Premium Thermoplastic Extrusions at Keller Plastics

Assorted colored pellets for thermoplastic extrusion on a factory line


Keller Plastics excels in the art and science of thermoplastic extrusions, offering a vast array of customized solutions that meet and surpass the requirements of diverse industries. With nearly seven decades of relentless innovation and a deep commitment to quality, we have positioned ourselves at the forefront of the plastic extrusion industry.

By seamlessly blending time-honored craftsmanship with cutting-edge technological advancements, Keller Plastics not only meets but sets industry standards. Whether you need assistance with initial design or are looking for end-to-end project execution, our team is equipped to handle all your thermoplastic extrusion needs.

Thermoplastic Extrusions for Custom Applications

At Keller Plastics, we excel in delivering bespoke thermoplastic extrusions tailored to our clients’ unique needs. Our innovative approach combines precision engineering with specialized materials to create custom profiles that not only meet but exceed the demands of various industries. With an emphasis on versatility and quality, our thermoplastic extrusion process enables the production of parts with intricate designs and enhanced functionalities.

Specialized Profiles for Medical, Aerospace, and Beyond

Keller Plastics specializes in producing high-grade thermoplastic extrusions for critical sectors such as medical and aerospace. Each profile is meticulously crafted to conform to stringent industry standards, ensuring optimal performance in demanding environments.

Medical Profiles

We manufacture medical tubes for intravenous therapies and catheters, structural components for medical imaging devices, and encasements for implantable devices. These products are produced in controlled environments to maintain sterility and are engineered to perform reliably in medical settings.

Aerospace Profiles

Our extrusions for the aerospace industry include air ducts, wiring conduits, and structural elements for cabin interiors. These components are lightweight yet strong, designed to endure aerospace applications’ pressures and environmental challenges without compromising safety or efficiency.

Our expertise in creating thermoplastic extrusions that meet the rigorous requirements of the medical and aerospace industries underscores our commitment to innovation and quality. These specialized profiles are functional and adhere to the highest safety and performance standards.

Custom Features: Biodegradable, Flame-Retardant, and Glow-in-the-Dark Innovations, and More

At the forefront of thermoplastic extrusion technology, Keller Plastics integrates unique material properties to meet specific environmental and safety requirements. Our custom features allow for a wide application range, enhancing both the utility and ecological footprint of our products.

  • Biodegradable Profiles: Designed for environmentally sensitive applications, these profiles are perfect for single-use products in the medical, agricultural, and packaging industries. They break down naturally without leaving harmful residues, supporting efforts towards sustainability.
  • Flame-Retardant Profiles: Used in construction, electronics, and transportation, these profiles are treated with advanced fire-retardant chemicals that inhibit flame propagation and resist high temperatures, enhancing safety in fire-prone environments.
  • Glow-in-the-Dark Profiles: Ideal for safety and emergency signage, as well as decorative applications, our glow-in-the-dark profiles ensure visibility in power outages or low-light conditions, providing safety and guidance during emergencies.

Our ability to customize thermoplastic extrusions with advanced features like biodegradability, flame retardance, and photoluminescence allows us to serve a diverse clientele, offering them products that are not only effective but also innovative and safe. This adaptability has positioned Keller Plastics as a leader in the field, ready to meet the future challenges of thermoplastic extrusion.

Our ability to customize thermoplastic extrusions with advanced features like biodegradability, flame retardance, and photoluminescence allows us to serve a diverse clientele, offering them products that are not only effective but also innovative and safe. This adaptability has positioned Keller Plastics as a leader in the field, ready to meet the future challenges of thermoplastic extrusion.

Thermoplastic Extrusion Process

Keller Plastics’ thermoplastic extrusion is a meticulously engineered process that transforms raw thermoplastic materials into precision profiles crucial for many applications. Leveraging advanced technology and extensive expertise, we ensure that each step of the thermoplastic extrusion process is optimized for efficiency and quality.

● Material Preparation: We begin with high-quality thermoplastic pellets, which are carefully selected based on their properties and the specific requirements of the project. These materials include but are not limited to, PVC, polyethylene, and innovative bioplastics.

● Heating and Melting: The pellets are fed into an extruder, where they are gradually heated to the precise temperature needed to achieve a homogenous melt. This step is crucial for ensuring the material’s malleability without degrading its inherent properties.

● Die Extrusion: The molten plastic is then forced through a die specifically designed for the project. This die shapes the plastic into the desired profile, ranging from simple tubes to complex, multi-dimensional structures.

