Blown Film Extrusion (Film Blowing)

Blown film extrusion is the process by which most commodity and specialized plastic films are
made for the packaging industry.

The Process

A typical set-up for blown film extrusion is shown in figure-2. In this instance the molten
polymer from the extruder enters the die from the side but entry can also be effected from the
bottom of the die. Once in the die, the molten polymer is made to flow round a mandrel and
emerges through a ring shaped die opening, in the form of a tube. The tube is expanded into a
bubble of the required diameter by an air pressure maintained through the centre of the mandrel.
The expansion of the bubble is accompanied by a corresponding reduction in thickness. Extrusion
of the tube is usually upwards but it can be extruded downwards, or even sideways, the bubble
pressure is maintained by pinch rolls at one end and by the die at the other. It is important that the
pressure of the air is kept constant in order to ensure uniform thickness and width of film. Other
factors that effect film thickness are extruder output, haul-off speed and temperatures of the die
and along the barrel. These must also be strictly controlled.
As with any extrusion process, film blowing becomes more economical as speeds are increased.
The limiting factor here is the rate at which the tubular extrudate can be cooled. Cooling is
usually achieved by blowing air against the outside surface of the bubble. Under constant air flow
conditions an increase in extrusion speed result in a higher 'frost' line (the line where
solidification of the extrudate commences) and this leads to bubble instability. Increasing the air
flow gives more rapid cooling and lowers the 'frost' its application because too high a velocity of
the air stream will distort the bubble. Various designs of air cooling rings have been worked out
in order to produce improved cooling without these attendant difficulties. On higher output lines,
the air inside the bubble is also exchanged. This is known as IBS (Internal Bubble Cooling). In
the cooling step of blown film extrusion, the amorphous, transparent melt crystallizes to form a
translucent, hazy, or opaque film. The point where opacity begins in the bubble is known as the
frost line. The lay-flat film 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. Blown film extrusion is an
extremely complex subject and there are many problems associated with the production of good
quality film.

The frost line height is controlled by several parameters: the air flow, film speed, and temperature
difference between the film and the surroundings.

Properties of the film, such as tensile strength, flexural strength, toughness, and optical
properties, drastically change depending on the orientation of the molecules. As the transverse or
hoop direction properties increase, the machine or longitudinal direction properties decrease. For
instance, if all the molecules were aligned in the machine direction, it would be easy to tear the
film in that direction, and very difficult in the transverse direction.

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.
 Fig. 2 : BLOWN FILM EXTRUSION

Common Problems
The film bubble may be established by supporting it with horizontal stationary guides or the
whole extruder may be protected from stray air currents by a film curtain. Other causes include
non-alignment of the guide roll and the pinch rolls, or non-uniformity of pressure across the face
of the pinch rolls. Among the surface defects mentioned earlier, 'fish eyes' are due to imperfect
mixing in the extruder or to contamination. Both of these factors are controlled by the screen pack
which not only screens out contaminating particles but improves homogeneity by increasing the
back pressure in the extruder. 'Orange peel' or 'apple sauce' are also surface defects caused by
inhomogeneity of the molten polymer. Since low density polyethylene forms by far the greatest
percentage of all film made, it will be useful to consider the influence of the various polymer
parameters such as metal flow index and molecular weight on the film properties. Impact
strength, for instance, increases with molecular weight (i.e. decreasing melt index and with
decreasing density. Heavy duty sacks, for instance, are normally made from polyethylene grades
having densities between 0.916 and 0.922 g/cm3 and melt indices between 0.2 and 0.5. For
thinner technical film as used in building applications or waterproof lining of ponds, higher melt
indices have to be used because of the difficulty of drawing down very viscous melts to thin film.
Melt indices of between 1 and 2.5 are more useful, therefore, and impact strengths are less than
for heavy duty sacks. Clarity is, however, improved. Where a good balance of properties is
 required as in the medium clarity/medium impact grades, slightly higher densities are used (0.920
to 0,925 g/cm3) and the melt index is varied between 0.75 and 2.5. For high clarity, a high
density and a high melt index are required since increases in both these properties cause an
increase in see-through clarity, a decrease in haze and an increase in gloss. High clarity film will,
of course, have a relatively poor impact strength because of the high melt index and such film
should not be used for packaging heavy items.
Among the many other defects low tensile strength, low impact strength, hazy film, blocking and
wrinkling. Air entrapment between film layers and rollers – this may cause film scratching or
wrinkling, or processing problems when winding up the film due to reduced friction. Wrinkling is
a particularly annoying problems because it can be costly, leading to scrapping of a roll of film,
and because it can arise from such a wide variety of causes that it is likely to occur even in the
best regulated extrusion shop. If the film is too cold when it reaches the pinch rolls, for instance it
will be stiff and this may cause crimping at the nip and wrinkling. One way of raising the film,
temperature at the nip rolls is to raise the melt temperature but this can lead to other troubles such
'as blocking. In fact, this is illustrative of the whole subject of film blowing inasmuch as
compromises are often necessary to achieve the best balance of properties. Wrinkling can also be
caused by the die gap being out of adjustment. This causes variations in film thickness and can
lead to uneven pull at the pinch rolls. Another cause of wrinkling may be surging from the
extruder or air currents in the extruder shop. Both of these factors can cause wobbling of the film
bubble and thus wrinkling at the wind-up stage. Another possible solutions to this is using a
vacuum to remove eentrapped air or by using winding rolls with a diamond shaped groove in the
rubber cover to increase surface area and decrease amount of entrapped air in the film.

Large output fluctuations from the die – this causes thickness variations, and can be prevented by
keeping the extruder clean and by using more consistently shaped pellets in the extruder.
• Melt fractures – these appear as roughness or wavy lines on the film surface, and can be
eliminated by lowering the viscosity of the polymer melt. This can be done by increasing
the melting temperature or by adding an internal lubricant to the material composition.
• Thickness variations in the film – this can be avoided by centering the die in the extrusion
line before every run, adjusting the air speed of the cooling system, or by using heated die
lips.
• Die lines on the surface of the film – this defect reduces the aesthetic appeal of the film,
reduces optical properties, and weakens mechanical properties such as tear strength. This
can usually be avoided by routinely cleaning the inner surfaces of the die and by
refinishing scratched or roughened flow surfaces.
• Gels – these defects are small, hard globules encapsulated in the film or stuck on the film
surface and reduce the aesthetic appeal of the film and cause stress concentration points
which may result in premature failure. These are caused by overheating to the point of
polymer degradation in the die, and can therefore be avoided by cleaning the inner
surfaces of the die on a regular basis.

