Satya Extrusion Technology

NIT, Faridabad, Haryana

Satya produces Breaker Plates for various applications for supplying to OEMs, direct end users and job shop extrusion units. We manufacture Breaker plates with standard design as well as special design keeping in mind your processing requirements. We produce Breaker plates with Straight Holes, Angled Holes, Slots and any other design to give the optimum results. We design & manufacture Breaker Plates to avoid dead areas to minimize backpressure and high abrasive resistance to last longer by applying our vast experience to customers advantage. We keep in mind to avoid streaking at the edges and ensure the melted plastic flows perfectly without discoloration. All the entry Holes are properly polished and chamfered on the downstream side to avoid sticking & burning of plastic compound in the Breaker Plate. We manufacture Breaker plates for high temperature applications also. The standard material used by us for these parts is 1.2379(SKD11/K110/AISID2), H-13, 1.7225 (4140), 1.2316 (AISI420SS) and Inconel. Satya Extrusion offers to keeps in stock the popular styles of Breaker plates for same day delivery at no extra cost to the customer. We ensure that the Breaker Plates are produced at a very competitive price and give the best return on Investment.

Satya Extrusion Technology is a leading designer and manufacturer of Customised High Quality Fixed Center Extrusion Cross-Heads and Adjustable Center Extrusion Cross-Heads in a range of sizes to fulfill the customers requirements. Satya Extrusions Cross-Heads are easy to Handle, easy to Operate, Clean and Maintain. Design Engineers at Satya Extrusion; have designed Crossheads to increase productivity and efficiency of men and machines keeping in mind actual usage patterns of the operators. Satya Extrusion manufactured Cross-Heads are Heat Treated in Vacuum Furnace to have better wear resistance & long life. Satya Extrusion offers a variety of options for applications such as: StripingMulti-LayerCo-extrusionFoam SkinFlat CableMulti ConductorFiber OpticJelly FilledNylonHigh Temperature applicationFeatures of Satya Extrusions Crossheads:Reduced Scrap MaterialIncreased ConcentricityIncreased ConcentricityReduced Raw Material ConsumptionReduced Set up timeEasy to Operate Assembling and Dis-assembling Kit availableMaterials Satya Extrusion use Certified and Documented Alloy materials for manufacturing our Cross-Heads is 1.2379(SKD11/K110/AISID2), 1.2316(S136/AISI420SS), 1.4125(AISI 440C), 1.2344 (ASTM H-13), 1.7225(42CrMo4/AISI4140), 2.4668 (Inconel) and Hastelloy. Satya Extrusion manufactured Cross-Heads are Heat Treated in Vacuum Furnace to have better wear resistance & long life. Heaters :Our Cross-Heads are provided with Mica-Band Heaters, Ceramic Heaters and Pencil type Cartridge Heaters, as per customers needs, likings and ease of operation. Assembly and Dis-Assembly Kits:Satya Extrusion provides Kits to its Customers for Assembling and Dis-Assembling the Crosshead with ease in the minimum possible time thus increasing efficiency and productivity at Customers plants. The Kit helps the operator to open the Crosshead part by part without having the need to hammer the parts or using blow-torch. This Kit eliminates the chances of damage to Crossheads thus saving Customers valuable money which they can use for better purposes.OEM CROSSHEAD REPLACEMENTSSatya Extrusion manufactures Crossheads for its own style and can manufacture Crossheads of other OEMs

The Extrusion Tips supplied by us are guaranteed a concentricity of .005mm for Fixed Centre Crossheads. The flow areas of the Tips are highly polished to give an even and all around flow of molten polymer layer over the core resulting in material saving and cost cutting at customers plant. Satya manufactures and Supplies Extrusion Tips in following options: 1). Hardened Steel 2). Hardened Steel with Tungsten Carbide Insert 3). Full Tungsten Carbide Body 4). Tip with Diamond Insert The inside cone of the Tip is made smooth to avoid any kind of wire breaks. Satya manufactured Tips have the outer cone as well as the Hole/Profile of the Tip well polished to offer smooth flow of plastic without burning. Satya Extrusion manufactures Extrusion Tips in standard Round Hole, Oval, Square, Rectangular, Multi Hole or any other profile as per requirements of the customers. The Fixed Center Tips manufactured by us are guaranteed a concentricity of .005mm or better to achieve perfect centering of insulation. Satya Extrusion manufactures Extrusion Tips from 0.40mm (0.015) onwards with a tolerance of .005mm ( 0.0005) in the hole sizes.

