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Understanding Film Extrusion: How It Works Film extrusion is a continuous manufacturing process where thermoplastic resins are heated, melted, and formed into thin, flexible sheets. The process starts by feeding plastic pellets or granules into a heated barrel equipped with a rotating screw. As the material moves through the barrel, it melts and becomes a uniform, viscous liquid. The molten plastic is then forced through a specially designed die, which determines the shape an