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Category: Blown Film Machine

Blown Film Machine

August 23, 2018 • Mrunal Ramanuj

Ocean Extrusions Pvt. Ltd.,


  • Blown Film Machine
  • Blown Film Machine India
  • Blown Film Machine in Ahmedabad
  • Blown Film Machine Plant
  • Blown Film Machine Line
  • Blown Film Machine Manufacturer
  • Blown Film Machine Unit
  • Blown Film Machine Exporter

  • Introduction
  • Blown film extrusion is a technology that is the most common method to make plastic  films, especially for the packaging industry. The process involves extruding a tube of molten polumer  through a die and inflating to several times its initial diameter to form a thin film bubble. This bubble is then collapsed and used as a lay-flat film or can be made into bags. Usually polyethylene  is used with this process, and other materials can be used as blends with these polymers. A diagram of a blowing film process.
  • The Film Blowing Process
  • Typically, blown film extrusion is carried out vertically upwards, however horizontal and downward extrusion processes are now becoming more common .
  • This procedure consists of four main steps:
  • The polymer material starts in a pellet form, which are successively compacted and melted to form a continuous, viscous   liquid . This molten plastic is then forced, or extruded , through an annular die.
  • Air is injected through a hole in the center of the die , and the pressure causes the extruded melt to expand into a bubble. The air entering the bubble replaces air leaving it, so that even and constant pressure is maintained to ensure uniform thickness of the film.
  • The bubble is pulled continually upwards from the die and a cooling ring blows air onto the film. The film can also be cooled from the inside using internal bubble cooling. This reduces the temperature inside the bubble, while maintaining the bubble diameter .
  • After solidification t the frost line, the film moves into a set of nip rollers which collapse the bubble and flatten it into two flat film layers. The puller rolls pull the film onto windup rollers. The film passes through idler rolls during this process to ensure that there is uniform tension in the film. Between the nip rollers and the windup rollers, the film may pass through a treatment centre, depending on the application. During this stage, the film may be slit to form one or two films, or surface treated.


  • Advantages

  • Blown film generally has a better balance of mechanical properties than cast or extruded films because it is drawn in both the transverse and machine directions. Mechanical properties of the thin film include tensile and flexural strength, and toughness. The nearly uniform properties in both directions allow for maximum toughness in the film .
  • Blown film extrusion can be used to make one large film, two smaller ones, or tubes that can be made into bags. Also, one die can make many different widths and sizes without significant trimming. This high level of flexibility in the process leads to less scrap material and higher productivity. Blown films also require lower melting temperatures than cast extrusion. Measured at the die opening, the temperature of cast film is about 220°C., where as the temperature of blown film is about 135°C. Furthermore, the cost of the equipment is approximately 50% of a line.

  • Disadvantages
  • Blown film has a less effective cooling process than flat film. Flat film cooling is done by means of  chill rolls or water., which have significantly higher specific heat capacities than the air that is used in the blown film cooling process. The higher  specific heat capacity allows the substance to absorb more heat with less change in the substance temperature. Compared to cast film, blown film has a more complicated and less accurate method to control film thickness; cast film has a thickness variation of 1 to 2% versus the 3 to 4% for blown film. The resins used for casting typically have a lower melt flow index, which is the amount of polymer that can be forced through a standard die in 10 minutes according to a standard procedure. The melt flow index for cast film is about 5.0 g/10 min where as for blown film it is about 1.0 g/10 min. Consequently, the production rates for cast film are higher: cast film lines can reach production rates of up to 300m/min where as blown film lines are usually less than half this value. And finally, cast film has better optical properties, including  transparency , haze, and gloss.

  • Applications
  • Consumer food wrap from plastic wrap  article.
  • Agricultural  film
  • Bags
  • Industry packaging, shrink film , stretch film
  • Consumer packaging, food wrap, transport packaging ( Figure  )
  • Laminating  film
  • Barrier film
  • Multilayer film

Research has been done to explore the incorporation of blown film extrusion into the large-scale manufacturing of carbon nanotube and  nanowire films.


 

 

Multilayer Blown Film Line

August 25, 2017 • Mrunal Ramanuj

Multilayer Blown Film Line

Multilayer Blown Film Line India

Multilayer Blown Film Line Manufacturer

Multilayer Blown Film Line Exporter

Multilayer Blown Film Line Machine

Multilayer films are used for varied crucial application in flexible packaging, which demand vital film properties like dart impact strength, puncture resistance, hot tack strength, gloss, oxygen and moisture barrier etc.

Multilayer blown film material is comparatively strong than two layer and mono layer blown films. It has strong impact in packaging industry as this product bears multiple protection properties including puncture and heat resistant, less or zero attraction to moisture and oxygen, etc. Multilayer Blown Film Plant is suitable for producing high barrier wrapping and stuffing material for packing food products, processed fluid consistency food items, etc. Multilayer blown film line can also be produced with this machine.

Ocean extrusions Pvt Ltd is a leading plastic extrusion machinery manufacturer & exporter in India, having core expertise in comprehensive range of extrusion machinery for plastic including plastic extruder such as multi layer blown film plant, mono layer blown film plant, air bubble sheet plant, raffia tape stretching plant, extrusion coating lamination plant, co-extrusion two layer blown film plant, PP-TQ blown film plant, monofilament plant, sutli plant, PP box strapping line, HDPE box strapping line, PET box strapping line and plastic reprocessing plant. Ocean extrusions Pvt Ltd is a well known trusted name for providing customized solutions of plastic extrusion machinery.

Application:

  • Multilayer films are used for varied crucial application in flexible packaging, which demand vital film properties like dart impact strength, puncture resistance, hot tack strength, gloss, oxygen and moisture barrier etc.
  • Water Pouch Film
  • Milk Film
  • Edible Oil Film
  • Lamination Film
  • Liquid Packaging
  • Tea Packaging
  • Tomato Catch Up Packaging
  • Food Packaging Film
  • Stretch Cling Film

For More Detail:

Website: http://www.oceanextrusions.com/

http://www.oceanextrusion.com/

http://www.blownfilmline.in/

http://www.plasticextrusionmachinemanufacturer.com/

http://www.oceanextrusionsmachine.com/

blown film making machine INDIA

June 27, 2014 • Mrunal Ramanuj

blown film extrusion plant Blown Film Making Machine manufacturers

June 6, 2014 • Mrunal Ramanuj

blown film extrusion plant Blown Film Making Machine manufacturers

Complete blown film extrusion lines for mono layer, and complex multi-layer films of HDPE, MDPE, LDPE, LLDPE, EVA, and PP. We have set out various series of specific blown film lines for processing different material and applications.
Blown Film Extrusion Line is the best choice for maximum volume and top quality output. Distinctive new screw design with automatic winder for high capacity output and efficiency.

blown film plant

Two Layer Blown Film Extrusion Lines with the best combination

Blown Film Plant
www.oceanextrusions.com

Two layer blown film Line has a great demand in global market for its wide range of packaging products that can be produced from it. Two layer blown film machine is an economical solution to create moderate barrier films for shopping bags, crop covers, carry bags used in textile sector, etc. It consumers low power and when it www.oceanextrusions.comcomes to return on investment, packaging industry can made good and fast profit. Similarly, two layer blown film line materials can also be produced from this single plant.

Two Layer Blown Film Extrusion Lines with the best combination of technology and performance. These low investment, power efficient, high – speed plants can give processors the competitive edge and quick return on their investment.
Two layer blown film Line has a great demand in global market for its wide range of packaging products that can be produced from it. Two layer blown film machine is an economical solution to create moderate barrier films for shopping bags, crop covers, carry bags used in textile sector, etc. It consumers low power and when it comes to return on investment, packaging industry can made good and fast profit. Similarly, two layer blown film line materials can also be produced from this single plant

https://www.youtube.com/watch?v=7S0_cCLssdgWatch Full Movie Online Streaming Online and Download

This process is the same as a regular extrusion process up until the die. There are three main types of dies used in this process: annular (or crosshead), spider, and spiral. Annular dies are the simplest, and rely on the polymer melt channeling around the entire cross section of the die before exiting the die; this can result in uneven flow. Spider dies consist of a central mandrel attached to the outer die ring via a number of “legs”; while flow is more symmetrical than in annular dies, a number of weld lines are produced which weaken the film. Spiral dies remove the issue of weld lines and asymmetrical flow, but are by far the most complex.
The melt is cooled somewhat before leaving the die to yield a weak semi-solid tube. This tube’s diameter is rapidly expanded via air pressure, and the tube is drawn upwards with rollers, yielding the plastic in both the transverse and draw directions. The drawing and blowing cause the film to be thinner than the extruded tube, and also preferentially aligns the polymer molecular chains in the direction that sees the most plastic strain. If the film is drawn more than it is blown (the final tube diameter is close to the extruded diameter) the polymer molecules will be highly aligned with the draw direction, making a film that is strong in that direction, but weak in the transverse direction. A film that has significantly larger diameter than the extruded diameter will have more strength in the transverse direction, but less in the draw direction.
In the case of polyethylene and other semi-crystalline polymers, as the film cools it crystallizes at what is known as the frost line. As the film continues to cool, it is drawn through several sets of nip rollers to flatten it into lay-flat tubing, which can then be spooled or cut.