The Extrusion Dies supplied by us are made from the highest possible Certified and Documented Material to ensure reliable product with very high dimensional control of the order of .005mm. The polymer flow areas of the Dies are Diamond mirror polished without disturbing the accuracy of the cone. The concentricity of the Fixed Center Die is ensured within .005mm ( 0.0005) or better for very high control of polymer layer. Satya Extrusion manufactures and supplies Extrusion Dies in various styles and sizes. The Dies can be in Standard Round Hole, Twin Hole, Multi-Hole or any Profile such as Oval, Rectangular, Serration, etc. Satya Extrusion supplies Extrusion Dies in the following options: 1). Hardened Steel 2). Hardened Steel with Tungsten Carbide Insert 3). Full Tungsten Carbide Body 4). Tip with Diamond Insert

extrusion tips and dies are one of the most critical parts of the extrusion crosshead as they give the finishing touch to the final product and its importance cannot be ignored. Satya extrusion is a leading quality manufacturer of a whole range of extrusion tips and dies with applications in the wire, cable, medical, pipe and hose industries. Our customers know us as a source that is dependable because of high wear resistance, low wire breaks and uniformity of size and dimensions. Our experienced and trained engineers do the utmost to design & manufacture products, which are more practical and cut above the rest and make sure they suit customers requirements as well. Our core strength is team work resulting in increased productivity while maintaining exceptional quality standards which works to the customers advantage. We can produce extrusion tooling by using your approved engineering drawing, sketch or just a sample of parts or our customers can also use the services of our in-house engineers to design a better tool.

while there are people who realize the importance of quality extrusion tips and dies manufactured from the professional companies like satya extrusion, capable of producing tooling using certified premium quality alloys, within tight tolerances as a dimensionally and geometrically correct tool can help you save a lot of expensive polymer that you will otherwise coat on the product and can potentially lead to leaner margins; but still many people fail to understand its true importance and go for extrusion tips and dies produced in-house or from small time job shops not capable of controlling tight tolerances and absolutely no knowledge of material to be used to give long life to the tools. Satya extrusion manufactures the standard round hole extrusion tips and dies and profiled extrusion tips and dies in various shapes such as oval, rectangular, square, serration and multi hole tools for multi conductor cables.

qualitycustomers achieve better product control on their products by using our extrusion tips and dies as we produce our extrusion tools on superior quality machines and heat treated properly to ensure a long life. All the tools are inspected individually by our quality control engineers using high resolution inspection equipments before they are dispatched to the customer. Our extrusion tooling is diamond polished and there is smooth transition in the inside cone of the die by avoiding all kinds of shoulders to give a superior finish on customers products.

reliability/certified tooling
while pricing is of essence keeping in mind prevailing business atmosphere, we offer tools that are dependable and delivered on time. To give a better dimensional control on the product, we guarantee concentricity of our fixed center tools to be within .005 mm. We provide a copy of quality certificates on specific request by customers which certifies its adherence to the parameters in the engineering drawing.

material
we manufacture extrusion tooling in hardened steel -1.2379(skd11/k110/aisid2), 1.2316(s136/aisi420ss) 1.2344 (astm h-13), 1.7225 (4140), inconel, as well as in full tungsten carbide & with tungsten carbide inserted in tool body and poly crystalline diamond to enhance the tool life. Carbide inserted tips can also be manufactured for multiple conductor extrusion tips.

services offered stockwe offer same day delivery for our regular customers for their standard tooling as we offer customer stocking program at no extra cost to them. This helps in better inventory control of extrusion tips and dies while still maintaining critical stock level.

of different oem styles
satya extrusion manufactures tooling for its own style of crossheads as well as for almost all the popular makes of cross-heads and in-line heads

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Satya Extrusion Techis a leading designer and manufacturer of Customized High Quality Fixed Center Extrusion Cross-Heads and Adjustable Center Extrusion Cross-Heads in a range of sizes to fulfill the customers requirements. Satya ExtrusionsCross-Headsare easy to Handle, easy to Operate, Clean and Maintain. Design Engineers at Satya Extrusion; have designed Crossheads to increase productivity and efficiency of men and machines keeping in mind actual usage patterns of the operators. Satya Extrusion manufactured Cross-Heads are Heat Treated in Vacuum Furnace to have better wear resistance & long life. Satya Extrusion offers a variety of options forapplications such as: Striping Multi-Layer Co-extrusion Foam Skin Flat Cable Multi Conductor Fiber Optic Jelly Filled Nylon High Temperature application Features of Satya Extrusions Crossheads: Reduced Scrap Material Increased Concentricity Increased Concentricity Reduced Raw Material Consumption Reduced Set up time Easy to Operate Assembling and Dis-assembling Kit available MaterialsSatya Extrusion use Certified and Documented Alloy materials for manufacturing our Cross-Heads is 1.2379(SKD11/K110/AISID2), 1.2316(S136/AISI420SS), 1.4125(AISI 440C), 1.2344 (ASTM H-13), 1.7225(42CrMo4/AISI4140), 2.4668 (Inconel) and Hastelloy. Satya Extrusion manufactured Cross-Heads are Heat Treated in Vacuum Furnace to have better wear resistance & long life. Heaters :Our Cross-Heads are provided with Mica-Band Heaters, Ceramic Heaters and Pencil type Cartridge Heaters, as per customers needs, likings and ease of operation. Assembly and Dis-Assembly Kits:Satya Extrusion provides Kits to its Customers for Assembling and Dis-Assembling the Crosshead with ease in the minimum possible time thus increasing efficiency and productivity at Customers plants. The Kit helps the operator to open the Crosshead part by part without having the need to hammer the parts or using blow-torch. This Kit eliminates the chances of damage to Crossheads thus saving Customers valuable money which they can use for better purposes. OEM CROSSHEAD REPLACEMENTS Satya Extrusion manufactures Crossheads for its own style and can manufacture Crossheads of other OEMs

