1. TPE Single-Screw Extruder: As we discussed, this is the heart of the line. It melts the raw TPE pellets and ensures a consistent flow of material.
2. Precision Flat Die Head: The molten TPE flows from the extruder into the die head. This tool is precisely machined to shape the material into a flat band with the exact width and thickness you require for your product.
3. Cooling System (Water Bath): The hot, newly formed TPE band immediately enters a cooling water bath. This station is critical for solidifying the band and locking in its dimensions. Proper cooling prevents warping and ensures a smooth surface finish.
4. Haul-Off Machine: This machine uses rollers to gently and consistently pull the cooled band away from the die. The speed of the haul-off machine is carefully calibrated with the extruder’s output to control the final thickness and tension of the band.
5. The Final Cutter: After the band is cooled and stable, it passes through an automatic cutter. This station uses a precise blade to cut the continuous band into any desired length, whether it’s a short tourniquet or a long resistance band.
6. The Semi-Manual Packaging Station: This is the most misunderstood—and most critical—part of the entire process. Due to TPE’s high elasticity and the subtle variations between different material grades, automatic winding is not recommended. Attempting to automatically roll the bands can stretch the material, ruining its elastic properties and leading to a high defect rate.
The proven, practical method used by our most successful clients is a cutter followed by a semi-manual packaging station. Here, workers take the perfectly cut bands and roll or fold them for packaging. This ensures every single product meets quality standards. We can even help you design simple auxiliary tools, like rolling jigs, to make this process fast and efficient for your workers.