ALL PRODUCT
Blown Film Plant

 

Blown Film Extrusion Lines with the best combination of technology and performance. These low investment, power efficient, high – speed plants can give processors the competitive edge and quick return on their investment.

Two layer blown film Line has a great demand in global market for its wide range of packaging products that can be produced from it. Two layer blown film machine is an economical solution to create moderate barrier films for shopping bags, crop covers, carry bags used in textile sector, etc. It consumers low power and when it comes to return on investment, packaging industry can made good and fast profit. Similarly, two layer blown film line materials can also be produced from this single plant.
Application of Two Layer Blown Film Line

 

BLOWN FILM MAKING MACHINE, MONO LAYER, MULTI LAYER, ABA – INDIA

June 1, 2014 • Mrunal Ramanuj

BLOWN FILM MAKING MACHINE

<s0″>pan style=”font-size: xx-small;”>CO-EXTRUDED MULTILAYER FILM

Location of the unit:

         Location of the unit must be based on availability of infrastructural facilities such as electricity, water, transport & communication, bank etc. are also available. 900 ft² additional shed making a total plinth area of 1800 ft². to accommodate the project.

Plant & Equipment:

         Principal items of plant and equipment needed for the manufacture of co-extruded blown film is as follows: –

i) Co-extrusion film plant
ii) Corona surface treating equipment
iii) Rotogravure printing machine
iv) Co-extrusion film plant

         Co-extrusion means, combining more than one material by means of plasticizing extrusion into a unit structure in such a way that the materials will constitute distinct layers. As the co-extrusion technique is relatively a new one, special care is to be taken in the selection and procurement of the plant.

The plant essentially consists of two single screw extruders, a control panel with separate thyrister control panel for each drive motors and a heating panel for all zone heaters, film die assembly, air cooling ring and blowers, an oscillating platform which can oscillate through 300 each way, take off tower unit, trimming attachment, a two station surface winder having a roller width of 800 mm. The machine and equipment are suitable for operation on 400/440volts, 3 phases with neutral 50 cycles AC supply. All electrical heaters are single phase but the load is distributed for 3-phase supply through control cabinet. Total power load required is 85 KW.watch The Magnificent Seven 2016 film now

Corona Surface treating equipment:

         Plastics in general and polyolefin’s in particular have got a tendency to reject printing inks from their un-polarized surfaces. Hence it is necessary to polarize the surface of the film by this pre-treatment so that during printing the necessary level of adhesion is achieved.
This equipment consists of a solid-state theater, HT transformer, and special oil for above transformer, enclosed type roller assembly, an extra pair special dielectric sleeve, one extra zone extraction unit etc/

Rotogravure printing machine:

         The printing machine is specially designed in such a way that all the printing units are identical with the possibility that additional color can be attached. The machine is equipped with DC motor coupled to a thyrister converter to operate on AC mains.

Raw materials:

         Plastic raw materials such as LDPE, LLDPE, HDPE, PP, and Nylon etc. can be used for the manufacture of co-extruded film depending upon the end use of the product. Since milk pouches are generally a two-layer film (LDPE/LDPE) and the project envisages production of plastic film for milk pouches, the requirement is only LDPE. The other important raw materials required are butanol, solvent IPA and gravure printing ink.

Marketability and Scope:

         Co-extruded films find extensive use in the manufacture of pouches for packaging of various edible consumer items like milk, ghee, oils, snacks etc. It is estimated that in India about 80% of co-extruded films are being consumed for milk pouches and ghee pouches. The market for blown films is expanding and it is envisaged that more and more items would be brought under this material for packaging purposes.

Basis and Presumptions:

        The efficiency of the unit is calculated at 80% of the total production capacity.
The unit will work 25 days in a month of 3 shifts and 300 days in a year.
The time period for achieving the full envisaged capacity utilization is one year.
The labor wages are as per the prevailing rates in the market.
The rate of interest for fixed and working capital is taken @ 14%.
The margin money requirement for this project is 25%.
The pay back period of this project is 5 years.
The land area is 500m and the constructed area is 250 m.

Implementation Schedule:

Preparation of project report
2 months
Selection of site
1 months
Registration as SSI
1 weeks
Acquiring loan
3 months
Machinery procurement, erection and commissioning
2 months
Recruitment of labors etc.
1 months
Trial runs
1 months

Process of Manufacture:

        Raw materials are fed into the hopper, which gets heated in the barrel with the help of the heater
The melt in the extruders is conveyed forwarded by the screw rotation
The 2 extruders individually feed the 2 channels within the die
All the flow channels coverage into a single flow channel, just a little distance before the material is blown out from the annular die orifice
The rotating die ensures even distribution of the melt flow while coming out of the die orifice
The rotating die ensures even distribution of the melt flow while coming out of the die orifice
The bubble is cooled by means of air circulation arrangements
The pre-determined size of the blown film is obtained by inserting compressed air through the die.
Iris rings, flattering boards, counter rotating nip rolls draw the film upwards and flatten it into a two layer lay flat film, which is wound on the winder.
The film is also treated with corona discharge equipment and then printed in rotogravure printing machine in desired colors.

Quality Control and Standards

         IS 10141: 1982/1997 or as per customers specification

Production Capacity (per annum)

        a)         Quantity      630 MT
b)         Value         441.00 lakhs

Motive Power

         The total connected load of the unit is 150 KWH. Assume 60% utilization of the connected load.

Pollution control:

         This unit has not been identified on the pollution making industry. However, proper ventilation of the working shed may be assured.

Energy Conservation

         Production by proper planning may save the energy.

Financial Aspects

A. Fixed Capital
i) Land and Building

Area
Rate Rs. / m
Value (Rs.)
Land
500
Working Shed
250
Offices and Stores
100
Rented
15,000

         ii) Machinery and Equipments

Sl.No.
Description
Qty. (Nos.)
Values (Rs.)
1
Co-extrusion Blown film plant
1
28,00,000
2
Corona surface treatment plant
1
2,50,000
3
Rotogravure machine
1
6,00,000
4
Slitter-cum- re-grinder machine
1
1,50,000
5
Testing equipment
LS
50,000
6
Electrification and Installation charges @ 10% of cost
3,85,000
7
Total cost of machinery and equipment
42,35,000
8
Cost of office equipment, working table etc.
50,000

         iii) Pre-operative Expenses: 20,000
Fixed Capital = 43, 20,000/-

B. Working Capital (per month)

i) Personnel

Designation
Nos.
Salary (Rs.)
Total (Rs.)
Manager
1
12,000
12,000
Machine Operator
2
6,000
12,000
Skilled Workers
3
3,000
9,000
Clerck-cum-Accountant
1
5,000
5,000
Unskilled Workers
3
1,500
4,500
Peon
1
1,500
1,500
Total
44,000
Perquisites @ 15% of salaries
6,600
Total
50,600
Or
Say
50,000

ii) Raw materials including Packaging requirement (PM)

Particulars
Qty.
Rate / Kg.
Values (Rs.)
LDPE
52,500
50
26,25,000
Printing Ink
50,000
Packaging Material
5,000
Total
26,28,000

iii) Utilities (per month)

        Power 96 KW x 500 hrs. x Rs.4 x 0.6 utilization———- 1,15,200
Water —————————————————–2,000
        Total —————————————————————-1,17,000

iv) Other Expenses (per month)

Other contingent expenses (per month)
Rs.
Rent
15,000
Postage and Stationery
10,000
Telephone
2,000
Consumable Store
1,000
Repair and Maintenance
1,000
Transportation Charge
10,000
Advertisement and Publicity
1,000
Insurance
4,000
35,000

v) Total Recurring Expenditure

Staff & Labor
Rae Material
Utilities
Other expenses
Total
For 3 Months

C. Total Capital Investment

        1. Fixed Capital —————–43, 20,000
2. Working Capital ————–86,46,000
Total —————————-1,29,66,000

Machinery Utilization

        Co-extrusion process will be the bottleneck operation for this project. The production capacity is 105 kegs. /hr.

i) Cost of Production (per year)

Cost of Production (per year)
Rs.
Total recurring cost
3,45,84,000
Depreciation on machineries @ 10%
4,23,500
Depreciation on office equipment @ 20%
10,000
Interest on total capital investment @ 14%
18,15,240
Total
3,68,32,740
or
Say
3,68,33,000

ii) Turnover (per year)

Item
Qty.(MT)
Rate / Kg.
Value (Rs.)
Co-extruded film
617
70,000
4,31,90,000
Scrap
13
20,000
2,60,000
4,34,50,000

iii) Net Profit (per year)

        Turn over – cost of production = 4,34,50,000 – 3,68,33,000
= 66,17,000

iv) Net Profit Ratio

        Net Profit per year x 100 / Turnover

        = 66, 17,000 x 100 / 4,34,50,000

        = 15.23 %

v) Rate of Return

        Net profit per year x 100 / Total Investment

        = 66, 17,000 x 100 / 1,29,66,000

        = 51.03 %

VI) Breakeven Point (% of Total Production Envisaged)

1
Fixed Cost
Rs.
a)
Depreciation on machinery and equipment
4,23,500
b)
Depreciation on Office Equipment
10,000
c)
Rent
1,80,000
d)
Interest on Capital Investment
18,15,240
e)
Insurance
48,000
f)
40% of Salary and Wages
2,40,000
g)
40% of other expenses
1,68,000
Total
28,84,740
or
Say
28,85,000

B.E.P. = Fixed Cost x 100 / Fixed Cost + Profit

        = 28,85,000 x 100 / 28,85,000 + 66,17,000

        = 28,85,000 x 100 / 95,01,740

        = 30.36 %

 

Blow extrusion of plastic film

The manufacture of plastic film for products such as shopping bags and continuous sheeting is achieved using a blown film line.

