce | Krauss Maffei
Managing Pressure and Temperature in Single Screw Extrusion Processing is essential for producing a consistent, quality final product. Optimizing Screw design, process heating zones, and melt delivery are key components in managing pressure and temperature. Monitoring and adjusting process conditions based on extruder and product feedback is key in maintaining a stable process. This presentation will provide practical guidance on how to control and maintain consistent processing conditions for continuous production.
1:30 pm - 2:00 pm
Screw and Barrel Designs for Film & Sheet
Speakers: Cheryl Sayer | Xaloy
Screw and barrel design critically influence melt quality, output stability, and product uniformity in film and sheet extrusion. Optimized geometry, temperature control, and material-specific configurations improve mixing, reduce degradation, enhance processing efficiency, and ensure consistent product quality in extrusion operations.
2:00 pm - 2:30 pm
In-Line Gauging in Sheet and Film Extrusion
Speakers: Grant Harpole | AIS Gauging
The presentation will discuss in detail how a melt pump operates, review important operating parameters, and discuss how removing the pressure generation operation from the extruder, improves the die pressure , minimizing output pulsation, improving dimensional control, reducing resin consumption/waste, lowering melt temperature, and helping to increase production rate.
Break 2:30 pm - 3:00 pm
3:00 pm - 3:30 pm
Melt Filtration Solutions for Challenging Applications
Speakers: Monika Gneuss | Gneuss Inc.
Melt filtration is a requirement for most extrusion lines today and screen changers or other filtration equipment can have a significant impact on the production line efficiency and end product quality. Reclaim use and desired filtration fineness play an important role when choosing the right filtration technology. Rotary Melt Filtration systems can offer solutions for challenging applications. Several case studies will be presented, including recycling with high contamination levels and double filtration for very fine filtration fineness requirements. The significance of material costs, screen costs and backflushing losses will be explored.
3:30 pm - 4:00 pm
Retrofitting Extrusion Lines with Melt Pumps
Speakers: Pablo Vaca | Maag Reduction Inc.
Melt pumps are internal gear pumps, positive-displacement devices, that supply a fixed volume and therefore a constant output rate. Adding a melt pump downstream from the extruder, significantly improves process stability, enhances product quality, and allows the extruder to increase line production.
4:00 pm - 4:30 pm
Viscometer Measurement in Recycled Plastic Extrusion
Speakers: David Malloy | Promix Solutions
Using powder pigments to formulate colors is labor intensive and causes inconsistencies in color due to improper manual weighing. Making adjustments during production using powder pigment batches causes downtime and lost production.
4:30 pm - 5:00 pm
Improved Sheet Die Design for More Balanced Flow
Speakers: Randy Brown | Extrusion Consulting, Inc.
Sheet extrusion has a fundamental problem in that it takes time to spread out to the ends of a wide sheet. This leads to long color and material changes. Or a shut down and clean out the die for every change. For PVC this can also mean burning on the edges due to high residence time. This means shorter run times and likely higher material cost due to the need for higher stabilizer levels. An innovative design methodology and improved design is presented to correct these known problems.
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