Reducing Production Costs with Custom Plastic Extrusion Solutions

Cost reduction in custom plastic extrusion involves a balance of thoughtful design, efficient production practices, and strategic material choices. Collaborating with experienced manufacturers and continually optimizing processes will help achieve cost-effective solutions without compromising product quality.

Reducing production costs in custom plastic extrusion projects requires strategic planning, efficient processes, and thoughtful design choices. Let’s take a closer look at how costs can be reduced.

Optimize Design for Manufacturability

Simplify Profiles

• Minimize intricate shapes, sharp corners, or unnecessary complexity in the design.
• Uniform wall thickness reduces material usage and prevents manufacturing issues.

Incorporate Standard Features

Use commonly available features and materials that require less custom tooling.

Adjust Tolerances

Avoid over-specifying tight tolerances unless necessary, as they increase production difficulty and costs.

Cost-Effective Materials

Select Suitable Plastics

Choose materials that meet performance needs without being over-engineered. For example, use PVC instead of polycarbonate for non-load-bearing applications.

Leverage Material Alternatives

Explore blended or recycled plastics for lower costs, provided they meet quality standards.

Reduce Additive Usage

Limit expensive additives (e.g., UV inhibitors, colorants) to only essential levels.

Efficient Tooling

High-Quality Dies

Invest in durable and precision-engineered dies to ensure consistency and minimize downtime for repairs.

Multi-Cavity Tooling

For high-volume production, multi-cavity dies can extrude multiple profiles simultaneously, increasing output and reducing per-unit costs.

Streamline the Extrusion Process

Optimize Production Parameters

Adjust temperature, pressure, and speed to ensure efficient extrusion without material waste or defects.

Minimize Setup Time

Use quick-change systems for dies and tooling to reduce machine downtime between production runs.

Automate Processes

Implement automation for material feeding, cooling, and cutting to reduce labor costs and improve consistency.

Reduce Waste & Scrap

Material Recycling

Collect and reprocess scrap material to reuse in production when feasible.

Consistent Quality Checks

Monitor production closely to detect issues early and reduce waste caused by defective parts.

Precision in Cutting

Use accurate cutting tools to minimize off-cuts and ensure consistent product length.

Partner with an Experienced Manufacturer

Expertise

Work with a manufacturer experienced in optimizing extrusion processes and materials for cost efficiency.

Specialized Operations

Delegate post-processing or specialized tasks (e.g., co-extrusion, finishing) to reduce specialized or unusual in-house costs.

Energy Efficiency

Up-to-Date Equipment

Use modern, energy-efficient extrusion machines that reduce electricity usage.

Process Optimization

Run machines at optimal speeds to balance energy consumption with output efficiency.

Custom Extrusion with Inplex

Looking for quality custom extrusion products and services? Inplex is one of the leading custom extrusion services in the US, with over 50 years of experience. We pride ourselves on our ability to put the right talent and technology in place to perform the best possible job for our clients.

We own a 42,000 sq. ft. facility in Naperville, Illinois, that is temperature-controlled and features an environmentally friendly closed-loop water cooling system. If you have specific needs or questions, don’t hesitate to contact us!