This process is the same as a regular extrusion process up until the die. There are three main types of dies used in this process: annular (or crosshead), spider, and spiral. Annular dies are the simplest, and rely on the polymer melt channeling around the entire cross section of the die before exiting the die; this can result in uneven flow. Spider dies consist of a central mandrel attached to the outer die ring via a number of “legs”; while flow is more symmetrical than in annular dies, a number of weld lines are produced which weaken the film. Spiral dies remove the issue of weld lines and asymmetrical flow, but are by far the most complex.

The melt is cooled somewhat before leaving the die to yield a weak semi-solid tube. This tube’s diameter is rapidly expanded via air pressure, and the tube is drawn upwards with rollers, yielding the plastic in both the transverse and draw directions. The drawing and blowing cause the film to be thinner than the extruded tube, and also preferentially aligns the polymer molecular chains in the direction that sees the most plastic strain. If the film is drawn more than it is blown (the final tube diameter is close to the extruded diameter) the polymer molecules will be highly aligned with the draw direction, making a film that is strong in that direction, but weak in the transverse direction. A film that has significantly larger diameter than the extruded diameter will have more strength in the transverse direction, but less in the draw direction.

In the case of polyethylene and other semi-crystalline polymers, as the film cools it crystallizes at what is known as the frost line. As the film continues to cool, it is drawn through several sets of nip rollers to flatten it into lay-flat tubing, which can then be spooled or cut.

Sheet/film extrusion

Sheet/film extrusion is used to extrude plastic sheets or films that are too thick to be blown. There are two types of dies used: T-shaped and coat hanger. The purpose of these dies is to reorient and guide the flow of polymer melt from a single round output from the extruder to a thin, flat planar flow. In both die types ensure constant, uniform flow across the entire cross sectional area of the die. Cooling is typically achieved by pulling through a set of cooling rolls (calender or “chill” rolls). In sheet extrusion, these rolls not only deliver the necessary cooling but also determine sheet thickness and surface texture.[6] Often co-extrusion is used to apply one or more layers on top of a base material to obtain specific properties such as UV-absorption, texture, oxygen permeation resistance, or energy reflection.

A common post-extrusion process for plastic sheet stock is thermoforming, where the sheet is heated until soft (plastic), and formed via a mold into a new shape. When vacuum is used, this is often described as vacuum forming. Orientation (i.e. ability/ available density of the sheet to be drawn to the mold which can vary in depths from 1 to 36 inches typically) is highly important and greatly affects forming cycle times for most plastics.

Tubing extrusion

Blown Film Plant

success in the blow film making machine, blown film machine, blown film extrusion, plastic inflation machine, blown film extruder, blown film machinery

May 30, 2014 • Mrunal Ramanuj

success in the blow film making machine, blown film machine, blown film extrusion, plastic inflation machine, blown film extruder, blown film machinery

know about blown film machine aba multi layer film line co-extrusion film plant 3-layer Co-extrusion Blown Film Extrusion Line Find out the properties of blown films and how the thickness of blown films results in enhancing in its resistance properties also. Learn about the different types of blown films and its package benefiting properties. Blown film is also applied as film line in packaging as lining gives additional strength to the outer material and keeps the product safe from external atmospheric influence. Mono layer blown film line acts as a lamination for jute bags, aluminum foils, woven sacks, etc. Multilayer blown films are many times thicker and tougher than mono layer blown films. It is widely applied for its puncture resistance and dart impact strength properties. Some of the industries that benefit from multi-layer blown films lines are beverages, edible oil, instant tea, and many liquid products. PPTQ blown film machine is applied to obtain high quality of tough blown films that can be used to obtain complete moisture resistance and sealing properties. Food industry finds a great percentage of application of PPTQ blown film line. Blown film and blown film line manufacturers like http://www.oceanextrusions.com/mono-layerblownfilmplant-.html offer high quality machinery to produce wide range of blown films that are then used for packaging industry. These machines can produce different types of blown films without any compromise made in its resistance properties. h. https://www.youtube.com/watch?v=UWcqjQWoEgY PE Blown film machine Plastic processing machinery Multilayer coextrusion blown film machine All Product                             has lead to . All polyethylene film applications in packaging, agriculture, lamination, and construction, consumer, industrial, and health care are reviewed and discussed in dept· Multi layer coextrusion … blown film coextrusion lines, multilayer films of HDPE, MDPE, LDPE, LLDPE, EVA, and PP · ABA 3 layer co extrude Single Screw Extrusion Extrusion Process Extrusion Safety Equipment Plastic Behavior Screw Design Processing Conditions Scale-up Shear Rates, Pressure Drops, and Other Extruder Calculations Glossary Twin Screw Extrusion Extrusion Process Extrusion Safety Equipment: Corotating, Counter-rotating, Non-intermeshing, and Conical Plastic Behavior Screw Design Shear Rates, and Other Twin Screw Calculations Polymeric Materials Definition and Identification of Different Polymer Types Polymerization Mechanism Polymer Types and Structure Effect of Molecular Weight on Extrusion Crystalline versus Amorphous Polymers Rheology Physical Properties Polymer Processing PART 2Troubleshooting the Extrusion Process Problem Solving Five Step Process Design of Experiments Quality Troubleshooting: Mechanical, Product, Sheet, Coextrusion, Pipe/Profile, Blown Film, Cast Film Auxiliary Equipment Feed Systems/Blenders Gravimetric/VolumetricFeeders Resin Dryers Gear Pumps Screen Changers Granulators/Pulverizers Screw Cleaning Purge Materials Coextrusion Objective of Coextrusion Equipment Material Consideration Extrusion Applications Compounding Sheet/Film Blown Film Profile Pipe/Tubing Wire Coating Monofilament Extrusion Blow Molding Coating/Lamination Foam Coextrusion Reprocessing Information on Different Types of Extrusion Machines [INFOGRAPH]

From hardware and materials through processing and properties, this book presents a broad coverage of blown film extrusion and ensures a useful balance of theory and practice. This book explains certain effects in the blown film process so readers are better able to troubleshoot and improve their operations. Also, current practices and equipment are emphasized to keep readers up-to-date with the most productive and efficient technology. Companion CD: The Blown Film Extrusion Simulator enhances the learning process. This software was developed to teach blown film extrusion equipment operation and processing principles. The realistic graphic interface and intuitive operating techniques were designed to emulate processing methods so learners can quickly move from the simulator to real production equipment. Click here to download a free software demo. New to This Edition: Materials: Polyvinylidene Chloride (PVDC) Processing: Double Bubble Processing Product Applications: Breathable Packaging, Shrink Film, High Barrier Film Troubleshooting: Wrinkles Successful production of coextruded products depends on several key factors, including polymer selections, hardware design (screw, feedblock/die, handling equipment, layer construction and optimal processing conditions). Proper selection and adjustment of each factor will minimize difficulties and ensure high quality coextrusion results   Successful production of coextruded products depends on several key factors, including polymer selections, hardware design (screw, feedblock/die, handling equipment, layer construction and optimal processing conditions). Proper selection and adjustment of each factor will minimize difficulties and ensure high quality coextrusion results. Troubleshooting methods for coextrusion become increasingly complex as the number of layers in the structure increases, as the asymmetry of multi-layer con- struction grows, or as processing and rheological characteristics of coextruded materials differ greatly from one another. Understanding the problems associated with nonuniform layer distribution and interfacial instability between layers or on film surfaces is very important when troubleshooting the coextrusion process.     THE UNIFORMITY PROBLEM Nonuniform layer distribution is one of the more common problems encoun- tered in film coextrusion. This nonuniformity may appear in either the direction of extrusion or tangential to the direction of film production. Layer uniformity in the machine direction can be influenced by die imperfec- tions, poor die design or adjustment, excessive extruder pressure variation, variable film tension, or film bubble or web instability. Layer uniformity tangential to machine direction can be influenced by poor melt temperature uniformity, viscosity mismatch between layers, poor hardware design, or viscoelastic flow characteristics induced by excessive shear stress. Poor layer uniformity tangential to machine direction is caused by nonuniform melt temperature across a melt pipe, feedblock and/or die, as well as poor melt- ing in an extruder. Melt temperature variance alters viscosity uniformity, which exhibits a change in flow characteristics and layer distribution. Melt temperature of a single polymer stream can often vary by as much as 30°F. A general rule of thumb is to achieve ±2°F or less variation in melt temperature for each extruder. Homogenous melt temperatures can be achieved through installation of a static mixer in the melt pipe, a dynamic mixer on the extrusion screw or a more efficient screw design, or through adjustment of pipe, feedblock and/or die temperatures. Variation in the thickness of a film, which eventually reaches a steady-state condition of nonuniformity (assuming homogenous melt temperature conditions for each polymer), can be caused by a viscosity mismatch between layers. In a coextrusion system, lower-viscosity polymers migrate to the region of highest shear stress (nearest the die wall) and tend to encapsulate higher-viscosity poly- mers. The amount of migration is dependent on the degree of viscosity mismatch, the length of the flow path, and the shear stress in the system.     IMPROVING LAYER VARIATION Improvements in layer variations that are caused by viscosity-induced flow behavior can be achieved through adjustment of melt temperature, modification of distribution channels in the feedblock or die, or selection of a polymer with different viscosity characteristics which most commonly are measured by melt index. Also, annular dies typically are more tolerant of viscosity mismatch than flat-die systems.     1   Nonuniform layer distribution in the direction tangential to extrusion can also be caused by poor hardware design. Improperly designed flow channels of the feedblock or die can cause poor steady-state layer distribution of materials, even with the most closely matched viscosities. Nonuniform distribution of layers, in the form of parabolic flow lines, inter- mixing of layers, roughness between polymer boundaries, melt fracture, or uncharacteristically high haze, can be caused by interfacial instability between layers or on film surfaces. The instabilities are believed to be a result of the viscoelastic behavior of polymers at the die land or region of highest shear stress. Improvements in layer instabilities can be achieved by reducing the shear stress between coextrusion layers and/or the die-land surfaces. Shear stress can be reduced by decreasing total output rate, increasing skin-layer melt temperature (decrease in viscosity), increasing the die gap, adding a process lubricant to the skin material, or selecting a lower viscosity material. An increase in the thickness of the skin layer can also reduce instability between polymer layers by moving the interface further from the high-shear-stress die wall. This is especially significant for asymmetric coextrusion constructions. Finally, if coextrusion layers exhibit dramatic differences in melt elasticity, then choose materials that match more closely in extrudateMacbeth movie elasticity as measured by extrudateMacbeth movie swell.   TROUBLESHOOTING AT A GLANCE Problem: Lines in the film surface Possible cause: Die imperfections Solutions:

