Ask the Expert: How to Prolong the Lifespan of Your Die
With 28 years of experience in the remanufacturing side of the extrusion die industry, our Aftermarket Supervisor, Mike Shakal, has seen firsthand what helps dies last. In this edition of our Ask the Expert series, we asked him a common customer question: "How do I prolong the lifespan of my die?"
From preventative maintenance and proper handling to operator training and refurbishment, Mike shares practical tips and strategies that help dies maintain consistent performance and maximize production efficiency.
Prioritize Preventative Maintenance
The number one factor in die lifespan is consistent preventive maintenance. Over time, normal wear, material buildup, and process conditions can affect performance if not addressed early. Routine inspections and cleanings help keep dies operating at peak condition and support long-term reliability. Perform a proper cleaning at least once per year. When working with corrosive materials, more frequent die cleanings are recommended.
Invest in Proper Team Training
One of the most impactful - and sometimes underestimated - factors in die longevity is operator and maintenance team training. Extrusion dies require careful handling, cleaning, and installation. Without proper training, actions like using the wrong cleaning tool, over-tightening components, or improper handling during changeovers can unintentionally damage your die. Ensure that operators and maintenance personnel understand correct cleaning procedures, proper handling and storage, installation and troubleshooting best practices, and performance changes to watch for. By investing in training opportunities for the team that handles the equipment critical to your operation, improved productivity can be quickly achieved.
Avoid Common (But Preventable) Mistakes
Even well-run operations can unintentionally shorten die life through a few avoidable missteps.
- Reinstalling worn or damaged bolts
Fasteners in poor condition can affect clamping consistency and overall die integrity. Always inspect hardware and replace when needed. -
Debris or loose items left inside during reassembly
Foreign material trapped inside the die can damage internal surfaces and disrupt performance. Clean, controlled assembly practices are essential. - Operating power tools on or near the die
Power tools can slip or apply excessive force, increasing risk of surface damage. - Improper cleaning
Incorrect cleaning methods can damage body seals, which may lead to leakage. Follow recommended procedures to protect sealing surfaces. - Disassembling the die with incorrect tools
Improper tools can leave marks or cause unnecessary wear during disassembly. Always follow recommended procedures and tool guidelines. - Improper lifting and turning techniques
Incorrect handling during movement or maintenance can strain components or cause accidental contact with critical surfaces. - Abrasive pads on flow surfaces
Flow surfaces require a precise finish. Abrasive pads or materials can alter surface quality and impact material distribution. - Setting die lip gaps with incorrect gauges or tools
Non-brass feeler gauges or inappropriate tools can mark or damage lip surfaces. Use approved, non-marring tools. - Scraping flow or seal surfaces with hard materials
Hard or sharp tools can damage critical surfaces. Only use approved, non-marring tools. - Foreign objects entering the process line
Contaminants traveling through the line can contact internal die surfaces that affect performance. Upstream filtration and process control are key preventative steps. - Leaving the die lips unprotected during maintenance
The lip area is especially sensitive. Keeping proper protection in place during maintenance helps prevent accidental nicks, scratches, or edge damage.
Restore to Like-New Condition with Refurbishment
Dies can be restored to near-original performance through professional refurbishment. Services like resurfacing, re-polishing, and replacing worn components can extend usable life and help maintain production quality. The better you take care of your equipment, the longer it will deliver consistent performance. And when wear does happen, refurbishment can add years to its usable life.
Maintenance and repair are vital to ensuring efficiency and product quality in the extrusion process. By implementing these best practices into your operations, it will help prolong your extrusion die, ensure consistent quality, reduce downtime, and save substantial costs over time.
Need Help Evaluating Your Die?
Our aftermarket team is here to help support with inspections, maintenance, refurbishment solutions and more.
Contact Mike to discuss questions you may have.