Optimization of the Process

Coextrusion

One way to improve the line efficiency of blown film extrusion is to implement coextrusion. This
is the process of extruding two or more materials simultaneously through a single die. The
orifices in the die are arranged such that the layers merge together before cooling. This process
saves time because it extrudes two or more layers at the same time, and it provides a method with
fewer steps to produce multilayer films. The production rate for a coextruded multilayer film of
three layers is about 65m/min, and the production rate for a single layer of blown film is about
130m/min[11]. Thus, in order to produce 10 000m of a three layer multilayer film, it would take
almost 4 hours using a single layer blown film process, and only 2 and a half hours using the
coextrusion process. Furthermore, the film produced from the single layer process would require
an extra step to glue the layers together using some sort of adhesive. Coextrusion is the least
expensive means of producing layered films and the coextrusion system is capable of quick
changeovers to minimize production line down time.

Minimizing the Melt Temperature

The efficiency of blown film extrusion can be improved by minimizing the temperature of the
polymer melt. Reduction of the melt temperature causes the melt to require less heating in the
extruder. Normal extrusion conditions have a melting temperature at about 190° C despite the fact
that the temperature of the melt only needs to be about 135°C. However, it is not always practical
to decrease the melting temperature by that much. By decreasing the melt temperature 2 to 20°C,
the motor load can be decreased by about 1 to 10%. Furthermore, reduction of the melt
temperature causes less need for cooling, so there is a reduced use of the cooling system.
Moreover, removing heat from the bubble is usually the rate-limiting factor in this extrusion
process, so by having less heat in the polymer to remove, the rate of the process can be increased,
thus yielding higher productivity. A way to maintain the melt temperature at a minimum is to
choose an extruder that is matched to the specific processing conditions, such as the material of
the melt, pressure, and throughput.

Heated Extrusion Die Lips

Typically, solutions to melt fractures involve decreasing the output or increasing the melt
temperature to decrease the shear stress in the extruder. Both of these methods are not ideal
because they both reduce the efficiency of the blown film line. Heated extrusion die lips can solve
this problem. This targeted heating method allows for film extruders to be run at higher
production rates with narrower die gaps while eliminating melt fractures. Direct heat is applied to
the surface of the polymer melt as it exits the die so that viscosity is reduced. Therefore, melt
fractures, which are caused when trying to extrude too much of the polymer at one time, will no
longer act as a limiting factor to increasing the production rate. Furthermore, heated die lips use
less energy than increasing the melting temperature because only the surface of the melt is heated
and not the bulk of the liquid. Another benefit of using heated die lips is that thickness variations
can be controlled by adding heat to certain areas along the die circumference to make the film at
that position thinner. This would ensure that no excess material is used.

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.

Materials:
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”.

Advantages:

• 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)
• Very high productivity
• Permits the combination of a number of different materials and properties

Applications:
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).

Cast Film Extrusion

Basic Concepts of Cast Extrusion
In the cast film extrusion process, the molten polymer travels through a flat die system to adopt
its final flat film shape. The die system is formed by the die and feedblock (if the process requires
coextrusion) or simply the die, if the process is that of mono-layer extrusion. Figure 1 shows a
coextrusion cast film line.
The process starts with the feeding of plastic resins by means of a gravimetric feeding system to
one or more extruders. The materials are then melted and mixed by the extruders, filtered and fed
to the die system.
Immediately after exiting the die, the molten curtain enters the cooling unit where its temperature
is lowered with a water cooled chill roll to freeze the film. The rollers are highly polished turning
roll, where it is quenched from one side. The speed of the roller controls the draw ratio and final
film thickness. The film is then sent to a second roller for cooling on the other side. Finally it
passes through a system of rollers and is wound onto a roll. The film is then passed downstream
where the edges are trimmed, corona treatment is applied (if a fabrication process such as printing
or coating is required) and the film is wound into rolls. A description of the main components of a
typical cast film line is presented below. Most flat dies are of T-slot or coat hanger designs, which
contain a manifold to spread the flowing polymer across the width of the die, followed
downstream by alternating narrow and open slits to create the desired flow distribution and
pressure drop. Most cast film lines manufactured today are coextrusion lines, combining layers
from as many as 7 extruders into the product through multimanifold dies, or else single manifold
dies with the aid of feedblocks.
In a cast film extrusion process, a thin film is extruded through a slit onto a chilled,
Thicker polymer sheets can be manufactured similarly. A sheet is distinguished from a film by its
thickness; by definition a sheet has a thickness exceeding 250 m . Otherwise, it is called a film.

Cast Film Line Components:

Gravimetric Feeding System

Gravimetric feeding systems control the amount of material that is fed into the extruders by
weight, not volume. The system is more precise than its volumetric counterpart and features a
reduced error tolerance in the order of 0.5%. In many cases, the film is fabricated with materials
that are blends of a base polymer with one or more secondary components. In state of the art
production lines, this blending is carried out inline.
Special care is needed to prevent premature melting of the pellets, especially when materials with
low melting temperatures are processed, or when the pellet size is small. Vibration and cooling of
the feeding hoppers are options recommended to alleviate this problem. It is also important to
ensure that the material being fed carries no moisture that could give rise to the appearance of
small bubbles, also known as fish eyes, in the final film. In some cases, drying of the material is
required. This may be performed by a separate unit or by a highly sophisticated feeding system
with built-in drying capabilities.

Extruder
The main functions of an extruder are to melt the plastics pellets and mix the resulting molten
polymer to achieve a homogeneous melt. This is done by conveying the material along a heated
barrel with a rotating screw. Commercially used extruder barrels are typically 3 (90 mm) to 6
(150 mm) in diameter. The screws are tailored to the specific characteristics of the extruded
materials and process parameters. The length of the screw is heavily influenced by their diameter.
Screw length to diameter (L/D) ratios commonly lie in the range of 26:1 to 30:1.
It is critical to ensure that the flow exiting the extruder is well controlled and constant with
variations on the screw's rotational speed not exceeding 1%. A failure to accurately control the
screw speed typically results in undesired pulsating flow that can cause periodic changes in film
thickness in the machine direction.
The metering section, or final section of the extruder, is designed to guarantee a precise dosing of
material from the extruder. In order to achieve the above, the gap between the screw and the
barrel is very small. This creates another challenge since it is difficult to maintain a constant gap
between the rotating screw and the barrel.
To overcome the above-mentioned potential problems, a melt pump is commonly employed
downstream of the extruder. The pump is a positive displacement device that produces a
consistent flow regardless of the discharge pressure of the extruder (Figures 2 and 3). The pump
alleviates the workload on the extruder by taking on the job of generating pressure. The reduced
extruder head pressure translates into energy consumption savings, a drop in the melt temperature
and less wear between the barrel and the screw.
In coextrusion lines, the number of extruders depends on the number of different materials being
extruded and not necessarily on the number of layers. This is because the existing feedblock
technology allows the flow from one extruder to be split into two or more layers in the final
coextrudate.