  • Clean die buildup
  • Remove contaminants from polymer melt channel
  • Repair die nicks and burrs

Problem: Gauge bands on film roll Possible cause: Poor die design Solutions:

  • Install spiral-channel die design to eliminate weld lines
  • Install rotating nip assembly in tower

Possible cause: Poor die adjustment Solutions:

  • Adjust concentricity of die gap
  • Center air ring in relation to die gap

Problem: Repeating pattern of variation in thickness of layer(s) Possible cause: Excessive extruder pressure variation (surging) Solutions:

  • Achieve ±1 percent or less variation in total head pressure for each extruder
  • Adjust extruder temperature profile (feed and transition zones)
  • Increase back pressure with restrictor flow plug
  • Increase back pressure by installing fine-mesh screen pack
  • Change screw design of surging extruder(s)
  • Check for worn screw(s) and replace if needed
  • Check extruder feedthroat(s) for bridging and correct if needed

Possible cause: Variable film tension Solution:

  • Eliminate variability in drive speed

Possible cause: Film bubble instability Solutions:

  • Protect bubble from atmospheric air turbulence
  • Correct pressure instability of air ring and/or internal air flow

2   Problem: Intermittent and somewhat random variation in thickness of layer(s) Possible cause: Poor melt temperature uniformity Solutions:

  • Achieve ±2°F or less variation in melt temperature for each extruder
  • Adjust extruder temperature profile to ensure complete melting of

extrudateMacbeth movie

  • Install new screw design with dynamic mixer for more efficient melting

capacity

  • Reduce screw speed for increased residence time to complete melting

of the polymer(s)

  • Adjust temperature of feed channels, die and/or feedblock

Problem: Variation in thickness of layer(s) that reaches steady-state distribution Possible cause: Viscosity mismatch of polymer layers Solutions:

  • Select polymers with matching viscosities
  • Adjust temperature of polymers to aid in matching viscosities

Possible cause: Poor hardware design Solution:

  • Change die and/or feedblock design

Problem: Uncharacteristically high film haze Possible cause: Viscoelastic flow characteristics induced by excessive shear stress between layers and/or feedblock/die surfaces Solutions:

  • Select lower-viscosity skin layer(s)
  • Increase melt temperature of skin-layer polymers
  • Increase die temperatures
  • Reduce total extrusion output
  • Increase die-gap opening
  • Add process lubricant to skin-layer polymer
  • Increase thickness of skin layers
  • Select polymer(s) that exhibit similar melt elasticity behavior

(extrudateMacbeth movie swell)   Problem: Parabolic-shaped flow lines in direction of extrusion Possible cause: Same as for uncharacteristically high, film-haze problem Solution:

  • Same as for uncharacteristically high, film-haze problem

Problem: Intermixing of polymer layers Possible cause: Same as for uncharacteristically high, film-haze problem Solution:

  • Same as for uncharacteristically high, film-haze problem

Problem: Roughness between polymer-layer boundaries Possible cause: Same as for uncharacteristically high, film-haze problem Solution:

  • Same as for uncharacteristically high, film-haze problem

Problem: Melt fracture of film surface Possible cause: Same as for uncharacteristically high, film-haze problem Solution: • Same as for uncharacteristically high, film-haze problem 2layer03 https://www.youtube.com/watch?v=ZJ4T36QQRlk Coextrusion Processing Defined The conversion of multiple thermoplastics, flowing through separate streams, that are combined into a common primary passage and then shaped by a die. Multiple layers provide properties that cannot be provided by a single material for high barrier coextrusion processing. The main classes are: film; sheet; tubing; coating; and blowmolded shapes.FILM COEXTRUSION: A Troubleshooting Guide 03 Successful Production of Coextruded Products Depends on Three Key Factors 1. Polymer Selections 2. Design of Hardware Screws, Feedblock/Die, Handling 3. Coextrusion Layer Construction 4. Optimal Processing ConditionsFILM COEXTRUSION: A Troubleshooting Guide 04 Layer Uniformity is Influenced by: • Variations in extrusion pressure • Nominal extrusion melt temperature • Viscosity-induced web flow • Bubble or melt instability • Variable film tension • Poor die design or improper adjustment • Die imperfections or contaminants Interfacial Flow Instability is Caused by: • Interfacial critical shear stressFILM COEXTRUSION: A Troubleshooting Guide 05 Extrusion Pressure Variations Variation in extrusion pressure, often referred to as surging, is directly related to feeding stability of an extruder. Improving layer uniformity caused by pressure variation can be achieved through: • Adjustment of back pressure – Screenback – Restrictor flow plug • Extrusion screw design of feed and transition sections • Adjustment of extrusion screw-temperature profile • Prevent polymer bridging in feedthroat • Replace/repair worn extrusion screwFILM COEXTRUSION: A Troubleshooting Guide 06 Head Pressure Trace 0 15 30 45 60 75 90 105 120 TIME (seconds) 1850 1840 1830 1820 1810 1800 1790 1780 1770 1760 1750 HEAD PRESSURE 1805 1795 1785 1775 1765 1755 1745 1734 1725 1715 1705 HEAD PRESSUREFILM COEXTRUSION: A Troubleshooting Guide 07 Layer Thickness Instability Caused by Pressure Variation FLOW DIRECTION STABLE FLOW Uniform thickness ONSET OF INSTABILITY Small gauge variation SEVERE INSTABILITY Large gauge variationFILM COEXTRUSION: A Troubleshooting Guide 08 Extrusion Flange Back Pressure Adjustment ADJUSTABLE VALVE INSTRUMENT PORTFILM COEXTRUSION: A Troubleshooting Guide 09 Typical Arrangement of Coarse and Fine Screens Between the Screw and Breaker Plate BREAKER PLATE COARSE SCREEN FINE SCREENS COARSE SCREEN RESIN FLOWFILM COEXTRUSION: A Troubleshooting Guide 10 Melt Temperature Variations Nonuniform melt temperature across a melt pipe, as well as poor polymer melting in an extruder, cause poor layer uniformity. Homogenous polymer melt temperatures can be achieved through: • Static and/or dynamic mixers • Adjustment of pipe and die temperatures • Adjustment of extrusion screw temperature profile • Replace/repair worn extrusion screwFILM COEXTRUSION: A Troubleshooting Guide 11 Melt Thermocouple Trace 0 15 30 45 60 75 90 105 120 TIME (seconds) 380 358 356 354 352 350 348 346 344 342 340 MELT TEMPERATURE 380 358 356 354 352 350 348 346 344 342 340 MELT TEMPERATUREFILM COEXTRUSION: A Troubleshooting Guide 12 414° 410° 406° 402° 398° °F 394° 390° 386° 382° 378° 374° 0 1/8 1/4 3/8 1/2 5/8 3/4 7/8 0 BARREL WALL BARREL CENTER LINE BARREL WALL Typical Temperature Profile of Polymer Melt Stream in PipeFILM COEXTRUSION: A Troubleshooting Guide 13 Layer Thickness Instability Caused by Nonuniform Melt Temperature FLOW DIRECTION STABLE FLOW Uniform thickness ONSET OF INSTABILITY Small gauge variation SEVERE INSTABILITY Large gauge variationFILM COEXTRUSION: A Troubleshooting Guide 14 Infographic- How does a blown film line and blown film plant is Better 2014-01-24 11-39-57 Coextrusion Processing Defined The conversion of multiple thermoplastics, flowing through separate streams, that are combined into a common primary passage and then shaped by a die. Multiple layers provide properties that cannot be provided by a single material for high barrier coextrusion processing. The main classes are: film; sheet; tubing; coating; and blowmolded shapes.FILM COEXTRUSION: A Troubleshooting Guide 03 Successful Production of Coextruded Products Depends on Three Key Factors 1. Polymer Selections 2. Design of Hardware Screws, Feedblock/Die, Handling 3. Coextrusion Layer Construction 4. Optimal Processing ConditionsFILM COEXTRUSION: A Troubleshooting Guide 04 Layer Uniformity is Influenced by: • Variations in extrusion pressure • Nominal extrusion melt temperature • Viscosity-induced web flow • Bubble or melt instability • Variable film tension • Poor die design or improper adjustment • Die imperfections or contaminants Interfacial Flow Instability is Caused by: • Interfacial critical shear stressFILM COEXTRUSION: A Troubleshooting Guide 05 Extrusion Pressure Variations Variation in extrusion pressure, often referred to as surging, is directly related to feeding stability of an extruder. Improving layer uniformity caused by pressure variation can be achieved through: • Adjustment of back pressure – Screenback – Restrictor flow plug • Extrusion screw design of feed and transition sections • Adjustment of extrusion screw-temperature profile • Prevent polymer bridging in feedthroat • Replace/repair worn extrusion screwFILM COEXTRUSION: A Troubleshooting Guide 06 Head Pressure Trace 0 15 30 45 60 75 90 105 120 TIME (seconds) 1850 1840 1830 1820 1810 1800 1790 1780 1770 1760 1750 HEAD PRESSURE 1805 1795 1785 1775 1765 1755 1745 1734 1725 1715 1705 HEAD PRESSUREFILM COEXTRUSION: A Troubleshooting Guide 07 Layer Thickness Instability Caused by Pressure Variation FLOW DIRECTION STABLE FLOW Uniform thickness ONSET OF INSTABILITY Small gauge variation SEVERE INSTABILITY Large gauge variationFILM COEXTRUSION: A Troubleshooting Guide 08 Extrusion Flange Back Pressure Adjustment ADJUSTABLE VALVE INSTRUMENT PORTFILM COEXTRUSION: A Troubleshooting Guide 09 Typical Arrangement of Coarse and Fine Screens Between the Screw and Breaker Plate BREAKER PLATE COARSE SCREEN FINE SCREENS COARSE SCREEN RESIN FLOWFILM COEXTRUSION: A Troubleshooting Guide 10 Melt Temperature Variations Nonuniform melt temperature across a melt pipe, as well as poor polymer melting in an extruder, cause poor layer uniformity. Homogenous polymer melt temperatures can be achieved through: • Static and/or dynamic mixers • Adjustment of pipe and die temperatures • Adjustment of extrusion screw temperature profile • Replace/repair worn extrusion screwFILM COEXTRUSION: A Troubleshooting Guide 11 Melt Thermocouple Trace 0 15 30 45 60 75 90 105 120 TIME (seconds) 380 358 356 354 352 350 348 346 344 342 340 MELT TEMPERATURE 380 358 356 354 352 350 348 346 344 342 340 MELT TEMPERATUREFILM COEXTRUSION: A Troubleshooting Guide 12 414° 410° 406° 402° 398° °F 394° 390° 386° 382° 378° 374° 0 1/8 1/4 3/8 1/2 5/8 3/4 7/8 0 BARREL WALL BARREL CENTER LINE BARREL WALL Typical Temperature Profile of Polymer Melt Stream in PipeFILM COEXTRUSION: A Troubleshooting Guide 13 Layer Thickness Instability Caused by Nonuniform Melt Temperature FLOW DIRECTION STABLE FLOW Uniform thickness ONSET OF INSTABILITY Small gauge variation SEVERE INSTABILITY Large gauge variationFILM COEXTRUSION: A Troubleshooting Guide 14 Adjustable Depth Prob

