Plastic Extrusion Machine Manufacturer and Exporter
Category: Plastic Processing Machinery
Ocean Extrusions Pvt Ltd, Ahmedabad is Manufacturer and Exporter of Plastic Extrusions Machinery Like Monolayer Blown Film Plant, Two layer Blown Film Plant, Multilayer Blown Film Plant, PP/HDPE Box Strapping Line, PET Box Strapping Line, Synthetic String (Sutli) Plant, PP Monofilament Plant, PET Monofilament Plant, Raffia Tape Stretching Line, Air Bubble Sheet Plant, Extrusion Coating Lamination Plant, PP-TQ Blown Film Plant, Plastic Recycling Machine, Fully Auto Die Face Cutter Recycling Machine, Rotogravure Printing Machine, Adhesive Coating Lamination Machine, LD PP Waste Washing Line, PET Waste Washing Line, Extrusion Cast Stretch Film Line, PU Tubing Plant, Slitting Rewinding Machine, Coma Paper Coating Machine
We are Exporting our Machine in Different Countries like Indonesia, Brazil, Nigeria, Bangladesh, Russia, Mexico, Japan, Ethiopia, Philippines, Viet Nam, Egypt, Iran, Germany,
Turkey, Thailand, U.K., France, Italy, Tanzania, South Africa, Myanmar, South Korea, Colombia, Kenya, Spain, Argentina, Sudan, Uganda, Algeria, Iraq, Poland, Canada, Morocco, Afghanistan, Saudi Arabia, Peru, Malaysia, Uzbekistan, Nepal, Ghana, North Korea, Australia, Sri Lanka, Syria, Zambia, Zimbabwe, Senegal, South Sudan, Tunisia, Belgium, Greece, Portugal, Belarus, United Arab Emirates, Serbia, Switzerland, Honduras, Jordan, Lebanon, Singapore, Denmark, Liberia, New Zealand, Kuwait, Georgia, Albania, Qatar, Mauritius, Fiji, Cyprus, Bhutan, Maldives, Etc.
Plastic Recycling Granules Making Machine Exporter
Plastic Recycling Granules Making Machine Manufacturer
Plastic Recycling Granules Making Machine Line
Plastic Granules Making Machine
Plastic Reprocess Plant
Plastic Dana Making Machine
Plastic Waste Reprocess Plant
Plastic Dana Machine
Recycling Machine India
Plastic Processing Machine India
Plastic Recycling Machine
Plastic Granules Making Plant
Plastic Processing Machine
Ocean Extrusions Pvt Ltd offers various models for palletizing plant to make granules form resin in various range in screw diameter 75mm, 90mm and 100mm with / without vent system screw and barrel, die and pattletizer.
Material: All kinds of plastics waste.
Online Force Feeding Film Trim, Tape Trim without cutting aglometer.
For the plastic waste of higher moister, heavy printing, heavy contamination.
This plastic reprocess machine is used to process PET and polyethylene plastic waste to recover the scraps and byproducts at the end of plastic fabrication. PET reprocess plant and PE reprocess plant are the two extrusion machineries with plastic extruder are widely used in plastic extrusion process.
Reducing plastic wastes by recycling process is a great help to save environment. There are list of re process plant than can be chosen from and PP/HDPE reprocess machine is one among the best choices. PP/HDPE reprocess plant can be fed with plastic and raffia wastes and this plastic reprocess machinery stays a cost effective solution that can be applied to make quality ropes, molded components and yarns. This equipment is compatible to accept ingredients including BOPP waste, HDPE wastes and polypropylene residues as well.
