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Blown Film Extrusion Technology
Presented by
General Extrusion Technology
(GET)
Blown Film Extrusion Technology
• The future trend of extrusion technology is high speed,
high output, less energy consumption at competitive cost
• The following slides will provide you an overview of
blown film extrusion technologies
• Some 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 Technology
• GET partners with some world best
component/system suppliers
Blown Film Extrusion Technology
• GET partners with some world best component/system
suppliers
Complete line control, gauge system, IBC control,
Germany
Extruder gearbox, Germany
Extruder high torque motor, Germany
AC motor and drive, ABB China
Gear motor for extruder, winder, haul-off and bubble cage,
SEW China
Blown Film Extrusion Technology
• GET partners with some world best component/system
suppliers
PLC control system for winder, Autria
All pneumatic web guide system, USA
Control cabinet, low voltage components, Schneider China
Solid state relay switch, Swiss
Control cabinet, Rittal China
Blown Film Extrusion Technology
• GET partners with some world best component/system
suppliers
Busbar system, Germany
Bearing for all rollers, NSK China
Brush spreader roller horizontal haul-off, Germany
Heater band, Watlow China
Melt pressure transducer, USA
Barrel and screw, USA
Blown Film Extrusion System
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System ACS 5300AS NAVIGATOR
Gravimetric System
Blown Film Extruder
Screen Changer
Blown Film Die Technology
Bubble Cage
Gauging System
Collapsing Frame
Haul-off System
Winder Technology
System ACS 5300AS NAVIGATOR
19” Color touch screen
System ACS 5300AS NAVIGATOR
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System ACS NAVIGATOR control principle
Plant wide control concept
Modular structure
Machine control NAVIGATOR
Temperature control
System ACS 5300AS NAVIGATOR
control principle
Plant wide control concept
Modem connection
Printer package
Office network link
Modular structure
Access to each individual system in the
network
Base module
Hall-wide status with efficiency and
summary information
Base module
Alarm report with trace function
Base module
Historical trace of process data
Expansion module of historical trend
Historical trace of profile data
Expansion module of historical profile trend
Handling of summary, shift and week
reports
Expansion module of report data base
Interrogation of logged data from
complete orders
Expansion module of order analysis
Complete material data base
management
Expansion module of material data base
Machine control NAVIGATOR
Machine control NAVIGATOR
Machine control NAVIGATOR
Temperature control
Temperature control
Machine control NAVIGATOR
Temperature control
Gravimetric batch blending system
•Plast Control batch blender PB422
•Mechanical advantages
•Weighing hopper concept
•Material conveyor PCH400/PCH800
•Pre-filter PCP 500
Gravimetric system advantages
• Rugged 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
Mechanical advantages
Rugged design
Manual refill
simple cleaning
Material viewing
glass
Quick change
attachment for
dosing screws
Manual slide valve
Material outlet
Weighing hopper concept
Synchronized ramping
Single node for data
communication
Integrated conveyor
control
Data link to:
- CAN (2nd generation)
- OPC (with sync'd data blocks)
- Devicenet
- Profibus DP
Material conveyor PCH400/PCH800
Material conveyor PCH400/PCH800
1) The metal filter is accessible without moving or
disconnecting the hoses
- Hoses don‘t 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 Extruder
•Direct drive with torque motor(gearless)
•Traditional drive motor with gearbox
•Screw and Barrel Technology
•Barrel cooling system
Direct drive with torque motor(gearless)
Torque motor benefits
• 10-20% less energy than a
DC motor; 5-10% less
energy than a AC motor
• High torque capability
permits higher outputs
• Virtually no vibration or noise
and need no maintenance
• Water-cooled and dust-free
and use less oil-advantages
for medical and foodpackaging films
• Compact size, an advantage
for coextrusion
Torque motor benefits
• Deliver constant torque over entire speed range, starting
from zero, whereas AC and DC motors lose torque at
low speeds
• Easier to install and require less wiring
• Contain 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 motor
• 2,000 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 gearbox
• Directly coupled motor and gearbox for energy and
space efficiency
• Compact design with high power rating
• Centerline to match application
• Full length steel base frame
• Maximum rigidity maintains alignment
• Minimize screw wear
Screw and Barrel Technology
• Some of the most important requirements are
• Processability of mixtures with different sized and different
shaped granules
• High plastificating performance
• Gentle but complete plastification
• Good melt homogeneity
• Controlled melt temperatures
• Minimal change in the material through degradation or
crosslinking
• High level of versatility: ability to process a broad selection of
raw materials with a wide range of throughput rates
• Low performance-related investment and operating cost
Smooth bore barrel
• Smooth bore barrel is largely
used by extruder builder in
USA, even as today
• Good for high-melttemperature polymers, like
nylon, PET, PC and
fluoropolymers
• Broad range of polymers
• Ability to introduce fluff
regrind
• Not suitable for HMW-HDPE
• Smooth bore extruder
operates against die
pressure and is difficult to
maintain desired melt
temperature as screw speed
increase to raise output
Grooved feed barrel
• Grooved bore debuted in
Europe in the 1950s