Filtration System
The objective of the filtration system is to prevent downstream passage of melt impurities and/or
gels that are formed during the extrusion process. Proper control at this stage is imperative to
prevent melt contamination. The most common filters are those containing a metallic mesh. The
case hosting the filter media has to be capable of bearing the forces exerted by the polymer flow
when subjected to the maximum pressure allowed by the extrusion process. It is highly
recommended to use continuous screen changers, in which the mesh is continuously regenerated,
to minimize the replacement time of the screen pack.
Applications of Cast Extrusion

The cast film process is used for very tight tolerances of thin film, or for lowviscosity resins. Cast
films are used for food and textiles packaging, flower wrapping, as photo album page protectors,
as coating substrates in extrusion coating processes or laminated to other materials in the
formation of more complex films, among others.

Typically, the cast film process involves the use of coextrusion, which is a simultaneous
extrusion of two or more materials from a single die to form a multi-layered film. This is because
in many cases the final application of the plastic film demands a performance that cannot be
achieved if the film is composed of only one material. For example, in many instances food
packaging applications require the use of films with oxygen barrier capabilities.
To meet the requirement a high oxygen barrier material like EVOH is combined with polyolefin
materials in a multi-layered structure. Coextruded films typically contain up to seven layers;
however, the use of more layers is becoming more common. The number of layers, their position
in the coextrudate and their individual thickness are all variables that change depending on the
particular application of the film.
Benefits/Limitations of Cast Extrusion
Unlike the blown film process, the cooling of the film with cast extrusion is highly efficient. This
allows for higher production line speeds resulting in higher production rates with superior optical
properties of the product. In chill roll or cast film extrusion, the molten polymer is cast through a
narrow slot die and drawn down and formed onto a rotating chill roll with the aid of a web
forming device. One or more additional chill rolls can be provided fro improved film cooling and
higher outputs. A heated roll can also be provided for annealing the film.
The degree of draw and orientation is significantly lower in the cast film process than in the
blown film process. This is the reason why the thickness distribution in the machine cross
direction is more uniform with cast processes (with variations that ould be as low as 1.5%).
However, the film mechanical properties in the machine cross direction are lower when compared
to those obtained with the blown film process due to the higher level of orientation that the film
experiences in the blown process.
The principal advantages of the film casting method compared with the quench-tank method are
substantial improvements in the control of optical properties of the film, potentially increased
output with larger diameter chill rolls, production of films with a higher modulus, improved
thickness and profile control.
The orientation of the die can vary greatly depending on the machinery manufacturer or process
conditions. A die that extrudes vertically downward is generally preferred. However, dies which
extrude horizontally or at any angle between vertical and horizontal can be used. Horizontal
orientation is typically used in the production of rigid sheet over ten mils in thickness. Some
European producers use angled dies in an attempt to minimize the distance from the die to the
casting roll and to prevent die lip drag. The most common film casting arrangement uses the die
in the vertical position.
In cast film extrusion, the molten polymer drops onto the chill roll and contacts tangentially or
above the tangent line. The alignment or parallelism of this roll to the die is critical in relation to
the falling film. Whenever wrinkling of the film occurs on the casting roll surface, the first roll
must be carefully repositioned in relation to the die lips.
In cast extrusion the edges of the film are trimmed due to dimensional irregularities and/or poor
layer distribution. As a result, the process can be negatively affected if the trimmed material
cannot be recycled. Recent flat die system technology has minimized this problem by
significantly reducing the amount of wasted material in coextrusion processes.This subject will be
covered to some extent in a subsequent section.

Sheet / Film Extrusion

Sheet / Film Extrusion is the process which is used for the products like plastic sheets or films.
During the extrusion of these plastic materials, the required cooling is achieved by the action of
pulling which is done through a specific set of cooling rolls that are generally three or four in
number. These cooling rolls are also called calender or “chill” rolls. Extremely fast running speed
develops “nerve”, which is an undesirable condition. This condition occurs when insufficient
contact time is permitted to dissipate the heat, which is available in the extruded plastic.
The units for the solid sheet extrusion comprises minimum one Extruder along with one sheet
extrusion die. These are supported by polishing stack which commonly includes 3 calenders that
calibrate & cool the sheet with the use of their calender nips or surfaces. Behind this, the draw-off
rolls to cool air and roller conveyor are located. The flat sheet may then be wound onto
continuous rolls, or "pre-sheared" into discrete lengths.
In the plastic sheet extrusion, extrusion of molten plastic materials occurs 0through a flat die
onto casting rolls. The rolls deliver the required cooling in addition to determining the sheet
thickness, width along with surface texture. This is done specially in the case of structured rolls;
i.e. levant, smooth, haircell, etc).
Plastic sheet may be extruded by an annular die onto a sizing mandrel. The pipe-like cross section
that is extruded will be slit in one or more places and then flattened and handled as sheet.
Commonly, co-extrusion is used for applying one or more layers for acquiring various specific
properties like soft touch or "grip", UV-absorption, matte surface or energy reflection. The
extruder, consisting of a heated barrel with an internal rotating screw, pumps the melted resin into
a flat sheet die which sizes the sheet (thickness and width).

Sheet Extrusion Characteristics

• Width more than 2 m

• Thicknesses range of 0.5 to 15 mm (approximately)
• No limitations of length
• Setup operates as multilayer sheets having functional surfaces (color, haptics, UV-
protection, etc.) Grain / structured surfaces
• Easier forming is possible (folding, corrugated panels, thermoforming...)

Materials And Applications

• Polystyrene is the most general polymer used in sheet extrusion. It is major plastic
material for the thermoformed packaging, and it gives competition to ABS & PP in the
technical markets.
• The end use applications of the sheet / film extrusion include margarine, tubs and pots
for yogurt and desserts manufacturing of luggage, refrigerator liners, and shower units.
• In the liquid packaging industry (wine boxes, juice cartons, etc.), the base if the process
of plastic extrusion onto paper. In addition, there is also an aluminum layer present in this
process.
• In the food packaging, the plastic film is occasionally metalized.
 • In the automotive industry, sheet is currently used to produce interior trim, panels, and
dashboards. Foamed polyolefin sheet, both cross-linked and non-cross-linked, is also
used in automotive applications.
• One of the main uses of extruded PS sheet is for thermal insulation materials for walls,
roofs, and under floors.

