How are recycled plastic lumber and other products manufactured and is there more then one process used?
Recycled plastic lumber and other of our plastic products are manufactured using two primary processes. One is called continuous extrusion and the other flow molding. Although both use an extruder in the first stages of the process, from that point on they are different. Continuous extrusion is a linear process, whereby the softened plastic exits the extruder moving through a forming tool creating the desired board shape (2×4, 2×6,etc) or a, contoured bleacher seat. The plastic is pulled very slowly down a line sixty or more feet in length periodically sprayed with water cooling as it moves. At a specific point, the plastic is automatically cut into the required board lengths and stacked to finish cooling. The benefit of this process (although limited to linear shapes), is board lengths can exceed 30-40’ feet. Flow molding is a process whereby the material exits the extruder flowing into an enclosed mold the shape of the desired end product – a wall mount bracket, mall end or, desired