• Produce 20-40% higher
output than smooth bore
extruder
• Required for HMW-HDPE
• Nearly constant pumping
rate regardless of head
pressure
• Lower melt temperature
• EVOH & nylon pellets must
be lubricated
• Lower rate on soft pellets,
like TPU, softer metallocene
polymers
• Not suitable for large volume
fluff regrind
Barrier screw for smooth bore barrel
Metering section
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Barrier section
Feed section
Deep 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 quality
Nylon and EVOH can be processed on the same screw
Barrier screw for grooved bore barrel
Homogenizing section
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Barrier section
Feed section
Good dispersive/distributive mixing effect
Heat transfer to the barrel
Low pressure loss
Effective separation of solids from melt
High homogenizing effect
Good control of melt temperature
Clear pressure build-up
Melt throughput geared to homogenizing capacity
Low pressure level
Low torque
Reduced wear and tear
Barrier screw for grooved bore barrel
•Barrier screw with homogenizing elements
Rhomboid mixing element
Spiral shearing element
Barrel cooling system
Barrel cooling system design concept
Heater
band
Barrel
Blower
Cooling
air flow
Barrel cooling system
• The heat exchange surface area between the barrel and
the cooling air flow is critical for the cooling efficiency
• GET’s cooling system is designed for high speed
extrusion with intensive cooling
• Finned aluminum heat sink for intensive cooling
• Finned ceramic heater band for intensive heating and cooling
Barrel cooling system
• GET’s innovative design
Patent pending
Barrel cooling system
• Finned ceramic heater
and aluminum heat sink
• Heating capacity up to
7w/cm2 max
• Much 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 solution
• Production complexity and investment cost defines the
solutions to be used
• A modular cooling element is preferred, which can be
adjusted to different barrel diameter and section length
relatively easily
• For best control of melt temperature, different cooling
system may require for different temperature zone
Screen changer
Old design
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GET new design
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
the ratchet type handle
No need for an additional flange since it
mounts directly onto the barrel flange
Easy removal of the complete unit
because it is bolted from the front
Blown film die system
•Blown film die technology
•Air ring technology
•Air ring cooling and die cart
•Internal bubble cooling(IBC) system
Blown film die system
Single air ring die system
Double stack air ring die system
Blown film die system
IBC cooling unit
Blown film die
Die cart
Dual lip air ring
IBC air in/out
Air ring air supply
Blown film die technology
• Spiral mandrel die
Die pin
Sizing ring
Heater band
Melt feed block
Out layer
Die cart
Middle layer
Die adjustment plate
Inner layer
Air supply
Blown die technology
•Low profile die design
•Single melt channel to dual channel melt channel
distribution. Spiral mandrel
•Short melt flow
•No flow channel plug, no melt dead point
•Short melt flow residence time
•Strong self-cleaning, shortest purging time
•No port lines
•Low pressure drop
•No layer leakage
•Easy die assembly, easy die clean by customer
Blown die technology
• Single to dual melt distribution and spiral mandrel die
Spiral mandrel melt flow channel
Binary pre-distribution)
Simulation of 400 mm 3-layer die
• Material: LDPE, FD0274, Qatar, MI: 2.4
• Output: 500 kg/h
• Temperature:=210 ℃
400 mm 3-layer blown film die melt flow
FEA simulation
• Resin: LDPE, FD0274, Qatar, MI: 2.4;
• Output: 500 kg/h; Temp:210 ℃
Simulation of the inner layer
Uniform
pressure
distribution in
the die
Simulation of the inner layer die
Uniform velocity
distribution in
the die
Simulation of middle layer
Uniform
pressure
distribution in
the die
Simulation of middle layer
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Uniform
velocity
distribution in
the die
Simulation of outer layer
Uniform pressure
distribution in the
die
Simulation of outer layer
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Uniform
velocity
distribution in
the die
Air ring technology
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External bubble cooling and forming
Dual lip air ring type
Perforated chimney dual lip air ring
Double stack air ring
Internal bubble cooling(IBC) system
Air ring technology
• External bubble cooling and bubble forming theory
Venturi effect:
When an air flows through a constricted area its speed increases
and pressure drops
Air ring technology
• External bubble cooling and bubble forming
Coanda effect:
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A free air jet emerging from a nozzle will tend to “attach”
itself and flow along an inclined or offset nearby surface(flat or curved)
Air ring technology
• External bubble cooling simulation
Cooling air flow around
a HDPE bubble
Leftside air flow: 25 lt/s
Rightside air flow: 12 lt/s
Air ring technology
• External bubble cooling simulation
Cooling air flow(12 lt/s)
Around a LLDPE bubble
for different adjusting
air ring setup
Left side: low position
Rightside: high position
Air ring technology
• External bubble cooling simulation
Coanda effect
greatly influences
the heat transfer
capability of the
cooling are and
stability of the bubble
Heat transfer coefficient profile at high and low positions of adjustable
air ring for LLDPE bubble shape
Air ring technology
• Dual lip air ring type
Dual-lip air rings come in three types that are adjusted by iris, perforated chimney,
or stabilizer rings. Each requires different adjustments for each bubble problem.