Profile Extrusion

For manufacturing plastic pipes, there is a use of a process called profile extrusion. This process
is used to generally produce plastic products with continuous cross-sections.

Typical examples include decorative molding, drinking straws, plastic evestroughing, window
trimming and numerous variety of other products polymers that are melt into the
hollow mold cavity under application of high pressure.
A typical profile extrusion process works like this. The plastic is first fed in a pellet form into the
Extruder. The material gets conveyed forward continuously by a rotating screw inside a heated
barrel. Here it is being softened by heat and friction. The softened plastic is subsequently forced
out via a die, directly into the cool water. The product gets solidified here. Afterwards it is
conveyed onwards into the take-off rollers. It is actually the take-of-rollers which does the pulling
act of the softened plastic from the die.

The die is basically a metal plate that is placed at one end of the extruder. It has a section cut out
of its interior. This cutout, along with the speed of the take-off rollers, plays a determining factor
in the cross-section of the product being manufactured Many grades of thermoplastic can be
extruded based on the application. The two primary categories are rigid and flexible extrusions.
Flexible materials are needed for profiles that are required to serve as seals (for example say
refrigerator gaskets) while rigid thermoplastics are needed if structural integrity is required.
Typical examples include rigid polyvinyl chloride, guttering and siding.

Features of Profile Extrusion

• Low Part Cost
• Low Tool Cost
• High Production Capability
• Shorter lead times in production
• Uniform cross section of parts
• Multiple materials/durometers are possible in
the same part
Materials for Profile Extrusion
Generally two classes of materials are manufactured into profiles. This of course depends upon
the application and needs of the final product. These two classes, rigid and flexible profiles, are
differentiated based on the starting material and final properties of the profile.

Rigid profiles are typically hard and relatively inflexible, often found in building applications.
They can be manufactured using different resins. Flexible profiles on the other hand are flexible.
The parts get bent easily, and are often soft (Typical durometer hardness range for them is from
50–95 ascertained by Shore A test). They are also easily compressible and generally used as
internal components of items. The following table summarizes a variety of resins that are used in
the profile extrusion.

Typical Raw Materials For Plastic Profiles

• HDPE (High Density Polyethylene)

• LDPE (Low Density Polyethylene)
• LLDPE (Linear Low Density Polyethylene)
• PETG
• Flexible PVC
• Butyrate
• Polypropylene
• Polystyrene
• ABS

Typical examples of Profile Extrusion

The following examples illustrate clearly illustrate the broad possibilities of Profile extrusion.
• Window profiles
• Sealing sections
• Modular drawer profiles
• Decorative trims

Advantages And Disadvantages of Profile Extrusion

The only main disadvantage of the profile extrusion is the limitations in the design possibilities,
which is due to the linear nature of the process. It has various advantages as well that are as
follows:

• Equipment widely available in all geographical areas

• Relatively low tooling costs
• Inexpensive process
• Product combinations possible
• Design freedom

Typical Applications & Design Possibilities

There are number of applications where the process of profile extrusion is extremely useful. Also,
there are many design possibilities with the use of this process. Typical applications and design
possibilities of the profile extrusion process are as follows:

• Windows profile
• Sealing sections
 • Modular drawer profiles
• Decorative trim

Co-Extrusion Process

Coextrusion:
The process of extruding two or more materials through a single die with two or more orifices
arranged so that the extrudates merge and weld together into a laminar structure before chilling.
Each material is fed to the die from a separate extruder, but the orifices may be arranged so that
each extruder supplies two or more plies of the same material. Coextrusion can be employed in
film blowing, free film extrusion, and extrusion coating processes. The advantage of coextrusion
is that each ply of the laminate imparts a desired characteristic property, such as stiffness, heat-
sealability, impermeability or resistance to some environment, all of which properties would be
impossible to attain with any single material. This process that allows the combination of
different materials and colors in a single sheet. This is done to achieve special properties which
are specific to a certain polymer, or for aesthetic effects with color, or for economic reasons
where an inexpensive material "sub-strata" is combined with a more expensive material "cap".
Co-extrusion may be employed in the processes of Film Blowing, Extrusion Coating, and Free
Film Extrusion. The general benefit of the co-extrusion process is that every laminate ply imparts
a required characteristic property like heat-sealability, stiffness, & impermeability, all of which
are impossible to attain by using any single material.
It is evident that co-extrusion is a better process than a single layer extrusion. For instance, in the
vinyl fencing industry, co-extrusion process is used for tailoring the layers on the basis of
whether these are exposed to weather or not. Generally, compound's thin layer is extruded that
contains high-priced weather resistant additives. This extrusion is done on the outside, whereas
inside there is an additive package which is more suitable for the structural performance and
impact resistance.

Tooling

Tooling is the assembly of precision machined components attached to discharge end of the
extruder(s) that combines the multiple materials (in the case of coextrusion) and forms the final
product shape. Coextrusion of film is accomplished by one of two distinctly different types of
tooling design; one is Feedblock Coextrusion and the other is Multi-Manifold Coextrusion.
The designs are very different, the operating parameters are very different, but, the end result
will be the same if all the defined rules for each are followed. One allows for broader material
selection; the other allows for much more flexibility in the number and arrangement of layers.

Flat Die System

It can be said that the die system is the heart of any coextrusion line. The die system is formed by
the coextrusion feedblock, the flat die and the melt transfer adapters that transport the different
molten polymers from the extruders to the feedblock inlet ports. The quality of the coextruded
film and the productivity of the process are greatly dependent on the design and performance
qualities of the die system.
The primary function of the die system is to form a multi-layered film that is uniformly
distributed across the width of the die with thickness variations on the film and thickness
variations on each individual layer within industry accepted tolerances (not to exceed ±2.5% for
the total thickness and within ±15 to ±20% for each layer).

This die is the simplest shape that can be produced. Its circular cross-section will produce circular
lines, like weed trimmer line or fishing line.

A tubing die is a little bit more complicated. It has a donut-shaped cross-section to make pipe and
tubing.

This die is called a clothes hanger die, and will produce sheet or thin film. The cross section
shows how the molten plastic from the extruder is spread out to produce a wide, thin sheet. In
general, a product is considered sheet if it is thicker than 0.1mm (0.004"), and film, if it is thinner
than 0.1mm (0.004"). However, these terms are sometimes used interchangeably
Upstream from the feedblock are the melt transfer adapters. The design criteria of this capillary
system must consider parameters such as material residence time, pressure drop and temperature
control. For instance, an excessive pressure drop could be addressed by increasing the pipe
diameter; however, this in turn would increase the residence time of the material and increase the
possibility of material degradation. Also, accurate wall thickness sizing and proper heater
specifications are necessary to prevent the pipes from heating or cooling the melts that they
transport. It is the task of the designer to find the proper balance between all these variables.
The coextrusion feedblock arranges the different melt streams in a predetermined layer sequence
and generates as many melt streams as layers are to be in the final coextrudate. Once this is done,
each stream adopts a planar geometry, meets its neighbouring layers and the final planar
coextrudate is formed.

