Extrusion line cost optimization

Extrusion line cost optimization

At the manufacturing stage of a continuous plastic extrusion line, certain choices prove to have a significant economic importance with a view to production cost optimization. Selecting the right filtration system and screen changer can move the needle on quality performance and cost effectiveness.

(Questo articolo è disponibile in italiano / This post is available in italian language)

In continuous plastic extrusion, focussing on how to optimize the production costs of high-quality BOPP, BOPET, PE, PP and PET film is essential.


The production of high-quality impurity-free film offers the chance to orient extrusion end products to food, medical and high-end applications. Therefore, the production of film intended for the above applications offers the chance to target a market that maximises end product sales revenues.


However, important decisions must be taken to manufacture impurity-free film with a view to cost effectiveness and revenue maximization. A list follows:

a. Virgin Raw Materials

Virgin or low-contamination raw materials are essential for high-purity plastic applications – i.e., the involved decision is to procure and use high-quality polymers.

b. Mixing with Recycled Plastics

On the other hand, the use of virgin raw materials significantly impacts on costs. Mixing virgin raw materials with a percentage content of low contaminant recycled plastic is a cost-effective solution offering efficient environmental impact in the production of new plastics. Several regulations already require plastic production to include a percentage of recycled raw materials. In other words, adding a percentage content of recycled raw material to virgin polymers offers raw material procurement and extrusion line management cost reduction.

c. The Right Screen Changer

When recycled – anyway not virgin – plastic is used in the extrusion process, an accurate impurity screening is required.

In fact, if recycled plastic is included into the extrusion process – even if in limited quantities – the extrusion system must be equipped with a suitable screen changer to offer filtering levels exceeding 10 microns, depending on end applications.

In this case, the screen changer filtering capacity is essential to provide high-end product quality and production cost-effectiveness and profitability.

d. A Continuous and Self-Cleaning Screen Changer

Given the above, how to choose the right screen changer? The best choice is a continuous self-cleaning screen changer, i.e., a screen changer that does not require the extrusion flow to be stopped and that relies upon automatic waste disposal process. Furthermore, a minimized – preferably zeroed – maintenance is preferable, offering uninterrupted operation.

E. Low-Investment Screen Changers

Last but not least, it is necessary to choose a screen changer that does not require high investments, besides not involving significant maintenance costs. For this purpose, simple operation, sturdy structure, and no need for any motor or hydraulic or pneumatic components – which are subject to failures, and tear and wear, and frequently require maintenance interventions – are essential. That is to say, the simpler, the better.


The AP series by Cofit is the best-in-class solution for a profitable production of high-quality film. Cofit AP manual, continuous and self-cleaning screen changers are suitable for the production of film intended for the most varied applications – food and medical ones included – and can be used with most of thermoplastic polymers – in particular, BOPP and BOPET. Cofit AP screen changers require minimized maintenance interventions and extremely low investments.

As far as structure is concerned, Cofit AP screen changers are amazingly simple and sturdy; in particular, AP does not need any motor or hydraulic or pneumatic components – this means that operation interruptions for maintenance interventions are minimized, and life cycle is extended. Besides, AP screen changers combine an unrivalled filtering strength and capacity as they can operate at over-500-bar pressure and offer filtering levels exceeding 10 microns. Have a look at AP technical data sheet.

Cofit deals with research, designing, manufacturing and distribution of continuous screen changers, either automatic or manual, intended for any sector and process material, in particular BOPP and BOPET film. Contact us to see how a manual and continuous screen changer can optimize your plastic extrusion process.

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