VULCAN Polycarbonate sheets Manufacturing Overview

Polycarbonate sheets are manufactured from raw materials including polycarbonate resins, colorants, and additives, which is dependant on the specification of the sheets produced. Factors such as sheet thickness, color, size, additional properties, and machinery to be used are all taken into consideration. The base polycarbonate resin has to be pre-dried and mixed together in calculated ratios to ensure uniformity throughout the batch and consistency between batches.

Once the raw materials are blended, they are heated, pressed through an extrusion die and oftentimes a co-extrusion die, and then drawn into a sheet through a set of rollers. While the sheet is still warm, it passes through additional roller sets to reach the desired thickness and specified surface texture. The rollers themselves also have to be heated and kept at a constant temperature with the help of heated water channels. As the sheet travels down the line, it gradually cools and is then cut to size. This process ensures dimensional stability, surface quality and uniform sheets.

VULCAN PLASTICS has a total of 6 extrusion lines, 2 for corrugated sheets and 4 for solid sheets, and a total capacity of 10 thousand tons per year.

Our machines are imported from Mitsubishi-Hitachi Zosen Japan, Omipa Italy and Breyer Germany. They are powered by Siemens motors, uses T-Die feed-blocks from the industry leading company EDI (Extrusion Dies Industries), and computer controlled by the also industry leading Dynisco.

  1. Optical Grade Solid sheet extrusion line.
    • Thickness: 2.0mm to 15mm.
    • Width: Max. 2100mm.
  2. Optical Grade Corrugated sheet co-extrusion line.
    • Thickness: 0.8mm to 2.0mm
    • Width: Max. 920mm
    • Enclosed in clean room
  3. Solid / Embossed sheet extrusion line.
    • Thickness: 1.8mm to 6mm.
    • Width: Max. 1800mm
  4. Multi-Functional Solid and Corrugated sheet co-extrusion line
    • Thickness: 0.7mm to 2.0mm
    • Width: Max. 1800mm
  5. Breyer Solid and Embossed Flat sheet co-extrusion line for Industrial Grade Sheets.
    • Thickness: 2.0mm to 12mm.
    • Width: Max. 1950mm
    • Enclosed in ISO Class 7 (FED STD 209E equivalent Class 10,000) clean room.
  6. Breyer Ultra-Thin Flat sheet co-extrusion line for Optical Grade Sheets.
    • Thickness: 0.4mm to 1.5mm.
    • Width: Max. 700mm
    • Enclosed in ISO Class 7 (FED STD 209E equivalent Class 10,000) clean room.



List of VULCAN Co-extrusion lines