Extrusion coating lamination machine is suitable for woven sacks, tarpaulins, jumbo bags, cotton fabrics, jute, paper, aluminum
Extrusions Coating Lamination Machine for rice bag bopp fabric coating paper lamination multi-function Extrusion coating extrusion coating lamination machine line plant for bopp lamination coating machine for paper For Coating thin layer of polyolefin’s (Mainly LDPE / PP) on substrates like Woven Sacks, Tarpaulins, Jumbo Bags, BOPP Film, Paper, Aluminum Foil, Polyester Film, Cotton Fabrics, Jute, Non Woven Fabrics, etc. Up to 5200 mm Web width applications. Tandem Lamination Plant for coating Circular Woven Fabrics, for producing multi layer laminates up to 5 layers along with the various substrates like Paper, Aluminum Foil, Polyester film etc. Lamination line material adds superior protection for products when they are packed. Extrusion coating lamination plant is a suitable solution to produce very slim lining layers made of PP, LDPE. This lining material will them be added to packaging components like woven sacks, giant size bags, aluminum foil, cotton and jute fabric bags, etc. Ocean Extrusions is a leading extrusion coating lamination plant manufacturer and our lamination plant will remain a revenue making investment as the machine components are made of reliable and quality materials. This video caters details about Extrusion Coating Lamination machine that is used for ldpe Coating Lamination, pp coating, pet Coating lamination, woven sacks, paper with Aluminium Foil Coating, bopp lamination with BOPP Film Coating extrusions lamination, metalized Polyester Coating Paper, Cotton Fabric Coating Paper with HDPE Woven Fabric Coating. Further more information visit at http://www.oceanextrusions.com/extrusion-coating-lamination-plant.htmlaminating machine is … The line uses PP or PE as raw material, through the flow-casting coating and … achieving single-sided / double-sided coating or paper-plastic lamination plant
Blown Film Extrusion machine multilayer plant monolayer line
One of the most common methods of film manufacture is Blown (also referred to as the Tubular Film) Extrusion. The process involves extrusion of a plastic through a circular die, followed by “bubble-like” expansion. The principal advantages of manufacturing film by this process include the ability to:
Produce tubing (both flat and gussetted) in a single operation
Regulation of film width and thichness by control of the volume of air in the bubble, the output of the extruder and the speed of the haul-off
Eliminate end effects such as edge bead trim and non uniform temperature that can result from flat die film extrusion
Capability of biaxial orientation (allowing uniformity of mechanical properties)
Blown Film Extrusion can be used for the manufacture of co-extruded, multi-layer films for high barrier applications such as food packaging.
Plastic melt is extruded through an annular slit die, usually vertically, to form a thin walled tube. Air is introduced via a hole in the centre of the die to blow up the tube like a balloon. Mounted on top of the die, a high-speed air ring blows onto the hot film to cool it. The tube of film then continues upwards, continually cooling, until it passes through nip rolls where the tube is flattened to create what is known as a ‘ lay-flat’ tube of film. This lay-flat or collapsed tube is then taken back down the extrusion ‘ tower’ via more rollers. On higher output lines, the air inside the bubble is also exchanged. This is known as IBS (Internal Bubble Cooling).
The lay-flat is then either kept as such or the edges of the lay-flat are slit off to produce two flat film sheets and wound up onto reels. If kept as lay-flat, the tube of film is made into bags by sealing across the width of film and cutting or perforating to make each bag. This is done either in line with the blown film process or at a later stage.
Typically, the expansion ratio between die and blown tube of film would be 1.5 to 4 times the die diameter. The drawdown between the melt wall thickness and the cooled film thickness occurs in both radial and longitudinal directions and is easily controlled by changing the volume of air inside the bubble and by altering the haul off speed. This gives blown film a better balance of properties than traditional cast or extruded film which is drawn down along the extrusion direction only.
3 layer die head with air ring and internal bubble cooling
Film bubble going into a collapsing frame
Control panel graphic from an automated blown film line
Taking an edge trim from film web
The layflat tube is separated into 2 single sheets
Blown Film Line In Action
Polyethylenes (HDPE, LDPE and LLDPE) are the most common resins in use, but a wide variety of other materials can be used as blends with these resins or as single layers in a multi-layer film structure. these include pp, pa, evoh. In some cases, these materials do not gel together, so a multi-layer film would delaminate. To overcome this, small layers of special adhesive resins are used in between. These are known as “tie layers”.
Blown film can be used either in tube form (e.g. for plastic bags and sacks) or the tube can be slit to form a sheet.Typical applications include Industry packaging (e.g. shrink film, stretch film, bag film or container liners), Consumer packaging (e.g. packaging film for frozen products, shrink film for transport packaging, food wrap film, packaging bags, or form, fill and seal packaging film), Laminating film (e.g. laminating of aluminium or paper used for packaging for example milk or coffee), Barrier film (e.g. film made of raw materials such as polyamides and EVOH acting as an aroma or oxygen barrier used for packaging food, e. g. cold meats and cheese), films for the packaging of medical products, Agricultural film (e.g. greenhouse film, crop forcing film, silage film, silage stretch film).
Applications made from Blow Film
The Extrusion Dies
Here are some cross section diagrams of blown film extrusion dies. Each layer in this 5 layer die is shown in a different colour dies are precision made and as such are expensive but their service life is considerable. Each die head will have a working range of die inserts at different diameters to suit the required application. Different die gaps can also be specified depending on the material being extruded.