Air ring technology
• Perforated Chimney type dual lip air ring
Forming cone and chimney manual adjustment
Air ring technology
• Perforated Chimney type dual lip air ring
Patent pending
Forming cone and chimney electrical adjustment
Air ring technology
• Operation theory of dual lip air ring
Chimney adjustable
Forming cone
Upper lip adjustable
Lower lip
Air ring technology
• Operation theory of dual lip air ring
• Lower Lip: provides initial quenching to strengthen the melt
provides venturi between bubble and cone to “set” the
bubble
• Forming Cone: guides lower lip air & supports bubble while
in the ‘semi-solid’ state
• Upper Lip: provides final “blast” of cooling air “adjustment”
provides ability to vary volume & velocity of air
-- to process wider variety of materials and BUR’s with same
lip geometry
• Chimney device: to further redirect the cooling air and
increase the stability of the bubble
Air ring technology
• Dual lip air ring
• Adjustable upper lip design for wider BURs
• +/- 0.5% air flow consistency
• Finished aluminum flow surfaces
• Adjustable chimney ring for improved le bubble stability
• Available from 75 to 2200 mm diameter
Air ring technology
• Double stack air ring
• Electrical actuator up/down
adjustment
• Suitable for high speed
extrusion
Air ring technology
• Autoprofile technology
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Autoprofile control principle
Autoprofile air ring
Autoprofile die
Autoprofile benefits
Air ring technology
• Autoprofile technology
• Autoprofile air
ring adjusts
according to
data from ACS
and scanner
• Scanner
monitors
thickness
sends data to
ACS
Autoprofile control principle
Air ring technology
• Autoprofile technology
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3.5mmx25m air chamber
Segmented air ring design
104 control zones for a
400 mm die
5x104=520x(3.5mm x
25mm) air chamber
A constant air flow blows
through heater cartridge
Air flow touches bubble at
very fine area. More
precise, more even
Film thickness control
more accurate
Air ring technology
• Autoprofile technology
• Segmented die
with heater
cartridge in
sizing ring
• 64 control zone
Heater cartridge
Autoprofile die
Air ring technology
• Autoprofile benefits
• Available in fixed or oscillating configuration
• Utilizes PlastControl ACS with any on-line thickness gage
• Varies the cooling effect on specific bubble segments
• Reduces long term repeatable film thickness variations
• Retrofitable to almost any blown film die
• Typical reduction of 30% of TD variation
Air ring technology
• Air ring cooling air supply and die cart
Die cart
Die centering and up/down
adjustment
Air ring air supply
Internal Bubble Cooling (IBC)
•Simulation of typical IBC system
•IBC control principle
•IBC cooling unit
Internal bubble cooling(IBC)
• Simulation of typical IBC system
Air flow comparison between the original and modified IBC system(0.5 lt/s)
Internal bubble cooling(IBC)
• IBC control principle
Six sensors system from PlastControl
Internal bubble cooling(IBC) unit
• H-Type IBC cooling unit with spiral cooling tube for
high speed extrusion as an option
Internal bubble cooling(IBC)
• V-Type IBC cooling unit with spiral cooling tube for
high speed extrusion as an option
Internal bubble cooling(IBC)
• Cooling area: 94cm2
• Heat venting area: 133cm2
• High cooling and venting efficiency. Suitable for high
speed extrusion
• IBC Cooling unit design more close to FEA simulation,
more cooling capacity
• IBC modular design, easy operation and maintenance
• V-Type and H-Type cooling units interchangeable for
different resin and different bubble shape
Bubble cage
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Centering bubble perfectly
All extruded alloy
aluminum structure
Whole cage Less than 650
Kg
Easy installation, operation
and maintenance
Aluminum roller cage arm
treated with synergistic
coating
Harder than tool steel upto
Rc 65
Lower COF as low as 0.05
Motorized cage height
adjustment
Electrical actuator bubble
diameter adjustment
PMMA cage cover to
protect bubble from dust
and unexpected air
turbulence
Bubble cage