Feedblock film coextrusion tooling consists of a feedblock and a standard flat film die.
The feedblock accepts the inputs of the various extruders (one for each material) and arranges
them in a predefined, segregated, fluid sequence and discharges them in a square or rectangular
shape for entry into the film die.

The film die takes this combined stream of fluid materials and reforms it or distributes it into a
flat thin film. The material sequence formed in the feedblock is exactly the same as the layer
sequence of the final film structure

After the materials leave the feedblock and enter the die, they are no longer confined individually
within steel channels. They are in intimate contact with each other and in the fluid state. They
remain segregated because plastics, when melted, are part of a family of fluids characterized as
being "non-Newtonian". Unlike Newtonian fluids, such as water or mineral oils which would
readily co-mingle if discharged together, plastics will remain separate and distinct. The
uniformity of the layers in the final film is a function of how carefully the primary rule of this
type of coextrusion is followed. That rule is "adjoining materials MUST have a reasonable
rheological match". Rheology is the flow performance of a given plastic material. It is graphically
represented in the form of viscosity versus shear rate, which is the fingerprint of a specific
material in terms of how it will flow when melted and pressurized. The rule simply states that the
"fingerprint" of adjoining materials must be similar if layer uniformity of the final product is
expected. The less the match, the less the uniformity that will result. When layer distortion occurs
it happens in the die, not the feedblock, during the transition or distribution in shape from the
square incoming stream to the wise thin film shape.
The flex lip adjusting mechanism is effective as a stand alone adjustment to correct flow
imbalnace only if the due opening is less than about 0.040 inches. Larger openings require the
addition of a restrictor bar (sometimes referred to as a choke bar) to balance flow.

The restrictor bar is a narrow bar about 1 inch wide that is positioned inside the die across the
entire width of the die. It includes a series of adjustment screws that push and pull the bar for
opening and closing the slot of material flow passing under it. This opening and closing of the
flow passage across the die width conventionally used in conjunection with a flex lip as an
additional and finer adjustment.

The flexible cantilevered lip, which defines the thickness of slot opening, is adjusted downward
(reducing slot thickness) by means of a series of adjustable push screws. These screws are spaced
approximately one inch apart across the entire width of the die. Thus, the die opening can be
adjusted from a full or maximum opening to a lesser opening by adjusting the push screws.

It is important to note that, after adjusting the slit opening to produce a uniform thickness of film,
the opening itself will not be dimensionally uniform across the width of the die. This variation in
opening will compensate for any mismatch between the material rheology and the die's static
internal distributor by acting as a variable flow valve.

Coextrusion feedblocks are grouped into two categories: Fixed and variable geometry blocks. In
the upstream section of these blocks the so-called selector plug or selector spool is found. This
cylindrical shaped removable part is responsible for routing each melt stream into its final
position in the coextrudate. The plug, if required, also splits those streams with a material that
feeds more than one layer in the structure. If a different layer sequence is required, it can be
achieved by simply changing the plug.
Fixed geometry blocks are most effective when the production line is devoted to only a few
different products that are similar in their rheological behavior. However, it is worth noting that
these blocks have removable flow inserts that could be machined or replaced if required to
process a wider spectrum of materials.
Variable geometry feedblocks are ideal for the coextrusion of high added value materials or when
the scope of the production line is more diversified. In general, these blocks feature movable
internal components that can adjust the width distribution of an individual layer prior to meeting
with neighboring layers and/or its velocity, which in turn affects its shear rate and viscosity.
Thus, problems inherent to coextrusion such as that of layer distortion and interfacial instability
can be overcome with adjustments of the feedblock.
In spite of all the capabilities of coextrusion feedblock technology to address flow anomalies
inherent to coextrusion flows, the production of an optimal coextrudate is only possible if the
feedblock operates in conjunction with a die conceived and properly designed to process a
coextrusion flow. The perfect synergy between the die and the feedblock is what will guarantee a
high quality product.
A well designed die must guarantee that in the process of spreading the coextrudate coming from
the feedblock the flatness of each individual layer is maintained within a tolerance of ±15 to
±20%. It must also be designed so that the residence time is not excessive in order to prevent
degradation problems or in some cases to prevent undesired heat transfer between layers. The die
must also be designed so that the pressure drop is kept at a level that is normal within the
extrusion process.
It is also critical that the die has the appropriate size, sufficient mass of steel and proper
mechanical design to guarantee thermal stability and to minimize the so-called clam-shelling
problem that manifests itself as an excessive deformation of the die lips when the die is subjected
to the high pressures inherent to the extrusion of thin films.
Recent advances in die technology have boosted the productivity of cast film production lines.
Special reference can be made to the so-called internal deckles. Inserted on both ends of the die,
the deckles allow changes to the film width and the consequent reduction of trim. They can be
fixed or adjustable and their length can exceed 20 inches.
Edge encapsulation technology has been introduced in recent times to reduce the negative
financial impact of material waste caused when the trim of the coextrudate is not recyclable. The
previous figure shows a band of a single material being coextruded side by side with a
coextrudate. The encapsulation material is of low cost, recyclable and has high mechanical
properties. The encapsulation material mainly forms the trim, which allows for its reinsertion into
the production process and great savings in material cost. In addition, edge encapsulation
technology is fully compatible with the internal deckle technology.

