THE HISTORY OF PLASTICS & PLASTIC EXTRUSION

The Early Days of Plastics: From Natural to Synthetic

Long before synthetic plastics, people used natural polymers like rubber, shellac, and horn for various applications. The turning point came in the 19th century when scientists began modifying these natural materials to improve their properties. 

1855 - The First Thermoplastics

Alexander Parkes developed Parkesine (cellulose nitrate), the first man-made thermoplastic. paving the way for future synthetic plastics.

Considered the first manufactured plastic, Parkesine was also a cheaper, and colourful, substitute for dearer materials such as ivory or tortoiseshell.

1907 - The Birth of Fully Synthetic Plastics

Leo Baekeland invented Bakelite, the first fully synthetic polymer, which did not rely on natural resources. Though not extrudable, it demonstrated the potential of engineered polymers and marked the beginning of modern plastics industry, sparking a consumer boom in affordable yet desirable products.

Notable products that became 20th-century icons include the Purma camera, the GPO telephone and the Ekco AD36 radio. 

GPO Telephone

1920s-1930s - The Rise of Modern Plastics

The creation of polystyrene (PS) polyvinyl chloride (PVC), and polyethylene (PE) enabled the development of flexible, durable, and melt-processable plastics - perfect candidates for plastic extrusion.

The Emergence of Plastic Extrusion

As new plastics were developed, the need for efficient, continuous shaping methods grew. Plastic extrusion, a technique adapted from metal extrusion principles, but modified for the viscoelastic behaviour of molten polymers, (heated plastic is 'forced' through a die to create continuous profiles), emerged as one of the most effective solutions.

1935 - The First Plastic Extrusion Machine

German engineer Paul Troester designed and built the first single screw extruder specifically for thermoplastics. Initially used for insulating wires, the machine formed the basis of today's high-output, precision-controlled, extruders. 

Image of One of The Earliest Plastic Extruders

1940s - The War-Driven Expansion

World War II drove demand for plastic components, leading to advancements in extrusion technology. New materials such as nylon and polytetrafluoroethylene (PTFE, or Teflon) emerged, expanding the possibilities of plastic manufacturing.

Macro Shot of Polytetrafluoroethylene Texture

1950s-1960s - Industrial Growth and Innovation

The post-war boom saw a rapid increase in plastic production. Extrusion became widely used for pipes, profiles, and films, with improvements in screw design and die engineering enhancing efficiency. 

Modern Plastic Extrusion and Co-Extrusion

Today, plastic extrusion is a cornerstone of industries such as construction, automotive, and packaging. Innovations such as co-extrusion, where multiple plastics are combined into a singular extrusion process, allow for stronger, more functional, and more sustainable products.

At our UK-based plastic extrusion company, we specialise in co-extrusion, using separate extruders to combine two materials into a single profile. This enables us to enhance product performance, combining the strength of one plastic, with the flexibility / aesthetic benefits of another. 

Co-Extrusion at BWC Profiles

Other modern capabilities include:

Multi-lumen tubing for medical or ventilation applications.

Foamed cores to reduce weight and material costs.

Custom colour matching and surface textures.

In-line embossing, perforation, or printing.

Conclusion

From the first thermoplastics to today's highly engineered extrusion processes, plastics and extrusion have evolved side by side. As materials and technologies continue to advance, plastic extrusion remains a vital process for manufacturing durable, high-performance components across multiple industries.

BWC Profiles' Plastics Facility

If you're looking for expert plastic extrusion services, including co-extrusion, get in touch with us today to discuss how we can meet your needs.