● Cooling and Solidification: As the extruded plastic exits the die, it passes through a cooling system to solidify the profile while maintaining its shape integrity. This rapid cooling is essential to prevent deformations and ensure the profile meets exact dimensional specifications.

● Cutting and Finishing: Once cooled, the profiles are cut to specified lengths and undergo any necessary post-extrusion finishing processes, such as drilling, printing, or texturing, which enhance the product’s functionality and aesthetic appeal.

Our control over the thermoplastic extrusion process allows Keller Plastics to produce superior plastic profiles that meet the evolving needs of industries ranging from construction to healthcare. By continually refining our techniques and investing in cutting-edge technologies, we maintain our leadership in thermoplastic extrusion, providing our clients with products that lead their markets in both quality and innovation.

The Science Behind the Extrusion of Thermoplastics

Thermoplastic extrusion at Keller Plastics is grounded in scientific precision and technological innovation. Our approach transforms engineering concepts into tangible, high-performance thermoplastic profiles integral to many industries. We meticulously control every stage of the thermoplastic extrusion process to produce consistently superior products.

Engineering Polycarbonate and Thermoplastic Elastomer Profiles

At Keller Plastics, our expertise in thermoplastic extrusion allows us to produce advanced polycarbonate and thermoplastic elastomer profiles. These materials are pivotal in sectors demanding high durability and flexibility.

Our polycarbonate profiles, known for their extraordinary clarity and robust impact resistance, are extensively utilized in safety and security applications such as bulletproof windows, protective visors, and aircraft canopies. Their ability to withstand high impact and extreme conditions without compromising transparency makes them indispensable in protective and optical applications.

Similarly, our thermoplastic elastomer profiles capitalize on their hybrid qualities, mimicking rubber but offering the processing efficiency of plastics. This material is perfect for creating weather-resistant seals in automotive windows, vibration-dampening components in consumer electronics, and soft-touch grips on tools.

The versatility of thermoplastic elastomers is further showcased in medical devices, where they are used for flexible joints and non-slip surfaces on various medical instruments, combining comfort with functionality.

Sustainable Solutions in Thermoplastic Extrusions

At Keller Plastics, we are committed to sustainable manufacturing through the innovative use of recycled and bio-based materials in our thermoplastic extrusion processes. Our advanced techniques transform post-consumer plastics and renewable resources like polylactic acid (PLA) into durable, high-quality extrusions used in everything from construction to biodegradable medical products.

These processes reduce waste and support a circular economy by creating eco-friendly products that meet rigorous environmental and industry standards. This approach positions Keller Plastics as a leader in sustainable practices, providing our clients with reliable, aesthetically pleasing products that uphold environmental commitments.

Why Keller Plastics is Your Ideal Partner for Thermoplastic Extrusions

Delivering superior thermoplastic extrusion solutions demands a partner with a deep commitment to supporting your project at every stage. At Keller Plastics, our approach ensures every client receives tailored, expert assistance that directly impacts the success and innovation of their projects.

Comprehensive Support from Design to Production

Our dedication to your success in thermoplastic extrusion is manifested through precise, client-focused support across all project phases:

  • Design Consultation: We collaborate closely with you to transform initial concepts into feasible, customized thermoplastic extrusion designs. This includes selecting the right profile shapes, optimizing the design for manufacturability, and ensuring all technical requirements are met.
  • Material Selection: With a vast array of thermoplastics at our disposal, we guide you in selecting the best materials that provide the desired properties, such as heat resistance, strength, or flexibility, necessary for your application.
  • Prototyping: Employing advanced thermoplastic extrusion techniques, we produce rapid prototypes that allow you to test and refine the functionality of your designs before full-scale production.
  • Production Scaling: Our facilities are equipped to handle both small and large production runs, maintaining the highest levels of precision and quality control for each thermoplastic extrusion, ensuring consistency across all batches.
  • Quality Assurance: Every thermoplastic extrusion undergoes stringent testing to verify it meets both our high internal standards and your specific industry requirements. This rigorous quality assurance process includes dimensional checks, material performance testing, and long-term durability assessments.
  • Post-Production Support: After manufacturing, we continue to support your project with services like custom packaging, inventory management, and logistical assistance to ensure smooth delivery and integration of the extruded profiles into your products or systems.

Partnering with Keller Plastics guarantees a comprehensive pathway from the initial design to the final delivery, ensuring your thermoplastic extrusion projects are not just completed but excel in their intended markets. Ready to start your next project with a leader in thermoplastic extrusion? Contact Keller Plastics — where your ideas get shaped into reality.

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