Once the film has been blown, it is drawn off from the tower using ancillary equipment. Dependent on the end product (film or lay-flat tube) various specialist machines are used. The blown Film Process is a continuous process, as such the machinery has to be designed to cope with both the high speeds involved and be able to operate on a 24 hour basis.
The photographs below show two types of take off winder, single station, and a tandem winder and two examples of dies…
Blown Film Extrusion Die
Single Station WInder
Film Extrusion is one of the most common polymer conversion processes in the world
multilayer line pp machine multilayer extrusion line
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
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 problems
Develop a working knowledge on maintaining a blown film machine
Principles of Blown Film Extrusion
Definition and Principle; Product and Applications; Fabrication Process; Types of Blown Machines
Raw Materials Use for Film Extrusion; Three Common Polyethylene Grades Used for Blown ; Suitable Grade index for
Safety Education for Operation
Safety Guideline and SOP; Personal Protective Equipment (PPE); Safety Devices; Warning Signs; Safety Rules for Operation; Safety Instructions on Operation
The Main Components of 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
Die and Air Ring as Major Components for Blown
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
Introduction to the Blown 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
Operating Skills for Blown 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
Die Dismantling, Cleaning and Mounting
Die Dismantling Procedure; Die Cleaning and Care; Understand Die Assembly and Mounting
Blown Film Extrusion Troubleshooting
Types of Trouble of Blown Film Process; Unstable Bubble; Appearance; Machine Malfunction
Common Secondary Film Processing Methods
Printing; Bag Making Process; Scrap Recycling
Quality Control of Blown Film
The blow film extrusion process is made of four main stages: the polymer in form of pellets are melted together forming a viscous fluid which is continuous. In the molten state the material is forced through an annular die. Injection of air is done midway the die causing the melted extrusion to form a bubble which is uniform in thickness. This is followed by pulling upwards the bubble from the die and the film cooled from inside to give the bubble uniform diameter. The bubble is then passed through a roller in the blow film line and gets flattened making two flat films. The multilayer blow film line is suitable for food packaging and industrial products, and agricultural and technical applications. Visit –http://www.oceanextrusions.com/mono-layerblownfilmplant-.html
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 co–extrusion blown film machine 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 co–extrusion … blown film coextrusion lines, multi–layer films of HDPE, MDPE, LDPE, LLDPE, EVA, and PP · ABA 3 layer co extrudeSingle 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
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
2Problem: 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
Install new screw design with dynamic mixer for more efficient melting
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 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 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
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Extrusion Coating Lamination Line woven sack, jumbo bag, fabric bag making machinery
Extrusion coating lamination machine is suitable for woven sacks, tarpaulins, jumbo bags, cotton fabrics, jute, paper, aluminum foil, non woven, BOPP, polyester, coating pe
Extrusion Coating Lamination Line – Ocean Extrusions
extrusion lamination coating machine
PE Coating, Extrusion coating and lamination and poly coating machine … Coating Plant, Poly Coating Machine, and Extrusion Lamination machine
The actual process of extrusion coating involves extruding resin from a slot die at temperatures up to 320°C directly onto the moving web which may then passed through a nip consisting of a rubber covered pressure roller and a chrome plated cooling roll. The latter cools the molten film back into the solid state and also imparts the desired finish to the plastic surface. The web is normally run much faster than the speed at which the resin is extruded from the die, creating a coating thickness which is in proportion to the speed ratio and the slot gap.
Extrusion laminating is a similar process except that the extruded hot molten resin acts as the bonding medium to a second web of material.
Co-extrusion is, again, a similar process but with two, or more, extruders coupled to a single die head in which the individually extruded melts are brought together and finally extruded as a multi-layer film.
The market for extrusion coating includes a variety of end-use applications such as liquid packaging, photographic, flexible packaging, mill and industrial wrappings, transport packaging, sack linings, building, envelopes, medical/hygiene, and release base.
Industrial/Fabric extrusion coating and lamination
In the heavy gauge extrusion coating process, polymers are extruded through a flat die to form a melt curtain which is applied onto a substrate then rapidly quenched on a chill roll. Coatings produced can be mono or multilayer. Coating weight can as high as 60 osy (2000 gsm). In the extrusion lamination process, the extrudate is applied between two substrates.