• Extruded aluminum roller
cage arm
• Arm surface treated with
synergistic coating at 30 um
thickness
• Hardened surface upto Rc
65
• Lower COF as low as 0.05
• Motorized cage height
Bubble cage-Chilled air bubble cage
Air in
Air amplifier
Bubble cage-Chilled air bubble cage
Patent pending
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Chilled air out
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Chilled water in/out
Air blow through
copper tube filled with
chilly water air on to
film bubble
Eliminate blocking
Output increase up to
25%
Scratch free
Perfect for sticky film
and protection film
applications
Better roll quality
Gauging system
• Contact and
non-contact
capacitive
rotating
scanner
Gauging system
Haul-off system
•Stationary primary nip
•Horizontal haul-off unit
•Collapsing frame
•Haul-off system
•Second nip station
Haul-off system
• Haul-off system
Haul-off system
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Equipped with Mink Web Spreader Brush Roll 10022, Germany
Less scratcher due relative MD or TD film movement
Low wear of nylon brushes
Small contact surface to film and large non contact area
Low heat transfer from film to brush
No roll temperature increase
No film bagging
Less contamination
Light weight, low height, easy installation
Haul-off system
– Mink Web Spreader Brush Roll 10022, Germany
Haul-off system
• Mink Web Spreader Brush Roll 10022, Germany
Haul-off system
• Horizontal haul-off unit
Airless turning bar
Spreader roller
Haul-off system
• Horizontal haul-off unit
Synergistic surface coating
Surface hardness: upto Rc65
Surface COF as low as 0.05
Heat resistance as high as
4600 C
Haul-off system
• Stationary primary nip
• Gearbox motor direct
coupled to steel shaft. No
pulley and belt
• High quality HYPAlON
rubber roll, long life, low
wear
• Easy access and
maintenance
• Optional water cooled steel
roll
Haul-off system
• Collapsing frame
• Assembled with all
extruded alloy alum parts,
light weight. Easy
installation and operation
• Extruded alloy alum slat,
Plasma Micro-Arc
Oxidation super hard
surface treatment
• Lower COF, wear and high
temperature resistance
• No film bagging, no film
scratch
Web guiding system
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Coast Control all pneumatic web guide system, USA
No motor, no electronics
No hydraulic
Easy installation
Easy operation
10 years warranty
on all parts
Web guiding system
Web guiding system
Haul-off system
• Secondary nip station
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Avail w/ dancer
or load cell
control
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Variety of roll
finished
available
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Configurable
w/S-wrap
cooling option
Winder Technology
•Surface winder
•Central surface winder
Winder technology
• Central/surface/gap winder
• Finished roll diameter:
1,500 mm max
• Line speed: upto 250
m/min
• Tension control: 40-400N,
surface winding,
• 15-150N central winding
• B&R, Austria, PCC control
system, color touch screen
operation. English/Chinese
operational language
• Central/surface mode,
reversing winding
• Lay-on pressure control
• Optional gap winding
Winder technology
Film tower
Thank you for your attention!
Internal bubble cooling(IBC)
•Simulation of typical IBC system
Internal bubble cooling(IBC)
• Simulation of typical IBC system
Heat transfer coefficient profile for original and modified designs
Improved grooved barrel/screw system
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No water cooling, electric
heating/air cooling is sufficient
Heating of grooved section to
process higher melt temperature
polymers, like PA, PC, PET,
PBT, PVDF
Low pressure in grooved feed
section (less back pressure)
No critical wear
Wide range of polymers
Controlled melt temperature
Venting is possible
Experiment result
Throughput vs. screw speed for grooved and smooth extrusion system
Experiment result
Throughput and melt temperature vs. screw speed
Experiment result
Back pressure and grooved bore pressure vs. screw speed
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