The Blown Film Extrusion Process

Labtech Blown Film Attachment

LF-400 LF-250

Attached to a 25 mm Attached to a benchtop single-screw extruder

single-screw extruder
Features of the Labtech Blown Film Attachment (LF-250 and LF-400):
 Nip rolls:
 Pneumatically operated
 Infinitely variable speed – using frequency inverter
 Nip roll open/close switch on control panel,

Nip roll pressure

gauge

Nip roll pressure

control valve

Nip rolls
Nip roll open and
speed close
controller selector
switch
 Nip rolls and guide rolls: 400 mm wide (LF-400) and 250 mm wide (LF-250)
Layflat film width: 350 mm max (LF-400) and 200 mm max (LF-250)

 Tower height: 2.4 m (LF-400) and 2.05 m (LF-250)

Height is manually adjustable

 Horizontal die adaptor (LF-250) or S-shaped adaptor (LF-400),

S-shaped
adaptor
(from LE25
extruder to
die)
 Die orifice: 50 mm diameter (std) (LF-400)
30 mm or 40 mm (LF-250)
 Die opening: 0.8 mm (std) (LF-400 and LF-250)

Die orifice diameter

Die
opening

DIE
 Guide frame and collapsing frame uses polished teak slats,

Adjustable guide cage (frame) Synchronously adjustable

collapsing frame (‘tent’)
 Three guide rollers on the down-side of the tower

 Dual channel air ring,

Adjustable lips.
1 HP blower.
 Inspection cabinet,

 Friction clutch for adjusting windup tension,

 Windup using easily removable bobbins.
Bobbin shaft ‘floats’ on toothed guide rails,

Windup bobbin

Toothed
guide rail

Handle to open and

close the back roll
Options for the blown film attachment:
 Variable speed blower:
 Uses frequency inverter – infinitely variable speed.
 Air flow rate adjusting knob is on the control panel.

 LE-20 and LE-30 extruders can also be used with LF-400

(LE-25 and LE-30 also available in vented versions)
 ‘Pancake’ die available as an option for the LF-400 attachment
 Motorized tower height adjustment:
 Increases height from 2.4 m to 3.5 m
 Tower up/down switch is on the control panel

Tower in
highest
position
Tower in
lowest
position
 Bobbin-free pneumatic expansion windup shaft,

Spring-loaded (for collapsing the shaft),

pneumatically expandable shaft
 Closed-loop control
Maintains a constant pressure of melt going to the die, therefore a
constant flow rate of melt
Useful when a screen changer is being used
Pressure/
temperature
transducer

Die
Extruder

Screen
changer
  Pressure and melt temperature transducer for screen changer

Recess for
Screen
placing new
changer screen

Pressure/
temperature
transducer

Pressure and melt temperature Die

transducer Extruder
(When a preset pressure is reached an
alarm will sound for changing the screen)
Screen
changer
 Blown Film Lines for Higher Output
(e.g. 40 to 50 kg/hr)

either LF-400 or LF-600 blown film attachment

Uses
either LE-30 or LE-45 single-screw extruders
 Blown Film Lines for Higher Output
 Similar basic features to the LF-400 + LE-25 blown film line
 Motorized tower height adjustment is standard
 Single channel cooling ring is standard
(Dual flow air ring optional)
 Nip rolls and guide rolls: 400 mm wide (LF-400) and 600 mm wide (LF-600)
Layflat film width: 350 mm max (LF-400) and 550 mm max (LF-600)

 Die orifice: 40 mm to 80 mm diameter

 Die opening: 0.8 mm (std) (other sizes available)
 Nip rolls (top of tower) can be water cooled (option)
 Blown Film Lines for Higher Output

Air ring. Air supplied by a 1 HP

turbo blower. Infinitely variable
Guide (stabilizing) cage with
speed air flow.
Teflon rollers – simultaneous
(standard –
quick adjustment feature
single channel)
(optional)
 Blown Film Lines for Higher Output
Other machine options:

 Collapsing frame (‘tent’) can be made with carbon fibre rollers

instead of polished teak – for minimum friction
 Blown Film Lines for Higher Output
Other machine options:

 Oscillating (360º) haul-off at top of tower

 Blown Film Lines for Higher Output
Other machine options:

 Automatic web guiding (centering) system

Control panel
for unit

A sensor sends signals for the take-off platform

(shown here) to turn if the film web moves off-centre
 Blown Film Lines for Higher Output
Other machine options:

 Film edge trimming – for making two single layers of film

Edge
trimmer
Nip rolls to
cutting
provide web
blades
tension
(adjustable
speed)

Edge trimmings are would up

on two separate cassettes
 Blown Film Lines for Higher Output
Other machine options:

 Two-station windup unit for the edge trimmed film

Optional:
Digital film meter counters
for each roll
Reset buttons
Flashing light and buzzer
to alert operator that set
film length is reached
 Blown Film Lines for Higher Output
Other machine options:

 Constant film tension windup system

For either single-station windup or two-station windup

A sensor detects the film roll diameter and adjusts the

torque drive accordingly

Film windup tension is constant at all roll diameters

Roll diameter up to a maximum of 600 mm

Pneumatic grippers for easy changing of bobbins

 Blown Film Lines for Higher Output

Standard height LE45-30 ‘Low boy’ LE45-30 single-

single-screw extruder screw extruder
 Multilayer Blown Film Extrusion

Three extruders

Master (central)
control cabinet

Can make up to 7-layer film

When 2 extruders are used:
 Melt from one extruder is
called A
Melt from the other extruder
is called B
Possible to have a single layer film, or 2 layers, i.e. AB,
or 3 layers, i.e. ABA

Extruder A
Spiral flow
Extruder B channels

Extruder A
When 3 extruders are used:
 Melt from one extruder is called
A
Melt from another extruder is
called B
Melt from the third extruder is
called C
Possible to have a 3 layer film, a 4 layer film, or a 5 layer film,
e.g. ABC and ABCBA.
When 4 extruders are used:
 Melt from one extruder is
called A
Melt from another extruder is
called B
Melt from the third extruder is
called C
Melt from the third extruder is
called D
Possible
Examples:to have a 4 layer film, a 5 layer film, a 6 layer film,
or a 7 layer film
A four layer film with different material for each layer:
ABCD
A seven layer film:
ABCDCBA
D could be a ‘barrier’ material
B could be a low cost ‘structural’ (supporting) material
C could be ‘tie’ layers (to bond the B layers to the D layer)
A could be a good printable or sealable material
 Extruder #3
(View from
above) Gear
pump

Mains
Blown film unit
Extruder #2 power
supply

Extruder #1

Central
control unit

Layout showing 3 extruders connected to the die

Extruder sizes: either 20 mm, 25 mm, 30 mm, and 45 mm

 Option: Gear Pump

(View from
DIE Hopper above)
Extruder barrel

Connecting
pipe Gear
pump

Gear
pump The gear pump supplies melt to the die
unit at consistent pressure, and therefore
consistent flow

The gear pump is equipped with a pressure/

temperature sensor coupled to a closed loop
system that ensures constant melt pressure at
the inlet of the gear pump
 The Pancake Die

Die plate

Flow channel

Die mandrel

Melt IN
5-layer pancake die (LPD40-75/4)
connected to 5 separate 20 mm extruders Principle of the flat plate
(’pancake’) die
 Multilayer Pancake Dies
Example: LPD40-75/3

Die can be used with annulus Die for making 3-layer film
diameters from 40mm to 75mm

 Can change the die lip ring and mandrel to have any diameter between 40 mm
and 75 mm. Similarly different rings and mandrels can be used to have any die
diameter between 80 mm and 120 mm for the LPD80-120 dies

 Dies are supplied for making film with a given number of layers, but . . .

 Spare mandrels can be fitted to the die to block flow channels inside the
die to produce film with fewer layers

 Can change the outer die ring only – for different die openings
 Features of the multilayer blown film line are:
 Blown film unit – basically the same as the single-layer blown film unit
 Single-screw extruders – basically the same as the standard single-
screw extruders
 Can have manual control or closed-loop control
 Uses jump plugs for relaying signals to the central control unit
 Central control unit – for manual or synchronous control of the
extruders,
End of Blown Film Extrusion