Satya Extrusion manufactures and supplies Extrusion Tips for Adjustable Centre and Fixed Centre Crossheads in
1) Pressure extrusion2) Semi-Pressure extrusion3) Sleeve extrusion.

The Extrusion Tips supplied by us are guaranteed a concentricity of .005mm for Fixed Centre Crossheads. The flow areas of the Tips are highly polished to give an even and all around flow of molten polymer layer over the core resulting in material saving and cost cutting at customers plant.

Satya manufactures and Supplies Extrusion Tips in following options:1). Hardened Steel2). Hardened Steel with Tungsten Carbide Insert3). Full Tungsten Carbide Body4). Tip with Diamond Insert

The inside cone of the Tip is made smooth to avoid any kind of wire breaks. Satya manufactured Tips have the outer cone as well as the Hole/Profile of the Tip well polished to offer smooth flow of plastic without burning. Satya Extrusion manufactures Extrusion Tips in standard Round Hole, Oval, Square, Rectangular, Multi Hole or any other profile as per requirements of the customers. The Fixed Center Tips manufactured by us are guaranteed a concentricity of .005mm or better to achieve perfect centering of insulation.

Satya Extrusion manufactures Extrusion Tips from 0.40mm (0.015) onwards with a tolerance of .005mm ( 0.0005) in the hole sizes.

Satya producesBreaker Platesfor various applications for supplying to OEMs, direct end users and job shop extrusion units. We manufacture Breaker plates with standard design as well as special design keeping in mind your processing requirements. We produce Breaker plates with Straight Holes, Angled Holes, Slots and any other design to give the optimum results. We design & manufacture Breaker Plates to avoid dead areas to minimize backpressure and high abrasive resistance to last longer by applying our vast experience to customers advantage.

We keep in mind to avoid streaking at the edges and ensure the melted plastic flows perfectly without discoloration. All the entry Holes are properly polished and chamfered on the downstream side to avoid sticking & burning of plastic compound in the Breaker Plate. We manufacture Breaker plates for high temperature applications also. The standard material used by us for these parts is 1.2379(SKD11/K110/AISID2), H-13, 1.7225 (4140), 1.2316 (AISI420SS) and Inconel. Satya Extrusion offers to keeps in stock the popular styles of Breaker plates for same day delivery at no extra cost to the customer. We ensure that the Breaker Plates are produced at a very competitive price and give the best return on Investment

Flangesare used for connecting the Extruder with the Crosshead. Satya Extrusion designs and manufactures Extrusion Flanges in various styles and sizes to fit any Extruder. The Flanges are manufactured as per Customers requirements so that they adapt to their existing setup of Crosshead and Extruder. We manufacture Flanges with Internal threads, External Threads, Bolt systems, Hub systems or any other style to suit customer requirements.

We manufacture Flanges as per the centre distance of Extrusion Lines at customers plants. Satya Extrusion incorporates the thermocouple threads (for sensing temperatures) and melt pressure adapter (optional). SET is also capable of designing and manufacturing Flanges with Purge Valves integrated into them, if there is sufficient space in the Extrusion line at Customers end. Satya Extrusion uses 1.2316 (AISI420SS), 1.2379(SKD11/K110/AISID2), and 1.7225 (4140) as standard material for the Flanges but we also manufacture Flanges in Inconel and Hastelloy.

Purge Valveis used for discharging molten polymer from the extruder into the Crosshead with the facility to check the molten polymers readiness for extrusion and also to check the proper change in color of the polymer before it goes into the Crosshead. Purge valves are used for the Primary extruders as well as Secondary or Piggy Back extruders. Satya Extrusion manufactures Purge Valves in various styles and sizes to suit the customers requirements. SET manufactured Purge Valves give extremely good wear resistance and long life as we use 1.2344 and 1.8550 steel.

ThePurge Valvesare given a proper heat treatment and is Gas Nitrided as well for a very good wear resistance ensuring longer trouble free functioning. SET manufactures Purge Valves for Manual as well as Hydraulic applications. They are high precision mating parts, which if not properly made will result in obstruction in flow of polymer and can also cause leakage of polymer. So, Satya Extrusion makes sure that Purge valves are made to correct tolerances for proper functioning without seizures.