Blown Film Extrusion Technology

Presented byGeneral Extrusion Technology(GET)

Blown Film Extrusion TechnologyThe future trend of extrusion technology is high speed, high output, less energy consumption at competitive costThe following slides will provide you an overview of blown film extrusion technologiesSome of those technologies are proven and some of them represent the latest development from General Extrusion Technology Ltd. The information contained in this presentation may be proprietary, confidential and privileged, and, therefore protected from disclosure

Blown Film Extrusion TechnologyGET partners with some world best component/system suppliers

Blown Film Extrusion TechnologyGET partners with some world best component/system suppliers

Complete line control, gauge system, IBC control, GermanyExtruder gearbox, GermanyExtruder high torque motor, GermanyAC motor and drive, ABB China Gear motor for extruder, winder, haul-off and bubble cage,SEW China

Blown Film Extrusion TechnologyGET partners with some world best component/system suppliers

PLC control system for winder, AutriaAll pneumatic web guide system, USAControl cabinet, low voltage components, Schneider ChinaSolid state relay switch, Swiss Control cabinet, Rittal China

Blown Film Extrusion TechnologyGET partners with some world best component/system suppliers

Bearing for all rollers, NSK ChinaBusbar system, GermanyBrush spreader roller horizontal haul-off, GermanyHeater band, Watlow ChinaMelt pressure transducer, USABarrel and screw, USA

Blown Film Extrusion SystemSystem ACS 5300AS NAVIGATORGravimetric SystemBlown Film ExtruderScreen ChangerBlown Film Die TechnologyBubble CageGauging SystemCollapsing FrameHaul-off SystemWinder Technology

System ACS 5300AS NAVIGATOR19 Color touch screen

System ACS 5300AS NAVIGATORSystem ACS NAVIGATOR control principlePlant wide control conceptModular structureMachine control NAVIGATORTemperature control

System ACS 5300AS NAVIGATOR control principle

Plant wide control concept

Modular structure

Base moduleAccess to each individual system in the network

Base moduleHall-wide status with efficiency and summary information

Base moduleAlarm report with trace function

Expansion module of historical trendHistorical trace of process data

Expansion module of historical profile trendHistorical trace of profile data

Expansion module of report data baseHandling of summary, shift and week reports

Expansion module of order analysisInterrogation of logged data from complete orders

Expansion module of material data baseComplete material data base management

Machine control NAVIGATOR

Machine control NAVIGATOR

Machine control NAVIGATOR

Temperature control

Temperature control

Machine control NAVIGATOR

Temperature control

Gravimetric batch blending systemPlast Control batch blender PB422Mechanical advantagesWeighing hopper conceptMaterial conveyor PCH400/PCH800Pre-filter PCP 500

Gravimetric system advantagesRugged mechanical design with easy refill possibility Weighing device completely tested and calibrated Density dependent hopper refill Precise summing even during order changes Easy understandable material conveying with clear text messages Integration into existing central conveying systems Overfill detection (e.g. after manual refill) Fast thruput cycles Intelligent error handling checks operator errors or mechanical vibrations Synchronized ramping of each material component Unified hopper sizes Unified load cell types for 400 g/h up to 650 kg/h

Material viewing glasssimple cleaningQuick change attachment for dosing screwsMaterial outletManual slide valveRugged designManual refillMechanical advantages

Weighing hopper conceptSynchronized rampingSingle node for data communicationIntegrated conveyor controlData link to:- CAN (2nd generation)- OPC (with sync'd data blocks)- Devicenet- Profibus DP

Material conveyor PCH400/PCH800

Material conveyor PCH400/PCH8001) The metal filter is accessible without moving or disconnecting the hoses - Hoses dont get bent and leak

2) Variable position of connectors - each connector can be positioned independently

3) Each electrical function with status LED- LED display of material demand- LED display of vacuum status- Optional LED display demand sensor- Optional LED display full sensor

4) Optional viewing glasses in the area of material flap - Operator can always check for sufficient material- Fast service diagnosis

Material conveyor

Pre-filter PCP 500

Blown Film ExtruderDirect drive with torque motor(gearless)Traditional drive motor with gearboxScrew and Barrel TechnologyBarrel cooling system