(pellets, flakes, powders, liquids) are fed into at least one of our four extruders (two twin-screw extruders and two single-screw extruders). Our twin-screw extruders (TSE’s) are equipped with gear pumps for direct extrusion; however, we also offer off-line compounding services. When TSE’s are used for extrusion of a single resin or an easy to disperse blend, we use a gentle screw configuration. This allows us to use our TSE as single screw extruder with better melt temperature control and optional atmospheric and/or vacuum venting of volatiles.
Materials are extruded through one of our two dies, either a 48″single manifold die or a 36″ triple manifold die. Each die is fed through a five-layer feedblock; the triple-manifold die is equipped with two bypass channels as well, for co-extrusion of up to seven layers. Various selector plug cartridges allow for a wide range of layer configurations. Coating profile can be controlled either manually or automatically thanks to on-line beta gauge measurements.
A substrate (film, non-woven, paper, aluminium, etc.) is unwound from an unwind unit and the melt curtain is applied to the substrate on ourcoating unit. The substrate and extrudate are nipped between a rubber coated roll and a steel roll. Matte and polished finishes are available, and the coating unit position can be adjusted in both the horizontal and vertical directions. A second unwind unit is available for extrusion lamination as well.
Our extrusion coating / lamination unit is equipped with two individually driven and temperature-controlled rolls and a non-driven, temperature controlled rubber-coated roll (temperature range from 15-130°C, 60-265°F; line speed from 0.15 to 100 m/min, 0.5 to 325 fpm). Nip pressure can be controlled up to 240 PLI (for a 36” wide structure). Matte and polished finishes are available for the entire thickness range, and embossing is possible as well.
The line is equipped with EGS Gauging’s System 21 Measurement and Control System, including:
Two Mark III Industrial Scanner frames
Two beta gauges : Sr 90 and Kr 85
One Full Spectrum Infrared sensor
EGS Gauging’s AutoGaugeTM automatic profile control
The strontium-90 gauge is typically used for webs in the range 50-7500 gsm (1.5 – 220 osy). The krypton-85 gauge is used for thinner webs, in the range 10-1000 gsm / (0.3 – 30 osy). The two gauges can be used together, for example to measure a film profile before and after MDO stretching, or, in an extrusion coating process, to measure the coating thickness alone (by measuring the substrate alone with the Kr gauge and the coated product with the Sr gauge)
For Extrusion Coating problems there exist numerous very
valuable trouble shoot guides, which often concentrate on
a specific field of interest.
In this presentation you will find in addition a selection of
experienced phenomena, where chemical and physical
analytical support helped a great deal in creating insight
in these selected phenomena and leading to problem
Extrusion Coating. By concentrating on the most
demanding segments in the Extrusion Coating Market, we
created in close co-operation with our customers a
number one quality product, which is applicable in almost
every Extrusion Coating application.
In this product development process it was crucial to
carefully analyse the experienced problems, in order to
distinguish between specific polymer related and machine
The direct material check will provide info about the structure
of the polymer and offers possibilities to predict the behaviour
of the product during and after processing. In short key words:
Density: Mechanical properties (e.g. rigidity, surface printing,
curling, friction), heat load.
MFR: Mechanical properties, sealing, neck in.
Swell Ratio: High swell – Long Chain Branching – low neck in.
Gel count: Superficial imperfections, Streaks, holes.
SEC MALLS: MWD info concerning High Molecular part (incl.
Branching) is essential to predict processing behaviour.
C5 extraction: Essential fraction for organoleptic prediction.
C6 extraction: Indication for waxes and volatiles
GC headspace: In search of special volatiles related to
organoleptic performance and environment.
Unsaturations: Unsaturations are relatively over represented in
the lower molecular region (sensitivity for oxidation).
Granulate: Particle Size and Shape Distribution (PSSD) qualify
the pellet quality = equal feeding of the extruder feed zone.Technical Marketing PE 8
Trouble shooting in Extrusion Coating
2. Dynamic tests
• Shear curves
• Melt Extension Ratio (MER=melt elongation)
• Melt Extension Force (MEF=melt strength)
• Brabender test: determining MFR before / MFR after k
Shear curves: Important info to predict rheological
behaviour in equipment both for mono and co-extrusion.
DMS: Dynamic Mechanical Spectroscopy gives insight in
elastic behaviour of the polymer.
MEF and MER: Prediction of Draw Down and Neck-in
Brabender test: Submission to shear at defined
temperature and residence time to indicate processing
stability of the polymer.
Trials on the Pilot Extrusion Coating Line provides direct
practical info about the processing characteristics. The
resulting coated products can be examined for e.g. degree
of oxidation in order to create insight in the processing
temperature effects on the polymer, thus predicting e.g.
printability and seal ability. A comparison of polymer
properties before and after coating can be of importance.
