Custom Plastic Extrusions

We do it all! When your design calls for Custom Plastic Extrusions, we can tackle the toughest jobs. We have been doing this for over 43 years! We are experts in Custom Plastic Extrusions.

Plastic Extrusion is a process in which very small pellets are fed into a machine with a rotating screw and a barrel that supplies heat. The small pellets (typically referred to as the “resin”) are slowly heated and melted to form the melt. The melt is then forced or squeezed through a die which forms the shape of the profile. The die may be in the form of a tube, rod, sheet, coating, film or as custom profile.

The heat is then removed and the melt which was created by the melting of the pellets, now takes the shape of the die as a permanent profile. The key to this process is that it is “continuous”.

Other Plastic Processes could make a profile but it would be much shorter than the lengths that are created through the creations of Plastic extrusions.

The beauty of plastic extrusions is that the lengths can be extremely short (less than .250”) or they can be extremely long and/or spooled into lengths of 1,000 feet or more. The machine that is used to create Plastic extrusions can also do many different materials and colors.

There are many post extrusion processes that can be applied to the plastic extrusions such as cutting to length, laminating, punching holes, embossing, and printing.

Call us at (603) 627-7887 for your
Custom Plastic Extrusion needs

The size of an extruder is generally based on the size of the screw. A 1-inch machine is relatively small and contains a screw that is 1 inch in diameter. These machines are typically used for medical products, R & D, and/or expensive materials. The output is generally low, around 50lbs/hr. On the other side of the spectrum, a 6-inch extruder, has a screw diameter of 6 inches and is capable of putting out over 2,500 lbs/hr. The extruder in essence is generally a simple machine in which a screw turns, heat is applied and pellets are melted.

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For over 4 decades, we have manufactured plastic extrusions, plastic extruded products, coextrusions, hollow profiles, recycled profiles, custom profiles, and more. We have the technical expertise on staff (even PhD’s) that includes materials, profile design, Senior Processing Engineers, and a Sales Staff that can answer all of your questions immediately. We run every type of material that is commercially available and we can even have custom formulations produced.

We service every industry today and we are very proud of our customer base in providing custom plastic extrusions. Plastics are our business. Therefore, our manufactured plastic profiles in ABS, PVC, nylon, and polycarbonate are created by no less than industry specialists. There is absolutely no design too simple or too complicated for our team of experts to design or manufacture, which is why offer custom materials and designs to meet your needs when it comes to Custom Plastic Extrusions.

We offer many services that also complement our Custom Plastic Extrusions.  We can custom color any color that you provide us.  We can apply pressure sensitive tape on any design and, with many of the newer technology tapes.  Here at Keller Products, you can expect specially designed screws during the manufacturing of plastic extrusions. The reason being for this engineering feat is in order to provide us the best melt with an ultimate degree of mixing for brilliant color dispersion. If you don’t already know, the ratio of the length of the screw to the diameter of the screw is typically conveyed as the L/D ratio. Thus, a low of 20/1 to 24 to 1. L/D’s ratios being a common length to diameter ratio can get as high as 30/1 here at Keller Products in order to get the best dispersion when it comes to color.

We have custom made drilling stations that can be positioned to provide any type of design scenario for holes.

We can also provide custom laminations and would be happy to send you samples upon request.  We currently have seven lamination stations that can handle many different types of custom plastic extrusions.

We offer custom packaging and are currently packaging an extruded profile product that is sold to a “Big Box” Company.

We have many customers that we provide inventory management in that we stock their Custom Plastic Extrusions so they can pull any number of units and drop ship them anywhere in the world. Keller Products is a versatile company that provides a number of capabilities and products backed by years of experience, allowing us to work with customers coming from various industries. We serve markets involving aerospace, consumer and retail, healthcare and medical, military, automotive, electrical, industrial, and recreational and sporting goods.

Keller Products runs all materials including, foamed profiles, elastomeric profiles, co-extruded profiles, and almost anything you can dream up.  We even tackle the toughest designs with the more exotic materials. Be it simple, complex, hollow, coextruded, or embossed, our team of experts can customize it for you. In addition, our specialists understand that no two jobs are the same and we plan to keep it that way.  This means that here Keller Products we can offer you any number of products for your design needs.

