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Film Extrusion of Crambe abyssinica/Wheat Gluten Blends

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Applying the Taguchi Method to Improve Key Parameters of Extrusion Vacuum-Forming Quality.

Dyi-Cheng Chen¹, Der-Fa Chen¹, Shih-Ming Huang²

¹Department of Industrial Education and Technology, National Changhua University of Education, No. 1, Jin-De Road, Changhua City 500, Taiwan.

|April 27, 2024

Summary

This study optimized plastic extrusion vacuum-thermoforming using the Taguchi method to control product weight and thickness. Key factors identified reduce variability, leading to significant cost and energy savings in manufacturing PP cup lids.

Keywords:

Delphi technique Taguchi method extrusion molding quality control

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Area of Science:

Manufacturing Engineering
Materials Science
Quality Control

Background:

Plastic extrusion vacuum-thermoforming requires precise control over thickness and weight for cost and energy efficiency.
Identifying critical influencing factors is essential for process optimization.
Existing methods lack robust parameter identification for minimizing variability.

Purpose of the Study:

To identify optimal key parameters for cost reduction and energy savings in plastic extrusion vacuum-thermoforming.
To improve the quality and reduce process variability in polypropylene (PP) cup lid manufacturing.
To establish robust production conditions for enhanced product quality control.

Main Methods:

Delphi technique employed with expert scholars to identify crucial influencing factors.
Taguchi method utilized for experimental design with an L18 orthogonal array.
Signal-to-Noise (S/N) ratio analysis to determine optimal control factor combinations.

Main Results:

Five key control factors identified: PP material ratio, T-die lips adjustment, mirror wheel temperature stability, molding vacuum pressure time, and mold area design.
Optimized parameters significantly improved product quality and weight control, achieving 3.4 ± 0.1 g.
A 2.6% cost saving in product weight was realized, contributing to environmental and energy efficiency goals.

Conclusions:

The study successfully identified optimal parameters for plastic extrusion vacuum-thermoforming, minimizing variability and enhancing product quality.
The developed quality control model and experimental design are applicable to various plastic and bio-based materials.
Significant cost savings and contributions to environmental conservation and energy efficiency were demonstrated.