Organoleptic evaluation by a professional Taste Panel,
whereby sample preparation and water incubation
procedures are very important.
Irregular pellet size, broad particle size distribution, fines and dust may
disturb the feed, giving rise to irregular extruder output. When working at
high capacity, the pellet quality is essential to guarantee a steady flow of
polymer into the feed zone of the extruder.
Edge waving may occur when the polymer reaches its draw down limit
When working at high capacity, the pellet quality is essential to guarantee
a steady flow of polymer into the feed zone of the extruder.
Screw geometry has to be fit for the specific polymer. A well designed
balance between feed, compression and metering zone will give constant
The outlet of the extruder in general shows a very irregular transverse
temperature profile. This irregular profile has to be equalised in the static
mixer in order to prevent uneven flow out of the die due to melt
Web temperature profile can also influenced by improper functioning of
the heating elements. In addition it must be clear, that the desired melt
temperature must be reached in the outlet of the extruder; in adapter and
die only minimal temperature corrections are allowed, as heat transfer in
these parts is very poor.
Improper heated or fouled deckled die spaces may contain a mix of wax
and cross linked products. When flowing to the die outlet these products
with high viscosity differences cause irregular flows.
Deckle geometry, material and the surface quality of it determine the
sticking of polymer to the surface. A fouled deckle negatively influences
the polymer outlet flow profile.Technical Marketing PE 13
Minimising dust, good house keeping and clean, well
maintained equipment are the key words in this case
HDPE/PP oriented sacks are becoming popular through out the world. This is because they are chemically inert & are water repellent & lighter in weight. They are free & possess sufficient strength & can easily be handled. They are competitive in price with other type of bags also. Air permissible sacks made of polythene strips are used for packing potatoes, coconut etc. The only problem is that the Conventional using of hooks to lift cannot be used with HDPE/PP bags. These bags are expected to substitute jute and craft paper bags in several areas. This would mean a considerable saving in foreign exchanges by avoiding recurring imports of multiwall paper which are at the order of Rs.5 million per annum on one hand and on the other hand lead to an increase in foreign exchange earning in the country by releasing more jute for exports. These bags are free and posses sufficient strength and can easily be printed. These are competitive in price with other available type of bags for this purpose. HDPE/PP woven sacks are having various advantages over the conventional jute fabrics as packing materials. They are water proof and resistant to damage by tear, water and acids. They are chemically inert, light in weight, and more suitable for packaging various chemicals in the form of granules and powders.
Plant Capacity 25000 Nos./Day
Land & Building (Area 12000 sq.mt.) Rs. 8.62 Cr.
Plant & Machinery Rs. 2.40 Cr.
W.C. for 3 Months Rs. 2.30 Cr.
Total Capital Investment Rs. 13.77 Cr.
Rate of Return 21%
Break Even Point 57%
Note: ITI can modify the Capacity and Project Cost based on your requirement.
Contents of the Project Reports
Uses and Applications
Detailed Process of Manufacture
Process Flow Sheet Diagram, Plant Layout,
Cost Economics with Profitability Analysis
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials Details/List and Costs
Power & Water Requirements
Utilities and Overheads
Total Capital Investment
Cost of Production
Break Even Point
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials
Cash Flow Statement
Projected Balance Sheet for 5 Years etc.
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.
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.
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.
Multi layer blown film plant incorporate most advanced features like grooved feed sections, barrier screws, oscillating platform, stackable die, internal bubble cooling, automatic bubble cage, fully automatic surface winder etc. applicable best to the packaging film like Milk packaging film, Oil packaging film, Stretch film, Lamination film along with other packaging industries like Medical and pharmaceutical packaging, Textile and Garments Packaging etc.
Co-extrusion is the extrusion of multiple layers of material simultaneously by co-extrusion two layer blown film plant. This type of extrusion utilizes two or more extruders to melt and deliver a steady volumetric throughput of different viscous plastics to a single extrusion head which will extrude the materials in the desired form. Eg. In the vinyl fencing industry, where co-extrusion is used by blown film line to tailor the layers based on whether they are exposed to the weather or not.
Most of plastic extrusion machines manufacturer acknowledge the fact that extrusion machinery industry is making a comeback after the recent economic downturn. Extrusion Machinery Exporters are making a conscious effort to put their best foot forward with the help of latest technologies to tap the upcoming opportunities all over the world.