Mono Layer Blown Film Extrusion lines, Multi Layer Blown Film blown film extrusion lines for mono layer, and complex multi-layer films of HM LD PP HDPE, MDPE, LDPE, LLDPE, EVA monolayer blown film plants, multilayer blown film plant Blown Film Extrusion Machine blown film machine, plastic bag making machine, film extrusion machine, flexo printing machine, stretch film Plastic Film Extruder, Blown Film Extruder, Film Blowing Machines, Blown Film Lines, Laboratory Extruders, Bag Making Machines

May 29, 2014 • Mrunal Ramanuj

Operate A Mono Layer Blown Film Extrusion Lines, Extrusion Machine Operate a blown film extrusion Plant for co-extrusion production Mono Layer Blown Film Extrusion lines, Multi Layer Blown Film blown film extrusion lines for mono layer, and complex multi-layer films of HM LD PP HDPE, MDPE, LDPE, LLDPE, EVA  monolayer blown film plants, multilayer blown film plant Blown Film Extrusion Machine blown film machine, plastic bag making machine, film extrusion machine, flexo printing machine, stretch film Plastic Film Extruder, Blown Film Extruder, Film Blowing Machines, Blown Film Lines, Laboratory Extruders, Bag Making Machines Multi-Layer Blown Film Plant- Among the different types of blown film plants and relative plastic extrusion machinery a multi-layer blown film plant can stay a best option for co extruder feature. There are advanced features added to multi layer blown film machinery such as the grooved feed barrel, dosing system, rotating die, automatic bubble cage, etc which helps in experiencing high productivity as well as better quality. Packaging for confectionaries, dairy products, fast foods, can be produced in addition to general types of food packaging requirements. Click here for the finest quality multi layer blown film plant. Visit –

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What is Blown Film Extrusion? 



  • Blown Film Extrusion is one of the most common polymer conversion processes in the world
  • Film is made by extruding molten plastic through a circular die, forming an inflated tubular bubble that moves through a cage as it cools, that is then collapsed and formed into rolls
  • The typical film blowing process consists of a series of stages, including extrusion, blowing, collapsing, and winding

HIPF Course Description


Course Objective

At the end of the course, the trainees will be able to:

  • Develop a working knowledge of and learn how to operate a Blown Film Extrusion machine
  • Understand the basics of blown film technology, the common material used, and some common problem solving situations
  • Analyze and solve practical blown film problems
  • Develop a working knowledge on maintaining a blown film machine

Course Outline

    1. Principles of Blown Film Extrusion

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      Definition and Principle; Product and Applications; Film Fabrication Process; Types of Blown Film Machines
    1. Resin Materials for Blown Film

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      Raw Materials Use for Blown Film Extrusion; Three Common Polyethylene Grades Used for Blown Film; Suitable Grade index for Blown Film
    1. Safety Education for Blown Film Operation

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      Safety Guideline and SOP; Personal Protective Equipment (PPE); Safety Devices; Warning Signs; Safety Rules for Operation; Safety Instructions on Operation
    1. The Main Components of Blown Film Machine

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      The Extruder; The Die Head and Die; The Bubble Cooling System; Bubble Stabilizer; The Take-Off System/Pinch or Nip Rolls; The Wind-Up System; Corona Treatment
    1. Die and Air Ring as Major Components for Blown Film

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      Kinds of Die for Blown Film; Details of Die and How It Works; Details of Air Ring and How It Works; Die and Air Ring Care and Maintenance
    1. Introduction to the Blown Film Extrusion Machine

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      BFE Process Flow; Start-Up of Blown Film Line; Quality Control for Blown Film; Scheduled Shut-Down of Blown Film Line; Emergency Shut-Down of Blown Film Line; Switching On After Emergency Stop
    1. Operating Skills for Blown Film Extrusion Technology

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      Checking of Machine Conditions Before Operation; Winder Preparations; Film Guide Set-Up and Importance; Blown Film Run Preparations; Die Checking and Adjustments; Parameter Setting-Up; Switching On After Emergency Stop; Changing Die; Changing Materials and Filling Procedures
    1. Die Dismantling, Cleaning and Mounting

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      Die Dismantling Procedure; Die Cleaning and Care; Understand Die Assembly and Mounting
    1. Blown Film Extrusion Troubleshooting

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      Types of Trouble of Blown Film Process; Unstable Bubble; Film Appearance; Machine Malfunction
    1. Common Secondary Film Processing Methods

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      Printing; Bag Making Process; Scrap Recycling
    1. Quality Control of Blown Film

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      Quality Check for Blown Film; Production Recording; How To Report the Result of Manufacturing
  1. Practice Plant Operations

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provides the blown film industry with the latest in high “value added” technologies. Since 1989, DRJ has established industry standards in internal bubble cooling (IBC) control, width control, and machine direction sealing technologies and continues to develop innovations that make our customers more competitive and more profitable.The quickest way to get to know about us is to view this 4 minute video. It describes our company, our industry and how our products ensure that you add value to your bottom line.

Next if you are interested in IBC technology, click on the Getting Started link below. You can also click on the blown film line picture to see specific details. Don’t forget our Products link to see everything we do to provide solutions not just answers for your blown film processing requirements.

Blown Film Extrusion Line

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  1. This processing guide focuses on how to produce films made from either high density polyethylene (HDPE) or linear low density polyethylene (LLDPE) resins.The HDPE FILM Resins section covers key terms and experience specific to polyethylene resins in

    general, and HDPE resins specifically. It is organized into five subsections:
    A.