Cooling Unit
The cooling unit is comprised of a primary quenching roll, a secondary roll, a motorized roll
positioning system for proper vertical and cross machine direction alignment of the rolls, and in
many cases a vacuum box and/or air knife.
The rolls are typically chrome plated to achieve a better surface finish and to enhance the heat
transfer process during film cooling. The cooling agent is commonly water that circulates inside
the rolls. The primary quenching roll cools one side of the film while the secondary roll cools the
opposite side of the film.
The die is positioned above the primary quenching roll at an angle that varies from 45° to 90°.
The distance between the die lips exit and the roll ranges from 0.8 to 2 inches.
The cooling system allows the line to operate at high speeds. As the line speed requirement
increases, so do the diameters specified for the rolls.
The rolls must be perfectly aligned with the web to guarantee a uniform tension and to minimize
thickness variations across the width of the film. In addition, the angular velocity of the rolls
must be well controlled to prevent film thickness fluctuations in the machine direction.
The use of a vacuum box, connected to the die fixed body, is necessary in certain applications,
like that of Cast PP, that require a more efficient cooling. PP materials, if not cooled
aggressively, tend to form crystals that ultimately give rise to hazy films.
The vacuum box removes entrained air between the primary quenching roll surface and the film
to minimize the air barrier between the hot web and the roll. This air barrier, if not reduced, acts
as a thermal insulation cushion that impedes the film cooling process. The box also reduces the
amount of necking in the film and the air gap and allows higher line speeds to be utilized.
The vacuum box can be combined with an air knife or an air chamber to further enhance the web
cooling.
Automatic Gauge Control System
Inline measuring and control of film thickness distribution across its width is the function of the
gauge control system or APC (Automatic Profile Control). When the flexible lip on the die is
manually controlled and the production process is well tuned, film thickness variations will be in
the range of ±3 to ±5%. In automatic mode, it is possible to reduce these variations by half. The
figure below shows an automatic die with the automatic control module mounted on the flex body
of the die. The so-called thermal translators or thermal bolts form the module. The distance
between the bolts is typically 1.125 inches.
The gauge control system includes a radiation emission unit and a control console. The radiation
unit travels in the machine cross direction, scanning the film in cycles (measured in minutes).
Commonly, the radiation originates from a beta ray source; although, x-ray and infrared sources
can also be used. In general terms, the film thickness is determined as a function of the film
radiation rate of absorption. Thus, variations on the absorption rate translate into film thickness
variations.

The control console is the interface between the control system and the automatic die. Each
adjustment point or thermal translator on the die is spatially correlated with a position on the
film. This is called mapping. The control system applies power to the thermal translators, as
required, and the lip gap is regulated via thermal expansion of the adjustment element. An
important variable associated with APC is the time constant. It is defined as the time needed for
an adjustment element to elongate 62.3% of its maximum elongation. The shorter the time
constant the more responsive the system is, translating to gains in productivity.

Corona Treatment
In order to facilitate the adherence of inks or coatings onto the film surface it is necessary to
apply a surface treatment. Corona treatment is the most commonly used of the existing methods.
Corona treatment increases the surface energy of the film and consequently its surface
tension. The system includes a power source and the treatment station. The power source
transform 50/60 Hz plant power into much higher frequency power in a range of 10 to 30 KHz.
This higher frequency energy is supplied to the treatment station and is applied to the film surface
by means of two electrodes, one with high potential and the other with low potential, through an
air gap that typically ranges from 0.5 inches to 1 inch. The surface tension on the film surface is
increased when the high potential difference that is generated ionizes the air. Corona treatment
can be done inline or as a separate downstream process once the film is produced. If performed
inline, special consideration must be given to the potential generation of toxic ozone. In some
cases, it is necessary to provide a ventilation system in the production area.
 Winder
In simple words winders are used to convert the extruded film into rolls of material. The winding
process has to be such that the film preserves its properties and dimensions when these rolls are
unwound and converted in other downstream processes.
There are three basic types of winders; surface winders, turret or center winders, and
center/surface winders. Surface winders wind film through the contact between a large diameter
drum and a winding shaft that is pressed against the drum with variable pressure. Turret winders
or center winders are any style of winding machine that use a driven shaft running through the
center of the building roll or on chucks supporting the core to drive the building roll. Finally, in
the combination approach of a center/surface winder (or gap winder) a small gap is maintained
between the surface winding roll or lay on roll and the winding roll. A center drive system drives
the winding roll independently of the surface drum. Films can be tacky or have some degree of
slip, have high or low elasticity, thin or thick, the required roll diameter can be large or small;
rolls can be narrow or wide, soft or hard. Winder technology is complex and the proper type of
winder used in a particular application depends on all of the above variables.

The use of turret or center winders is typical in cast film applications. With this type of winder
the web tension decreases as the roll diameter increases. This is controlled by the rotational
speed of the winding spindle. A lay on roll prevents or allows the entrapment of small amounts
of air between the layers. The latter is recommended for winding films with high tack or for
winding soft rolls. In order to evenly distribute defects on the extruded film (thickness variations)
a randomizer is used. The randomizer moves the film back and forth, as it is slit and wound. An
alternative approach is to move the slitter and winder back and forth relative to the film.

Computerized Supervisory and Control System

The main components of a cast extrusion line have been enumerated and described. These
components do not act on their own but are integrated and governed by a computerized
supervisory and control system. The main computer is the brain that couples and drives the
controls of all the line components in an orchestrated way.
The main tasks of the computer are:

• To control start-up, shutdown and speed of the line;

• To monitor the weight of material fed into the extruders and to control the speed of the
extruders in order to maintain a constant throughput;
• To control all temperature zones and the temperatures of all the materials;
• To coordinate the interaction between the gauge control system, the response of the
automatic die and the line speed;
• To control the web tension; and
• To store and handle all product recipes, store operational data and control the alarm
system.

A good control system must provide operators with an easy to operate graphical interface or
monitor system.

Advantages of Co extrusion Process

Combining rigid and flexible material is able to exploit the different and individual strengths of
each material in to a single product. Another advantage is that it permits multicoloured products.
This can range from decorative finishes to even product identification. As discussed
 • High quality mono-layer extrusion coatings in larger varieties of line speeds and widths
• Use of lower cost materials for filling purpose, assists in saving on the amount of
qualitative resins
• Capability of making multi-layer as well as multi-functional structures that too in a single
pass
• Reduction in the number of steps required in general extrusion process
• Provides targeted performance with the use of definite polymers in particular layers
• Reduction in setup and trim scrap
• Potential for use of a recycle layer t
• It is possible to impart a desired distinct property. This could be in terms of stiffness,
resistance to chemicals, impermeability, heat-sealability

Disadvantages Of Co-extrusion
As per a number of globally reckoned companies, there are some disadvantages related with the
process of co-extrusion. Some of these disadvantages are as follows:

• Minor differences in physical properties are responsible for making a combination

desirable, but these differences are also responsible for making the combination
incompatible
• For this process, polymers must have similar melt viscosities to sustain a laminar flow.
All the viscosity differences may be more or less tolerable, according to the material
location inside the composite structure along with the layer's thinness
• Requires more sophisticated extruder and its operator. This implies extra maintenance
cost of the equipment.
• Demands considerable planning as well as forethought in the system design

Applications of Co extrusion
The Co extrusion process is a widely used technique these days, producing many products for
critical industrial applications. To understand the importance of co extrusion let us consider a
very simple example of a striped drinking straw. It is a perfect example of a coextruded tube. For
example, a white straw gets extruded from polypropylene, a colored polypropylene material
could be coextruded in a smaller area for creating a striped tube.
A relatively new application is the Co-extruded plastic films. These are having a wide use in
packaging industry. Another emerging sector for co extrusion is the industrial films and
laminations. The medical industry is another area where co-extruded tubing products are used.
Further irrigation devices as used in the agricultural industry has a great use for co extruded
stripes.
Overjacketing And Tubing Extrusion

Overjacketing and tubing extrusion are highly preferred processes for extruding a range of plastic
materials. The overjacketing extrusion process is discussed here. In the process of wire coating,
the bare wire or some bundles of jacketed wires, filaments, etc. are pulled through the die's
center, which is similar to the tubing die. The different materials that are used here, depends on
the application. Basically, an insulated wire is a tube (thin walled) that is formed around bare
wire.