Direct drive with torque motor(gearless)

Torque motor benefits10-20% less energy than a DC motor; 5-10% less energy than a AC motorHigh torque capability permits higher outputsVirtually no vibration or noise and need no maintenanceWater-cooled and dust-free and use less oil-advantages for medical and food-packaging filmsCompact size, an advantage for coextrusion

Torque motor benefitsDeliver constant torque over entire speed range, starting from zero, whereas AC and DC motors lose torque at low speedsEasier to install and require less wiringContain a very high number of magnetic pole pairs-up to 10 times more than other types of electric motors. Torque may have from 8 to 40 pole pairs, vs 2, 4, 6 for DC motor and 4, 6 for AC motor2,000 to 11,000 Nm at low speeds of 20-500 rpm vs similar torque at 2,000-3,000 rpm

Traditional drive motor with gearbox

Traditional drive motor with gearboxDirectly coupled motor and gearbox for energy and space efficiencyCompact design with high power ratingCenterline to match applicationFull length steel base frame Maximum rigidity maintains alignmentMinimize screw wear

Screw and Barrel TechnologySome of the most important requirements areProcessability of mixtures with different sized and different shaped granulesHigh plastificating performanceGentle but complete plastification Good melt homogeneityControlled melt temperaturesMinimal change in the material through degradation or crosslinkingHigh level of versatility: ability to process a broad selection of raw materials with a wide range of throughput ratesLow performance-related investment and operating cost

Smooth bore barrelSmooth bore barrel is largely used by extruder builder in USA, even as todayGood for high-melt-temperature polymers, like nylon, PET, PC and fluoropolymersBroad range of polymersAbility to introduce fluff regrindNot suitable for HMW-HDPESmooth bore extruder operates against die pressure and is difficult to maintain desired melt temperature as screw speed increase to raise output

Grooved feed barrelGrooved bore debuted in Europe in the 1950sProduce 20-40% higher output than smooth bore extruderRequired for HMW-HDPENearly constant pumping rate regardless of head pressureLower melt temperatureEVOH & nylon pellets must be lubricatedLower rate on soft pellets, like TPU, softer metallocene polymersNot suitable for large volume fluff regrind

Barrier screw for smooth bore barrelDeep screw has colder melt, but less mixing, medium screw has best versatility, shallow screw has best mixing, but higher melt temperature Maddock mixer is used to improve melt qualityNylon and EVOH can be processed on the same screwMetering sectionBarrier sectionFeed section

Barrier screw for grooved bore barrelGood dispersive/distributive mixing effectHeat transfer to the barrelLow pressure lossEffective separation of solids from meltHigh homogenizing effectGood control of melt temperatureClear pressure build-upMelt throughput geared to homogenizing capacityLow pressure levelLow torque Reduced wear and tearHomogenizing sectionBarrier sectionFeed section

Barrier screw for grooved bore barrelBarrier screw with homogenizing elementsRhomboid mixing elementSpiral shearing element

Barrel cooling system

Barrel cooling system design conceptBarrelBlowerHeater bandCooling air flow

Barrel cooling systemThe heat exchange surface area between the barrel and the cooling air flow is critical for the cooling efficiencyGETs cooling system is designed for high speed extrusion with intensive coolingFinned aluminum heat sink for intensive coolingFinned ceramic heater band for intensive heating and cooling

Barrel cooling systemGETs innovative designPatent pending

Barrel cooling systemFinned ceramic heater and aluminum heat sinkHeating capacity up to 7w/cm2 maxMuch more cooling surface than traditional heater band Extruded structure aluminum shroud cover filled foamed asbestos to prevent energy loss

Barrel cooling system

Choose a right solutionProduction complexity and investment cost defines the solutions to be usedA modular cooling element is preferred, which can be adjusted to different barrel diameter and section length relatively easilyFor best control of melt temperature, different cooling system may require for different temperature zone

Screen changer

The new manual screen changer addresses several problems of the older design. It offers:Easy access to the screens by swinging them out completely Full 360 degrees circular heaters (without the half-moon cut-outs) Less space requirements because of