    B. C. D. E.

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    Blown Film Extrusion

    Blow-Up Ratio

    Extrusion Conditions

    Processing Conditions

    Extruder And Die Temperature Settings
    The LLDPE Film Resins section covers key terms and experience specific to LLDPE resins. It is organized

    into two subsections:

    A. Blown Film Extrusion

    B. Extruder And Die Temperature Settings

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    In addition, Table 1 presents a very useful polyethylene film processing troubleshooting guide.

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    The information, terminology and experience provided in this guide compile many years of technical

    and operational knowledge into one handy resource, useful in most situations most of the time. For

    more in-depth processing and troubleshooting assistance,

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Polyethylene Film Processing Guide

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I. HDPE FILM RESINS

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high density polyethylene (HDPE) resins for

mainly blown film applications. The workhorse of Formosa Plastic’s HDPE film resins is the Formolene®

High Molecular Weight High Density Polyethylene (HMW-HDPE) resin product line, which is produced

using a unique Nippon Petrochemical bimodal process. These HMW-HDPE film products are designed to

have a broad, bimodal Molecular Weight Distribution (MWD) that provides both excellent extrusion processing and physical film properties.

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Formosa Plastics also produces a family of conventional HDPE film resins from

process. These HDPE film resins from this process are categorized into two types of resins: Medium Molecular Weight High Density Polyethylene (MMW-HDPE) film resins and MMW-HDPE Moisture Vapor Transmission Rate (MVTR) barrier film resins.

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HMW HDPE film resins range in density from 0.949 to 0.953 with a melt

index ranging from 0.040 to 0.15. These resins are designed with different melt index, density and/or additive packages for a variety of applications. Technical Data Sheets for these products are available at www.fpcusa.com/pe/index.html.

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Films produced with HMW and MMW HDPE resins exhibit high impact and film stiffness, as well as good

tear strength and excellent tensile strength. The combination of a broad, bimodal MWD, low melt index

and high density of the Formolene® brand HDPE film resins provide an excellent balance of film performance properties for a variety of film applications.

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HDPE film resins are easily processed into very thin gauge films as low as 6 microns

(0.25 mils), as well as into heavy gauge films on the order of 96 microns (4.0 mils) or greater. The

broad MWD of Formolene® brand HDPE film resins enables them to be processed at lower melt

temperatures than competitive HMW HDPE blown film resins. This provides for better bubble stability and gauge control, as well as improved energy savings.

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HDPE film resins are designed with excellent stabilization packages to protect the

integrity of the polymer from degradation, especially for applications requiring a high level of trim

recycle such as grocery bags commonly referred to as “T-Shirt” bags due to their resemblance to the undergarment.

Polyethylene Film Processing Troubleshooting Guide
Common film processing problems and possible corrective actions
1. Low Dart Impact 5. Gels, Holes, Bubble Breaks 9. Low Extruder Output
2. Low MD Tear; Split Film 6. High Gauge Variation 10. High Extruder Pressure
3. Melt Fracture 7. Die Line 11. Poor Roll Geometry
4. Poor Bubble Stability 8. Port Line
Abbreviations: BUR = Blow-Up Ratio MD = Machine Direction MI = Melt Index
Problem Observed Possible Causes Possible Corrective Actions
1. Low Dart Impact 1. High melt temperature
2. Inadequate cooling
1. Reduce melt temperature
2. Increase cooling, neck height, BUR
2. Low MD Tear / Split Film 1. Too much film orientation
2. Resin density too high
3. Thermal degradation of the
polymer during extrusion
1a. Increase BUR
1b. Decrease die gap
1c. Increase frost line height
2. Use a lower density resin
3a. Decrease melt temperature
3b. Add an antioxidant masterbatch
3. Melt Fracture 1. Low extrusion temperature
2. Inadequate die gap
3. Excessive friction at die lip
4. Resin MI too low for extrusion
conditions or equipment
1. Increase melt temperature
2. Increase die gap
3a. Lower processing rate
3b. Add processing aid to reduce COF
4. Use a higher melt flow resin
4. Poor Bubble Stability 1. Melt temperature to high
2. Too much or too little cooling air
3. MI too high for process
4. Output rate too high
5. Misalignment of nip rolls
1. Reduce melt temperature
2. Adjust cooling air
3. Lower processing rate
4. Reduce output rate
5. Realign nip rolls
5. Gels, Holes, Bubble Breaks 1. Contamination
2. Excessive regrind or reprocessed
material
3. Dirty screw, die or screen pack
4. Poor mixing
1. Check for contamination in silos, transfer
systems, colors and other masterbatches
2. Stop or reduce the ratio of regrind and
reprocessed material until problem improves
3. Clean screw and die plus change screen pack
4a. Check screw
4b. Check heater bands and thermocouples
6. High Gauge Variation 1. Dirty screw, die or screen pack
2. Uneven cooling
1a. Clean screw and die plus change screen pack
1b. Clean die
2. Check temperature settings & recalibrate
7. Die LIne 1. Dirty or damaged die lip
2. Insufficient purging
1. Clean or repair die
2. Increase purge time between transitions
8. Port lines 1. Resin viscosity too high for die
design
2. Die and melt temperature off
3. Melt temperature too low
1a. Use a resin with a higher MI
1b. Consider using a processing aid
2. Narrow the temperature differences between
the die and polymer melt temperature
3. Increase the melt temperature
9. Low Extruder Output 1. Melt temperature too high

1a. Reduce melt temperature.
1b. Check external cooling.
1c. Check extruder screw wear.
10. High Extruder Pressure 1. Contamination 1a. Check extruder heaters, screen pack.
1b. Check for contamination.
11. Poor Roll Geometry 1. Poor bubble stability 1a. Reduce melt temperature.
1b. Increase cooling, die temperature.
1c. Clean die.Blown Film Plant

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B. BLOW-UP-RATIO (BUR) AND POLYMER ORIENTATION

To produce the best physical properties in an extruded film, the proper balance of film orientation in
the machine and transverse direction of a film must be achieved. This relationship is achieved by
adjusting the blow up ratio of the film. The blow up ratio (BUR) is the ratio of bubble diameter to the
die diameter; it indicates the amount of stretching the polymer is undergoing during the shaping of the
film.
Blow Up Ratio (BUR) = (0.637 x Lay-Flat Width) / Die Diameter
Where:
 Lay-Flat is the width of the collapsed film
 Die Diameter is the fixed diameter of a given die

The HMW-HDPE blown film lines typically have small diameter dies to achieve the relatively high BUR
ratios required to obtain optimum film properties. Other polyethylene resins, such as low density
polyethylene (LDPE) and linear low density (LLDPE) resins, normally operate at much lower BURs of 2 to
3. The typical die gaps for HDPE blown film lines are 1.0 to 1.5 mm (40 to 60 mils), which are narrower
than die gaps used for conventional LDPE and LLDPE blown film lines.

As shown in Figure 1 below, HDPE blown films lines have a very unique “High Stalk” bubble shape. The
stalk height recommended for HMW HDPE blown film lines is 7 times to 9 times the die diameter. The
characteristic high stalk bubble shape used for HMW-HDPE Blown film production results in a very high
frost line, which is the transitional phase from molten polymer to solid film. A high frost line enables
the polymer to achieve a balance of film properties by imparting more bi-axial molecular orientation in
the film in the transverse direction (TD) to match the machine direction (MD) orientation.

Figure 1
HMW HDPE AND LLDPE BLOWN FILM

Bi-axial orientation of the polymer molecules in a blown film is important to achieve a balance of the
film’s physical properties. Bi-axial orientation of HDPE blown film is much more difficult than with
either LDPE or LLDPE blown film due to the inherent differences of the polymer structures. Long side
chain molecular branching is prevalent in LDPE and to a lesser degree in LLDPE, but HDPE has very few

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Mono Layer Blown Film Extrusion Lines, Extrusion Machine

May 29, 2014 • Mrunal Ramanuj

  Mono Layer Blown Film Extrusion Lines, Extrusion Machine 

Operate A Mono Layer Blown Film Extrusion Lines, Extrusion Machine Operate a blown film extrusion Plant for co-extrusion productionAll Product

What is Blown Film Extrusion?