For coating a wire, there are mainly two different kinds of extrusion tooling used. These are
called "pressure" tooling or "jacketing" tooling. The selection of the type of tooling to be used
depends on the fact that whether the specific application needs intimate contact or if it needs
polymer adhesion to the wire or not. In case there is the requirement of an intimate contact or
adhesion, pressure tooling is used or else, jacketing tooling is selected.

Jacketing Tooling vs Pressure Tooling

Jacketing tooling differs with pressure tooling on the parameter of pin's position with respect to
the die. In case of jacketing tooling, the pin is extended all the way and flushed with die. Upon
feeding the bare wire through the pin, it does not directly makes contact with molten polymer
unless it leaves the die. In pressure tooling, the pin's end is retracted in the crosshead, where it
contacts with polymer at a higher pressure.

Tubing Extrusion
The process of tubing extrusion or extruded tubing process is used to manufacture products like
medical tubing and drinking straws. This process is exactly similar to the process of regular
extrusion, until the stage of die. To extrude the hollow sections, a pin or mandrel is placed inside
the die and in various cases, positive pressure is applied through the pin onto the internal
cavities.
For specialty applications, it is required to make tubings with a number of lumens or holes. For
such applications, tooling is created with the placement of more than one pin in die's center for
the production of required number of lumens. In large number of cases, the pins are available
with air pressure from a range of sources. This way, it becomes easy to adjust individual lumen
sizes with the adjustment of pressure to the individual pins.

Crosshead Extrusion Process (Wire & Cable Coating)

Crosshead extrusion process is widely used to coat wires and cables with a polymer. The basic
procedure includes pulling of the wire / cable to be coated at a uniform rate via a crosshead die,
where it is covered with the molten plastic. This extrusion process for coating is used in most
wires and cables that find usage in telecommunication and electrical applications along with
electronic industry. For more coatings, two extruders can also be used in tandem.

Development Of Standard Two-Wire-Plus-Ground Cable By Crosshead Extrusion

Consider the example of the development of standard two-wire-plus-ground cable, which is
commonly used in home wiring. In the beginning, white insulation is used to coat one copper
wire and black insulation is used for the other. In a secondary process, following procedures are
followed:

• A paper-wrapped copper wire is combined with the black & white insulated wires. This
third wire is used for the ground.
• All the wires are fed through die
• In the die, final insulating jacket is applied for protecting all the wires together. The
insulating jacket also assists in holding the three wires in a common plastic sleeve, which
is used home wiring

Another approach to produce this product, is via the continuous process of production. In this,
two extruders are used to individually apply white as well as back coating on the two conductive
wires. The successive processes are as follows:

• These two products brought together by using a third copper ground wire
• The three wires are sent via a third crosshead die, where the addition of exterior jacket
takes place
As all the three extruders are running at similar speeds, the end product is developed with
minimal handling. A negative point of this process is the amount of production loss occurred, in
case any of the three extruders is not running efficiently or there is some problem with only one
of the extruders.
Wire coating is generally done by the use of single screw extruders, in which the crosshead
extrusion process is carried out. The job of the extruder is to melt the resin & forward it to the die
at an even & constant melt pressure and temperature. The crosshead extrusion process is carried
out by using a general equipment in the line, which includes following basic pieces:

• Unwind station or some other wire / cable source for feeding the line
• Pretensioning station for setting the tension throughout the process
• Preheat station for preparing the wire for coating
• Crosshead die
• Cooling trough for solidifying the polymeric coating
• Test stations for assuring that the wire is suitably coated
• Puller for providing constant tension through out the process
• Winder for collecting the product

Typical Polymers Used In Wire Coating Applications

There are various polymers that are used in wire coating applications by the crosshead extrusion
process. The characteristics of these polymers, which make them ideal for this purpose are their
flexibility, electrical properties, ability to withstand abuse, and durability. Typical polymers are
as follows:

• Polyethylene
• Polyvinylchloride
• Polyamide
• Polybutylene terephthalate
• Thermoplastic elastomers
• Ethylene propylene copolymers
• Polypropylene
• Fluoropolymers

In the wire coating operation, cross linked polyethylene is used. The wire is extrusion coated with
this polymer in this process. At the end of coating operation, polyethylene is cross-linked on to
the wire.

Monofilament Fiber Extrusion

The process of Monofilament Fiber Extrusion is highly useful for the development of products
that are used in almost all walks of life. In fact, monofilaments are an essential part of our
everyday work, making our work simpler along with making our leisure more enjoyable. For
instance, monofilament finds usage for fishing line and to make strings for squash, tennis,
racketball rackets and badminton. It is also used for making synthetic monoyarn which is used in
the weaving process as well as in synthetic rope which finds usage in fences, construction,
greenhouses, orchards, fastening, and many others.
Various products that are developed using Monofilament Fiber Extrusion process are as
follows:

• Decorative tapes
 • Ribbons
• Webbing in lawn chairs Bristles for toothbrushes
• Grass trimmer lines
• Tire reinforcements
• Sewing thread for industrial textiles, apparel, home furnishings and floor coverings

Common Polymers Used For Producing Monofilaments

• Polyamide (nylon 6, nylon 6,6, and nylon 6,10)

• Polyester
• Copolyester
• Polypropylene
• Polyethylene
• Polyphenylene sulfide
• Polyvinyilidene fluoride

Process Of Monofilament Fiber Extrusion

In the monofilament extrusion process, smaller extruders and longer lines are used. The products
developed from this process have a very small diameter and many number of ends. Smaller
diameter allows very swift cooling that too in a small space. On the cooling of filaments, they are
drawn and wound onto the packages. The drawing process is done using comparatively large
ovens having godet rolls on its every side. These rolls are used for drawing the filaments to the
accurate denier (grams/9000 meters). After this process, the product is wound onto bobbins,
wherein these can be utilized directly or by combination for producing some other products like
rope etc.
Steps Followed In A Monofilament Line

• In general, 2.5 - 3.5 inch single screw extruder is used in most monofilament processes.
• A gear pump placed between the die and extruder provides consistent polymer flow &
pressure.
• Filaments are extruded vertically by circular dies into the cooling bath. Here, the
filaments are separated so that every filament runs separately via the line, where their
wrapping process takes place. The wrapping is done on a bobbin or spool.
• After quitting the water bath, filaments are dried & further and passed via godet rolls,
which are controlling the speed as well as draw from the die.

