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.


Custom Plastic ExtrusionsPlastic 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.



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.


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.


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


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.
Custom Plastic Extrusion at Keller PlasticsWe 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!


Products made from plastic extrusion are all around us. Without plastic, much of what you see around us would not exist. There are plenty of companies that can handle your plastic extrusions needs. However, not all companies can create the same quality at a consistent pace as Keller Plastics can. Keep reading to learn about the extrusion process, the different products, and how Keller Plastics can create products to benefit you and your company.


All About Plastic Extrusions


The process of turning raw plastic into a specific shape is called plastic extrusion. The plastic is then extruded into customized objects. Extrusion can use new plastic or recycled plastic.


The possibilities are endless when it comes to plastic extrusion manufacturers. Just to name a few of the products that are made with this process include weather stripping, piping, insulation, fencing, plastic sheets, and thermoplastic coatings. There are many more plastic extruded products that can be made. Give us a call to learn about all the different possibilities.


The process of extrusion can use a variety of different types of plastic. PVP, ABS, PVC, elastomers, nylon, and more can be used to create a limitless array of products.


Plastic extruded products can be useful for companies across almost every industry in the present day. Plastic can be used to make toys, medical supplies, building supplies, gardening supplies, and more. The extrusion of plastics has already changed the world, and Keller Plastics intends to see how else we can benefit society. Contact us today to get started.


The Benefits of Extrusion


The main benefit boasted by plastic extruders manufacturers is that plastic can be molded into anything imaginable. Below are just a few of the many benefits associated with plastic extrusion.


Low Cost: Other molding processes are expensive. Plastic extrusion is a fast and low cost. The process is flexible because raw plastic products are reused across several different projects. It is fast and easy to reheat the plastic, unlike metals. Metals require much higher temperatures than plastic, costing metal molders more and more money. The extrusion of plastics is also done 24 hours a day, meaning supply is always high, keeping the price low.


Flexibility: Plastic Extruders Manufacturers can work with any company to meet their needs. It is much easier for a plastic worker to adapt to the customer’s needs than, let’s say, a metal worker. With just a small alteration to the process, the plastic can be worked into any needed shape.


Alterations: After the plastic has been removed from the extruder, it remains exceptionally malleable. This allows the workers at Keller Plastics to further customize the plastic outside of the extrusion limitations. This is where fine details can be crafted into the plastic, creating exactly what the customer requires, for example, decorative extrusions.


Plastic Profile Extrusion and its Many Products


As previously mentioned, the possibilities are nearly limitless when it comes to plastic profile extrusion; however, there are a few best-sellers – products that are usually always in production and high demand. Below are just a few of the typical plastic products created here at Keller Plastics. To learn even more, contact us today.


Plastic Tubes


We can offer our customers custom plastic tubes ranging from one-half inch diameter up to five inches. We take pride in our plastic tubes because not all plastic extrusion manufacturers have the experience and know-how needed to make perfect plastic cylinders. Our plastic tubes can be made from a wide range of our plastics, meaning we can customize our product’s color, sturdiness, and flexibility.




Polycarbonate has many advantages in plastics; however, it can be challenging to work with. It has a somewhat high melting point. It only begins to become malleable at temperatures above 250 degrees Fahrenheit. Polycarbonate is used to create football helmets, lighting, bulletproof glass, and fire-retardant equipment. Many call it the toughest plastic on the market today.


ABS Plastic


ABS, which stands for Acrylonitrile butadiene styrene, is a thermoplastic. It is typically used to create children’s toys. It is also the material commonly used to create a car’s interior. Contact us to find out exactly what kind of products we can make with ABS. ABS can also be frequently mixed with other forms of plastics to create a harder, sturdier product. There are genuinely few limitations when it comes to ABS and its uses.




PVC is one of the most versatile plastics available. It is typically used to create plumbing tubing or pipes, and can be formulated to be rigid or flexible to customize the look, feel, and sturdiness of a product. PVC products are resistant against the weather, it is long-lasting, and it is even somewhat heat resistant. PVC is used to create hundreds of different products; however, it is also used in vehicles, electronics, and the health care industry. You could even use PVC to make a sturdy plastic door or window covering.


Choosing Us for Your Plastic Needs


Plastic extrusion has been around for decades; however, that doesn’t mean everyone can do it proficiently. Plastic extrusion is an art, and if you want the highest quality products around, you want to use the best plastic profile extrusion, manufacturers. That means using Keller Plastics for your next product. We have over six decades in the business, and we have perfected the craft during this time. The average member of our staff has 20 years of experience, and in total, our members have a combined 120 years of experience in plastic extrusion.


Don’t take our word for it. Just have a look at some of the quality products we have created over the years. Contact us today if you have any questions or consider using us for your plastic extrusion needs.


Give us a call, we know you will have a wonderful experience the moment you make contact with us.


Give us a call at (603) 627-7887, we know you will have a wonderful experience the moment you make contact with us regarding your Custom Plastic Extrusion needs.