  • Blown Film Extrusion is one of the most common polymer conversion processes in the world
  • Film is made by extruding molten plastic through a circular die, forming an inflated tubular bubble that moves through a cage as it cools, that is then collapsed and formed into rolls
  • The typical film blowing process consists of a series of stages, including extrusion, blowing, collapsing, and winding

HIPF Course Description


Course Objective

At the end of the course, the trainees will be able to:

  • Develop a working knowledge of and learn how to operate a Blown Film Extrusion machine
  • Understand the basics of blown film technology, the common material used, and some common problem solving situations
  • Analyze and solve practical blown film problems
  • Develop a working knowledge on maintaining a blown film machine

Course Outline

    1. Principles of Blown Film Extrusion

 

      Definition and Principle; Product and Applications; Film Fabrication Process; Types of Blown Film Machines
    1. Resin Materials for Blown Film

 

      Raw Materials Use for Blown Film Extrusion; Three Common Polyethylene Grades Used for Blown Film; Suitable Grade index for Blown Film
    1. Safety Education for Blown Film Operation

 

      Safety Guideline and SOP; Personal Protective Equipment (PPE); Safety Devices; Warning Signs; Safety Rules for Operation; Safety Instructions on Operation
    1. The Main Components of Blown Film Machine

 

      The Extruder; The Die Head and Die; The Bubble Cooling System; Bubble Stabilizer; The Take-Off System/Pinch or Nip Rolls; The Wind-Up System; Corona Treatment
    1. Die and Air Ring as Major Components for Blown Film

 

      Kinds of Die for Blown Film; Details of Die and How It Works; Details of Air Ring and How It Works; Die and Air Ring Care and Maintenance
    1. Introduction to the Blown Film Extrusion Machine

 

      BFE Process Flow; Start-Up of Blown Film Line; Quality Control for Blown Film; Scheduled Shut-Down of Blown Film Line; Emergency Shut-Down of Blown Film Line; Switching On After Emergency Stop
    1. Operating Skills for Blown Film Extrusion Technology

 

      Checking of Machine Conditions Before Operation; Winder Preparations; Film Guide Set-Up and Importance; Blown Film Run Preparations; Die Checking and Adjustments; Parameter Setting-Up; Switching On After Emergency Stop; Changing Die; Changing Materials and Filling Procedures
    1. Die Dismantling, Cleaning and Mounting

 

      Die Dismantling Procedure; Die Cleaning and Care; Understand Die Assembly and Mounting
    1. Blown Film Extrusion Troubleshooting

 

      Types of Trouble of Blown Film Process; Unstable Bubble; Film Appearance; Machine Malfunction
    1. Common Secondary Film Processing Methods

 

      Printing; Bag Making Process; Scrap Recycling
    1. Quality Control of Blown Film

 

      Quality Check for Blown Film; Production Recording; How To Report the Result of Manufacturing
  1. Practice Plant Operations

 

provides the blown film industry with the latest in high “value added” technologies. Since 1989, DRJ has established industry standards in internal bubble cooling (IBC) control, width control, and machine direction sealing technologies and continues to develop innovations that make our customers more competitive and more profitable.

The quickest way to get to know about us is to view this 4 minute video. It describes our company, our industry and how our products ensure that you add value to your bottom line.

Next if you are interested in IBC technology, click on the Getting Started link below. You can also click on the blown film line picture to see specific details. Don’t forget our Products link to see everything we do to provide solutions not just answers for your blown film processing requirements.Blown Film Extrusion Line

 

  1. This processing guide focuses on how to produce films made from either high density polyethylene (HDPE) or linear low density polyethylene (LLDPE) resins. 

    The HDPE FILM Resins section covers key terms and experience specific to polyethylene resins in

    general, and HDPE resins specifically. It is organized into five subsections:
    A.

    B. C. D. E.

     

    Blown Film Extrusion

    Blow-Up Ratio

    Extrusion Conditions

    Processing Conditions

    Extruder And Die Temperature Settings
    The LLDPE Film Resins section covers key terms and experience specific to LLDPE resins. It is organized

    into two subsections:

    A. Blown Film Extrusion

    B. Extruder And Die Temperature Settings

     

    In addition, Table 1 presents a very useful polyethylene film processing troubleshooting guide.

     

    The information, terminology and experience provided in this guide compile many years of technical

    and operational knowledge into one handy resource, useful in most situations most of the time. For

    more in-depth processing and troubleshooting assistance,

 

Polyethylene Film Processing Guide

 

 

I. HDPE FILM RESINS

 

high density polyethylene (HDPE) resins for

mainly blown film applications. The workhorse of Formosa Plastic’s HDPE film resins is the Formolene®

High Molecular Weight High Density Polyethylene (HMW-HDPE) resin product line, which is produced

using a unique Nippon Petrochemical bimodal process. These HMW-HDPE film products are designed to

have a broad, bimodal Molecular Weight Distribution (MWD) that provides both excellent extrusion processing and physical film properties.

 

Formosa Plastics also produces a family of conventional HDPE film resins from

process. These HDPE film resins from this process are categorized into two types of resins: Medium Molecular Weight High Density Polyethylene (MMW-HDPE) film resins and MMW-HDPE Moisture Vapor Transmission Rate (MVTR) barrier film resins.

 

HMW HDPE film resins range in density from 0.949 to 0.953 with a melt

index ranging from 0.040 to 0.15. These resins are designed with different melt index, density and/or additive packages for a variety of applications. Technical Data Sheets for these products are available at www.fpcusa.com/pe/index.html.

 

Films produced with HMW and MMW HDPE resins exhibit high impact and film stiffness, as well as good

tear strength and excellent tensile strength. The combination of a broad, bimodal MWD, low melt index

and high density of the Formolene® brand HDPE film resins provide an excellent balance of film performance properties for a variety of film applications.

 

HDPE film resins are easily processed into very thin gauge films as low as 6 microns

(0.25 mils), as well as into heavy gauge films on the order of 96 microns (4.0 mils) or greater. The

broad MWD of Formolene® brand HDPE film resins enables them to be processed at lower melt

temperatures than competitive HMW HDPE blown film resins. This provides for better bubble stability and gauge control, as well as improved energy savings.

 

HDPE film resins are designed with excellent stabilization packages to protect the

integrity of the polymer from degradation, especially for applications requiring a high level of trim

recycle such as grocery bags commonly referred to as “T-Shirt” bags due to their resemblance to the undergarment.

Polyethylene Film Processing Troubleshooting Guide
Common film processing problems and possible corrective actions
1. Low Dart Impact 5. Gels, Holes, Bubble Breaks 9. Low Extruder Output
2. Low MD Tear; Split Film 6. High Gauge Variation 10. High Extruder Pressure
3. Melt Fracture 7. Die Line 11. Poor Roll Geometry
4. Poor Bubble Stability 8. Port Line
Abbreviations: BUR = Blow-Up Ratio MD = Machine Direction MI = Melt Index
Problem Observed Possible Causes Possible Corrective Actions
1. Low Dart Impact 1. High melt temperature
2. Inadequate cooling
1. Reduce melt temperature
2. Increase cooling, neck height, BUR
2. Low MD Tear / Split Film 1. Too much film orientation
2. Resin density too high
3. Thermal degradation of the
polymer during extrusion
1a. Increase BUR
1b. Decrease die gap
1c. Increase frost line height
2. Use a lower density resin
3a. Decrease melt temperature
3b. Add an antioxidant masterbatch
3. Melt Fracture 1. Low extrusion temperature
2. Inadequate die gap
3. Excessive friction at die lip
4. Resin MI too low for extrusion
conditions or equipment
1. Increase melt temperature
2. Increase die gap
3a. Lower processing rate
3b. Add processing aid to reduce COF
4. Use a higher melt flow resin
4. Poor Bubble Stability 1. Melt temperature to high
2. Too much or too little cooling air
3. MI too high for process
4. Output rate too high
5. Misalignment of nip rolls
1. Reduce melt temperature
2. Adjust cooling air
3. Lower processing rate
4. Reduce output rate
5. Realign nip rolls
5. Gels, Holes, Bubble Breaks 1. Contamination
2. Excessive regrind or reprocessed
material
3. Dirty screw, die or screen pack
4. Poor mixing
1. Check for contamination in silos, transfer
systems, colors and other masterbatches
2. Stop or reduce the ratio of regrind and
reprocessed material until problem improves
3. Clean screw and die plus change screen pack
4a. Check screw
4b. Check heater bands and thermocouples
6. High Gauge Variation 1. Dirty screw, die or screen pack
2. Uneven cooling
1a. Clean screw and die plus change screen pack
1b. Clean die
2. Check temperature settings & recalibrate
7. Die LIne 1. Dirty or damaged die lip
2. Insufficient purging
1. Clean or repair die
2. Increase purge time between transitions
8. Port lines 1. Resin viscosity too high for die
design
2. Die and melt temperature off
3. Melt temperature too low
1a. Use a resin with a higher MI
1b. Consider using a processing aid
2. Narrow the temperature differences between
the die and polymer melt temperature
3. Increase the melt temperature
9. Low Extruder Output 1. Melt temperature too high

1a. Reduce melt temperature.
1b. Check external cooling.
1c. Check extruder screw wear.
10. High Extruder Pressure 1. Contamination 1a. Check extruder heaters, screen pack.
1b. Check for contamination.
11. Poor Roll Geometry 1. Poor bubble stability 1a. Reduce melt temperature.
1b. Increase cooling, die temperature.
1c. Clean die. Blown Film Plant

 

 

 

 

 

 

 

 

 

 

 

 

B. BLOW-UP-RATIO (BUR) AND POLYMER ORIENTATION

To produce the best physical properties in an extruded film, the proper balance of film orientation in
the machine and transverse direction of a film must be achieved. This relationship is achieved by
adjusting the blow up ratio of the film. The blow up ratio (BUR) is the ratio of bubble diameter to the
die diameter; it indicates the amount of stretching the polymer is undergoing during the shaping of the
film.
Blow Up Ratio (BUR) = (0.637 x Lay-Flat Width) / Die Diameter
Where:
 Lay-Flat is the width of the collapsed film
 Die Diameter is the fixed diameter of a given die

The HMW-HDPE blown film lines typically have small diameter dies to achieve the relatively high BUR
ratios required to obtain optimum film properties. Other polyethylene resins, such as low density
polyethylene (LDPE) and linear low density (LLDPE) resins, normally operate at much lower BURs of 2 to
3. The typical die gaps for HDPE blown film lines are 1.0 to 1.5 mm (40 to 60 mils), which are narrower
than die gaps used for conventional LDPE and LLDPE blown film lines.

