Although rigid PVC has been extruded for many decades, more recent scientific evidence on primary particle flow units, crystalline structure, melting and recrystallization, transition from melt fracture to viscous flow, and differences in shear history between cubes and powder help to understand PVC extrusion. This understanding can replace some of the art of PVC extrusion with science. In this paper this science is applied to PVC extrusion, trouble shooting, scrap recovery, and property development.