• A large oven placed between two godet roll stands heat the filaments for facilitating the
filament drawing. Second godet roll stand operates at a much higher speed than the first
and is responsible for the determination of the draw inside the oven. The number of godet
rolls and ovens completely depends on the sophistication of line and the draw required.
After the filaments exist the last godet roll, they may be passed through a laser
micrometer for monitoring individual filament diameters. Lastly, every monofilament is
wrapped on separate package for being used in subsequent operations.

The products created by the process of Monofilament Fiber Extrusion are tested on the
parameters of water shrinkage, hot air shrinkage, diameter uniformity, denier, color and
filament smoothness.

Extrusion coating
Extrusion coating is a process of coating thermoplastic material onto a substrate such as woven
fabric, paper, paperboard aluminum foil, PET, BOPP film etc. The resins most commonly used
are polyolefins such as polyethylene, ionomers, ethylene vinyl acetate copolymers and
polypropylene.
Advatanges of extrusion coating are:
As a process:
♦ Double sided coating can be done to achieve desired properties.
♦ Solvent/adhesive free
♦ Thickness of the coating can be varied depending on the end use
♦ Higher line speeds
As an end product;
♦ Provides moisture barrier properties
♦ Avoid direct contact of content to the substrate
♦ Provide heat sealable characteristics
♦ Reduces loss of content
Process of extrusion coating:
Extrusion coating is a process in which a substrate is coated with an accurately metered film of
molten plastics. Extruded thin molten film is pulled down on a substrate and into the nip between
the chill roll and pressure roll below the die (fig. 1) The pressure between these two rolls forces
the plastic onto the surface moving at a speed faster than the extruded film and drawing the film
to the required thickness.

Extrusion coating line consists of:

♦ Extruder
♦ Die
♦ Chrome plated chilled roll
♦ Back up roll
♦ Winders/Unwinders
An extruder converts solid pellets of thermoplastic resin into a uniform, homogeneous melt.
Extruders with L/D ratio of 24:1 to 26:1 are normally used for LDPE whereas for LLDPE, L/D
ratio of 26:1 or above is recommended for better results. Die commonly used are flat, coathanger
type with adjustable die lip. Melt extruded through the die comes in the nip formed by chrome
plated chilled roll and soft rubber coated back roll. A large diameter chilled roll provides enough
contact time to cool the product sufficiently to allow the film to be stripped from the roll without
damage. This cooling requirement is often the limiting factor in the running speed for a particular
product. The surface of the chilled roll may be bright, dull, matte, embossed depending upon the
desired surface characteristics.

Factors influencing coating performance:

1. Melt temp: Extrusion coating lines are normally operated at higher temperature. The resins for
extrusion coating contains lower level of antioxidants. Higher processing temperatures oxidizes
the polymer partially and promotes good bonding to the substrate. Further it lowers melt viscosity
promoting uniform flow of melt through the die. Higher temperature (>300 deg.C) is necessary to
achieve acceptable level of adhesion to the substrate at high line speeds.
2. Die gap: The die gap is the critical control point on any extrusion coating line. The slit die with
die opening of 0.5 mm to 0.8 mm is commonly used. Higher die gaps give higher flow variation.
3. Air Gap: The gap between the die exit and substrate on chilled roll is called air gap which
need to be optimized with respect to coating material. Some oxidation of the melt takes place
after exit from the die, facilitating adhesion of polymer to the substrate. Higher gap leads to
higher necking and cooling of the melt, leading to improper adhesion of polymer to the substrate.
For LLDPE/LDPE (1) blend, the air gap is normally maintained between 30 - 40 mm.
4. Chilled roll temperature : It has influence on coating adhesion and stiffness. Optimum chilled
roll temperature for polyethylene is 30 deg. c.

Material Selection for Extrusion Coating:

The resin most commonly used for extrusion coating are LDPE, LLDPE and their binary blends.
Each polymer offers unique advantages over the other and their binary blend strikes the balance
of properties. Due to presence of long chain branching and broader molecular weight distribution
in LDPE, it shows a good processability, superior hot melt strength. Further, LDPE shows a
phenomenon called 'strain hardening' by virtue of which elongation visciosity increases with the
line speed. Hence draw down to thinner gauges are possible at higher line speed without
appreciable neck-in.
Extrusion coating grades with LLDPE have shown that neck-in is high and increases with line
speed. The increase in neck-in is attributed to the drop in elongational viscosity with increase in
line speed. This phenomenon is termed as 'tension thinning and is due to narrow molecular
weight distribution and absence of long chain branching. However LLDPE held a new distinct
advantages over LDPE extrusion coating grade. The main advantage of LLDPE over LDPE is
high mechanical strength which allows downgauging. The relatively lower thermo-oxidative
stability of LLDPE over LDPE leads former to oxidize faster resulting in better adhesion to non
porous substrates like aluminium foil and tapes. A marked improvement in sealing properties is
observed when LLDPE is blended with LDPE.
The most practical method to utilize LLDPE in extrusion coating is by blending with highly
branched LDPE> Blending of polyolefins generally has an additive effect. LLDPE rich blends
offer much better mechanical properties and sealing properties as compared to those of LDPE.
The processing characteristics of such blends can be enhanced further by using narrower die gap
(0.4 mm - 0.6. mm)
Resin Characteristics for Extrusion Coating:
• Higher melt index-required for better adhesion
• Additive free
• Appropriate amount of antioxidants
• Reduce neck-in properties
• Good adhesion to substrate at higher line speeds

Applications Of Extrusion Coating

The extrusion coated products are wide used in the segment of synthetics woven sacks. These are
also used for coating on the non-raffia substrates that primarily includes coating on Al-foil, Paper,
PET & BOPP substrates. The major application areas of extrusion coating are as follows:

• Woven sacks for fertilizer packaging

• Tarpaulins
• Coating on conventional jute bags
• Soap wraps
• Pharmaceutical strip packaging
• Cable wraps
• Coating on paper used in packaging of salt and sugar (sachets)