Post Reply: 5 Common Mistakes Most Extrusion Industries Make (and How to Avoid Them)

<blockquote><div class="quotetitle">Quote from <a class="profile-link highlight-moderator" href="#">Omari Kitula</a> on May 25, 2025, 7:42 pm</div>Hey fellow professionals,

I’ve noticed that many companies regardless of their size often repeat a few key mistakes that can negatively impact product quality, operational efficiency, and profitability. Here are five of the most common mistakes extrusion industries make:

1. Inadequate Raw Material Quality Control.

Many extrusion operations fail to test raw materials thoroughly for moisture content, particle size, or consistency. Poor-quality inputs can cause irregular extrudate texture, increased waste, and even machine blockages. Implementing a strict quality check at intake is critical.

2. Poor Control of Process Parameters

Temperature, pressure, screw speed, and moisture levels are vital in extrusion. Yet, some operators run machines without real-time monitoring or adjustments, leading to inconsistent products. Investing in automation and training can improve control and uniformity.

3. Neglecting Preventive Maintenance

Machines are often run continuously with minimal downtime, but skipping scheduled maintenance can lead to unexpected breakdowns and costly repairs. A preventive maintenance schedule should be non-negotiable to ensure long-term reliability.

4. Lack of Skilled Operators

Some companies hire operators with limited knowledge of extrusion science. This results in trial-and-error production runs and high wastage. Regular training and certification of staff can significantly enhance operational efficiency and product consistency.

5. Ignoring Product Innovation and Market Trends

The market is evolving fast especially in food and biodegradable packaging. Extrusion companies that fail to innovate or adapt to changing consumer demands risk becoming obsolete. R&amp;D investment and market analysis should be part of strategic planning.

The extrusion industry has immense potential, but avoiding these common mistakes is crucial for sustained success.

Have you experienced any of these issues in your plant? What measures have worked for you? Let’s discuss.</blockquote><br>

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