As shown in Figure 1 below, HDPE blown films lines have a very unique “High Stalk” bubble shape. The
stalk height recommended for HMW HDPE blown film lines is 7 times to 9 times the die diameter. The
characteristic high stalk bubble shape used for HMW-HDPE Blown film production results in a very high
frost line, which is the transitional phase from molten polymer to solid film. A high frost line enables
the polymer to achieve a balance of film properties by imparting more bi-axial molecular orientation in
the film in the transverse direction (TD) to match the machine direction (MD) orientation.

Figure 1
HMW HDPE AND LLDPE BLOWN FILM

Bi-axial orientation of the polymer molecules in a blown film is important to achieve a balance of the
film’s physical properties. Bi-axial orientation of HDPE blown film is much more difficult than with
either LDPE or LLDPE blown film due to the inherent differences of the polymer structures. Long side
chain molecular branching is prevalent in LDPE and to a lesser degree in LLDPE, but HDPE has very few

 

 

 

 

Application Development of PPTQ Blown Film Machine; Technology that Takes Your Business to New Heights

March 19, 2014 • Mrunal Ramanuj
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woven sack machinery

Development of PPTQ Blown Film Machine and its Application

Its application areas include: food packaging industries, hosiery, confectionery, bakery packing, flowers packing, garment packing, lamination film, blood bags and high general packaging film. The machines are developed with different widths depending on various application areas. The manufactures develop supreme quality products that incorporate the latest technological advancements that meet various customers’ needs. The machines are developed per international standards and certified for use in different industries. The machines are developed with customers at heart with utmost energy efficient and give optimum production. Develop with high precision engineering expertise in meeting modern market.

Advance Features and of PPTQ Blown Film Machine

The machine incorporate advanced features like long life service, manual as well as automatic screen, internal bubble cooling, high productivity, high performances, online thickness monitoring control, surface and center winders, constructed with very high quality materials, auto tension control, manual and automatic screen changer, dosing systems, flexibility and grooved feed barrel. The attractiveness of utilization of this film machine for packaging is basically based on various mechanical operations that are being done in the field. The machines are technologically advanced with automatic screen changer that enhances efficiency and easy operation.

Benefits of Using PPTQ Blown Film Machine in Packaging Industries

The machine are manufactured in various combinations such PP and PE grades to meet customer needs and specific requirement. They are very efficient and are of great importance in enhancing quality and adding attractiveness of the packed products. This resulted to increase in production input resulting to profit maximization. The machine reduces the operating work load and increases the production efficiency. The packaging industries deserved a packaging film machine that keeps good safe, environmental friendly, superior quality, reliable, durable and affordable to packing industries.

PP-TQ Blown Film Plant

Technology Advancement and Innovations in PPTQ Blown Film Machine

 Every packaging industry that seek to increase their profits and maximizes on production must use technologically advanced PPTQ blown film machine. Their advance technological features boost high precision, ease operation, quality standards, fast, accuracy, saves time and cost effective as well as consistent performance. The machines are designed by professional who ensures quality, presentable, originality and innovativeness design in meeting customers’ demands.

Cost Advantages and Extra High Performance with PPTQ Blown Film Machine

There are various advantages in which packaging industries can comfortably enjoy while using high quality and extra performing machine for packaging. Its advantages includes: high speed, effectiveness and exceptional high performances. These merits overdo the cost of purchasing this machine.

The Current Market Trends and Demand for PPTQ Blown Film Machine

In the current market trend this machine is geared by inventiveness and originality in meeting the client demand globally. The market trend is very competitive and the manufacture ensures quality design that meets all the client needs and desires. They embrace newest technology to meets the client description requirement with tangible results. Get more details visit at http://www.oceanextrusions.com/product.html.

Conclusion

The PPTQ blown film machines are specialized fabricated with quality standard raw materials. They have embraced latest technological advancements and efficiently integrated them in meeting industrial demand. The offer extensive desirable benefits to the packing industries such as overall cost saving, durability, conveniences, cost effectiveness, user friendly, preserve item for a long time , aesthetics, and add attractiveness to the packed products hence help in maximizing returns.

Do you know that the Resistance Property of Blown Films gets enhanced when processed for Multi-Layer Form?

January 27, 2014 • Mrunal Ramanuj

Popularity of Blown Film in Packaging Industry

Plastic remains an important ingredient in packaging sector. Comparing the resistance and protection properties, blending plastic and flexible materials with polymers gives out excellent heat and moisture resistant properties.

Significance of Extrusion in making Blown Films

Extrusion is the process of blending polymers with plastic which is then turned to molten condition and send through a extruder to obtain film bubbles of the desired diameter. This extrusion technology stays very advantageous as it increase the barrier property of the packaging films.

Ingredients added in Blown Film Manufacturing

Blown film is made by blending plastic with polymers which is then transformed into polyolefin plastics, polyethylene, etc. The blend enhances the flexibility of the filming material thus variety of blown films is made in accordance with the packaging requirement of respective industries.

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Properties of Blown Film

Blown films are flexible for shaping and a variety of polymers such as LDPE, HDPE, PE, etc can be treated to obtain blown films. This product has several beneficial properties such as high tensile strength, hear and moisture resistance texture, etc.

Resistant Property

Blown films applied in food industry is selected based on is resistance property. The blown film in general stays tough to react with heat and damp condition and the inclusion of polymers make it flame and UV resistance, antibacterial and antifungal resistant as well.

Enhancing Layering in Blown Film Manufacturing

The thickness of blown films can be enhanced with the help of extrusion technology. The production rate of two layered, three layered and multilayered blown film requires different time span in order to obtain the required thickness and it is done by applying co-extrusion technology.

Industrial applications of Mono Layer Blown Film line

Blown film is also applied as film line in packaging as lining gives additional strength to the outer material and keeps the product safe from external atmospheric influence. Mono layer blown film line acts as a lamination for jute bags, aluminum foils, woven sacks, etc

Two layer and three layer Blown Films and its resistance capabilities

Double or two layer blown film line is little thicker than single layer blown film and it stays very useful in packaging industries that produces shopping bags, liners for jute bags, lamination films as well as biodegradable films.

4

Application benefits of Multilayered Blown Film

Multilayer blown films are many times thicker and tougher than mono layer blown films. It is widely applied for its puncture resistance and dart impact strength properties. Some of the industries that benefit from multi-layer blown films lines are beverages, edible oil, instant tea, and many liquid products.

PPTQ Blown Film Machine

PPTQ blown film machine is applied to obtain high quality of tough blown films that can be used to obtain complete moisture resistance and sealing properties. Food industry finds a great percentage of application of PPTQ blown film line.

Conclusion

Blown film and blown film line manufacturers like Ocean Extrusions offer high quality machinery to produce wide range of blown films that are then used for packaging industry. These machines can produce different types of blown films without any compromise made in its resistance properties.

Categories: Blown Film Machine

Blown Film Line and Blown Film Plant is Better than Other Packaging Machinery?

January 25, 2014 • Mrunal Ramanuj

Blown film is considered a tremendous invention for smart packaging options. Investing in a blown film plant will certainly bring more and more benefits in terms of making different kinds of synthetic film. Ocean Extrusions is the right place to find the best Blown film plant.

Ocean Extrusions is a manufacturer of packaging film machinery. With their range of machineries that offer reliable and high quality machinery for more production requirement.  Visit at http://www.oceanextrusions.com/mono-layerblownfilmplant-.html.

Infographic- How does a blown film line and blown film plant is Better 2014-01-24 11-39-57

Categories: Blown Film Machine

Blown Film Line and Blown Film Plant is Better than other Packaging Machinery

December 19, 2013 • Mrunal Ramanuj

What is Blown Film?

  • Among the different types flexible packaging films available a blown film is one that is made of synthetic ingredients like polyethylene.
  • It is made by a technology called blown extrusion where the film in obtained by processing through a spherical dies.

What Features Make Blown Film Special?

  • Blown film or extrusion of blown film is the popular flexible box up film trend preferred in most of the industries.
  • Majority of films made with plastic resins are made with this technology.

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  • Blown film line is a technology with which high quality barrier films can be produced
  • Since, the need for barrier films has been increasing for its advantageous features buying a blown film line will stay a economic as well as profit making option

Advantages of Installing Blown Film Plant

  • Blown film plant is a high end option in extrusion machinery.
  • With blown film plant excellent quality of packaging materials can be produced.

Blown Film Plant from Ocean Extrusions

  • Ocean Extrusions is a manufacturer of packaging film machinery.
  •  With their range of machineries that offer reliable and high quality machinery for more production requirement.
  • Further more information about blown film line and blown film plant, visit –  http://oceanextrusions.com/

Conclusion

Blown film is considered a tremendous invention for smart packaging options. Investing in a blown film plant will certainly bring more and more benefits in terms of making different kinds of synthetic film. Ocean Extrusions is the right place to find the best Blown film plant.

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