We offer complete Engineering Design services and can even offer up 3D print prototypes, yes, even in Extrusion! With our focus on innovation, we can assist you in designing virtually any plastic profile and even develop new types.

We have been the leader in the latest extrusion technology and we pride ourselves in offering you a quick solution for your extrusion needs. We offer support in any decisions you make and provide assistance in addressing all designing and manufacturing issues.  Keller Products is definitely more than just a leading plastic extrusion house because we also aim to be your business partner.

We deliver innovation.  We guarantee Quality, Service, and Value Every Day!

Custom Plastic Extrusions


Plastic extrusions have many different applications and use. If you need a plastic part, then plastic extruding is an excellent place to start. If you need multiple plastic parts of the same shape, size, color, etc., then the extrusion process is perfect for your needs. In fact, as one of the best plastic extrusion companies, we can make custom plastic extrusions designed specifically for your company’s and products’ unique needs.


How Much Does Extrusion Cost?


There’s no short answer to this. It depends on what you need, how much you need, and the process by which something is extruded. Most people don’t realize that there are multiple processes and a wide range of extruding custom parts. Not all companies utilize the same processes either. You can ask us for a quote based on your custom parts needs, and we will give you the best possible quote.


Can You Extrude Plastic?


We can, but it’s unlikely individual customers can extrude plastic because of what’s involved in the process. Slowly melting plastic polymer beads into a melt and then forcing them through unique extrusion tooling is not something everyone can do. However, seeing as this process of producing plastic parts is the expert focus of what we do, we can definitely produce quality parts and extrusion products via the equipment we own and operate daily.


What Are Plastic Profiles?


A profile is the cross-section view of plastic as it exits the machine. Essentially if you take a plastic hose and cut the end off any which way, you get a different look at the materials and how the hose was made. This would be the profile of the hose. Similarly, the plastic profile extrusion produced through plastic extrusion tooling is how the product looks when it leaves the die machine.


An example of extrude profiles is a co-extrusion or tri-extrusion product. The co-extrusion produces a product with two different textures. Its profile has a smooth, bumpy, scratchy, or other texture combined with the first chosen texture. The tri-extrusion is just like the co-extrusion, except that we’re working with three different materials.


The custom plastic profiles of the products you request will be unlike anything else because you are requesting a custom product. You can look at profile extrusions of other products that we produce before we begin your custom order. Sample products might include wire and cable, extruded plastic tubing that is hollow or solid to various widths, aluminum rod and tube extrusion for aluminum tubing, etc. The extrusion die for each of these is unique to the product extruded.


Likewise, the machines used to cut the parts or add something special to the parts are unique devices in their own right. Computer Numerical Control or CNC machining may be used to cut, punch, twist, extend, or coat plastic parts. Wire EDM, or Electrical Discharge Machining, uses a thin electrically charged wire to slice and manipulate the material to provide it with a smooth finish and little wasted material left. Crosshead extrusion forces a material over and through a crosshead single die to cover a substrate.


Can Extruded Plastic Produce Sheets?


It absolutely can! Sometimes clients want sheets of plastic coated with a crosshead extrusion coating or with Armorbond. Armorbond is a mix of plastic and plywood sheets melded together to increase the strength and resiliency of the two products. Other high-quality extrusion coating is used to create plastic sheets with different textures or properties that are desirable (e.g., sheets that have higher melting points than sheets without a special coating).


Sometimes producing plastic sheets is the first step in creating embossed or stamped plastic products. The sheets provide stability during the stamping or embossing processes so that the plastic doesn’t break, split or crack when the stamp or embosser hits the plastic. The impact of these tools spreads out over the whole of the sheet reducing the force as it leaves the desired imprint or cut.


The Best Custom Plastic Extrusion Company, Bar None!


Our company has tackled some of the most challenging requests for custom plastics and rose to the challenge with eagerness. We want to help you with your project, regardless of the type of plastic product or how it’s extruded. We would be happy to show you some of our most challenging products (as long as there is no proprietary information disclosed by viewing the product) so you can see for yourself how we succeed at what we do.


At any rate, you can give us a shot at the product you need. Our engineers will design it to meet your specs, and we can even customize the color of the parts you want. Here at Keller Plastics, we guarantee that you receive quality service and value. Call us today for a quote on your custom plastics.

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