27

In the temperature response control, if the temperature rises

rapidly and precisely, stable value will be required in stable state mode.
The temperature system has non linearity, long delay time, large time
constant and undetermined system (Kanagaraj et. al. 2008). The difficult
task of modelling and controlling is complex in real world system,
especially, when implementation issues are considered. The
conventional controllers require restrictive assumptions to design the
plant model. The assumptions are not taken into account and it may
result in a number of unknown variables that the controller design
techniques will be unable to handle (Iranian and Zabihinejad 2011). This
is the reason, the process of industry machines, human, have lack of
ability to solve the problems using imprecise information.

Over the years, control of process system plants in the industry

is customarily done by experts through the conventional control
techniques (Seema Nara et. al. 2010). This is due to its simplicity, low
cost design and robust performance in a wide range of operating
conditions. Different types of polymer will have different screw designs.
In most processes, a heating profile is set for the barrel, in which three
or more independent conventional controlled heater zones gradually
increase the temperature of the barrel from the rear (where the plastic
enters) to the front (Ying Xin Liao et. al. 2009).

This allows the plastic beads to melt gradually, as they are

pushed through the barrel and lowers the risk of overheating avoids
degradation in the polymer. Extra heat is contributed by the intense
pressure and the friction takes place inside the barrel. In fact, if an
extrusion line is able to run certain material fast enough, then the heaters
 28

can be shut off and the melting temperature is maintained only by

pressure and friction inside the barrel (Emine Dogru Bolat 2007).

In most extruders, if too much heat is generated, cooling fans

are present to keep the temperature below a set value (Yonghong Huang
and Xuejun Yang 2008). If forced air cooling proves insufficient and
then cast in heater jackets are employed, and they generally use a closed
loop of distilled water in heat exchange with cooling tower. At the front
of the barrel, the molten plastic leaves the screw and travels through a
screen pack to remove any contaminants in the melt (Kangling Fang and
Lei Yao 1996). Since the pressure at this point exceeds 5000 PSI,
screens are reinforced by a breaker plate (a thick metal puck with many
holes drilled through it). The screen pack and breaker plate assembly
also serves to create back pressure in the barrel. Back pressure is
required for uniform melting and proper mixing of the polymer.

The pressure generated can be changed by varying screen pack

composition either by changing the number of screens or by adjusting
wire weave size or also by changing other parameters (Yanjuan Yang et.
al. 2008). The function of converting rotational of the molten plastic into
longitudinal memory is done by breaker plate and screen pack
combination (Yinghua Song et. al. 2007). After passing through the
breaker plate, molten plastic enters the die.

The die gives the final product. The die profile must be
designed effectively such that the molten plastic evenly flows from a
cylindrical profile to the profile shape of the product. Uneven flow at
this stage would produce the product with unwanted stresses at certain