1. Blown Film Extrusion Technology Presented by General Extrusion Technology (GET)

3. 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

4. Blown Film Extrusion Technology
GET partners with some world best component/system suppliers

5. 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

6. 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

7. 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

9. Blown Film Extrusion System
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

10. System ACS 5300AS NAVIGATOR
19” Color touch screen

11. System ACS 5300AS NAVIGATOR
System ACS NAVIGATOR control principle
Plant wide control concept
Modular structure
Machine control NAVIGATOR
Temperature control

12. System ACS 5300AS NAVIGATOR control principle

13. Plant wide control concept
Modem connection
Printer package
Office network link

14. Modular structure

15. Access to each individual system in the network
Base module

16. Hall-wide status with efficiency and summary information
Base module

17. Alarm report with trace function
Base module

18. Historical trace of process data
Expansion module of historical trend

19. Historical trace of profile data
Expansion module of historical profile trend

20. Handling of summary, shift and week reports
Expansion module of report data base

21. Interrogation of logged data from complete orders
Expansion module of order analysis

22. Complete material data base management
Expansion module of material data base

23. Machine control NAVIGATOR

24. Machine control NAVIGATOR

25. Machine control NAVIGATOR

26. Temperature control

27. Temperature control

28. Machine control NAVIGATOR

29. Temperature control

30. Gravimetric batch blending system
Plast Control batch blender PB422
Mechanical advantages
Weighing hopper concept
Material conveyor PCH400/PCH800
Pre-filter PCP 500

31. 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

33. Mechanical advantages
Rugged design
Manual refill
simple cleaning
Material viewing glass
Manual slide valve
Quick change attachment for dosing screws
Material outlet

34. 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

35. Material conveyor PCH400/PCH800

36. 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

37. Material conveyor

38. Pre-filter PCP 500

39. Blown Film Extruder Direct drive with torque motor(gearless)
Traditional drive motor with gearbox
Screw and Barrel Technology
Barrel cooling system

40. Direct drive with torque motor(gearless)

41. 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 food-packaging films
Compact size, an advantage for coextrusion

42. 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 rpm vs similar torque at 2,000-3,000 rpm

43. Traditional drive motor with gearbox

44. 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

45. 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

46. Smooth bore barrel
Smooth bore barrel is largely used by extruder builder in USA, even as today
Good for high-melt-temperature 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

47. 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

48. Barrier screw for smooth bore barrel
Feed section
Metering section
Barrier 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

49. Barrier screw for grooved bore barrel
Homogenizing section
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

50. Barrier screw for grooved bore barrel
Barrier screw with homogenizing elements
Rhomboid mixing element
Spiral shearing element

51. Barrel cooling system Barrel cooling system design concept Heater band
Cooling air flow
Blower

52. 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

53. Barrel cooling system
Patent pending
GET’s innovative design

54. 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

55. Barrel cooling system

56. 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

57. Screen changer Old design 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
Old design
GET new design

58. Blown film die system Blown film die technology Air ring technology
Air ring cooling and die cart
Internal bubble cooling(IBC) system

59. Blown film die system Single air ring die system
Double stack air ring die system

60. Blown film die system IBC cooling unit Dual lip air ring
IBC air in/out
Die cart
Air ring air supply

61. 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

62. 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

63. Blown die technology
Single to dual melt distribution and spiral mandrel die
Spiral mandrel melt flow channel
Binary pre-distribution)

64. Simulation of 400 mm 3-layer die
Material: LDPE, FD0274, Qatar, MI: 2.4
Output: 500 kg/h
Temperature:=210 ℃

65. 400 mm 3-layer blown film die melt flow FEA simulation
Resin: LDPE, FD0274, Qatar, MI: 2.4;
Output: 500 kg/h; Temp:210 ℃

66. Simulation of the inner layer
Uniform pressure distribution in the die

67. Simulation of the inner layer die
Uniform velocity
distribution in
the die

68. Simulation of middle layer
Uniform
pressure
distribution in
the die

69. Simulation of middle layer
Uniform velocity distribution in the die

70. Simulation of outer layer
Uniform pressure
distribution in the
die

71. Simulation of outer layer
Uniform velocity distribution in the die

72. Air ring technology 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

73. 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

74. Air ring technology External bubble cooling and bubble forming
Coanda effect:
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)

75. 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

76. 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

77. 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

78. 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.

79. Air ring technology Perforated Chimney type dual lip air ring
Forming cone and chimney manual adjustment

80. Air ring technology Patent pending
Perforated Chimney type dual lip air ring
Patent pending
Forming cone and chimney electrical adjustment

81. Air ring technology Operation theory of dual lip air ring
Chimney adjustable
Forming cone
Upper lip adjustable
Lower lip

82. 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

83. 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

84. Air ring technology Double stack air ring Electrical actuator up/down
adjustment
Suitable for high speed
extrusion

85. Air ring technology Autoprofile technology
Autoprofile control principle
Autoprofile air ring
Autoprofile die
Autoprofile benefits

86. 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

87. Air ring technology Autoprofile technology 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
3.5mmx25m air chamber

88. Air ring technology Autoprofile technology
Segmented die with heater cartridge in sizing ring
64 control zone
Heater cartridge
Autoprofile die

89. 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

90. Air ring technology Air ring cooling air supply and die cart Die cart
Die centering and up/down
adjustment
Air ring air supply

91. Internal Bubble Cooling (IBC)
Simulation of typical IBC system
IBC control principle
IBC cooling unit

92. Internal bubble cooling(IBC)
Simulation of typical IBC system
Air flow comparison between the original and modified IBC system(0.5 lt/s)

93. Internal bubble cooling(IBC)
IBC control principle
Six sensors system from PlastControl

94. Internal bubble cooling(IBC) unit
H-Type IBC cooling unit with spiral cooling tube for high speed extrusion as an option

95. Internal bubble cooling(IBC)
V-Type IBC cooling unit with spiral cooling tube for high speed extrusion as an option

96. 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

97. Bubble cage 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

98. 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

99. Bubble cage-Chilled air bubble cage
Air in
Air amplifier

100. Bubble cage-Chilled air bubble cage
Patent pending
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
Chilled air out
Chilled water in/out

101. Gauging system
Contact and non-contact capacitive rotating scanner

102. Gauging system

103. Haul-off system Stationary primary nip Horizontal haul-off unit
Collapsing frame
Haul-off system
Second nip station

104. Haul-off system
Haul-off system

105. Haul-off system
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

106. Haul-off system
Mink Web Spreader Brush Roll 10022, Germany

107. Haul-off system
Mink Web Spreader Brush Roll 10022, Germany

108. Haul-off system Horizontal haul-off unit Airless turning bar
Spreader roller

109. 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

110. 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

111. 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

112. Web guiding system Coast Control all pneumatic web guide system, USA
No motor, no electronics
No hydraulic
Easy installation
Easy operation
10 years warranty
on all parts

113. Web guiding system

114. Web guiding system

115. Haul-off system Secondary nip station
Avail w/ dancer or load cell control
Variety of roll finished available
Configurable w/S-wrap cooling option

116. Surface winder Central surface winder
Winder Technology
Surface winder
Central surface winder

117. Winder technology Central/surface/gap winder
Finished roll diameter: 1,500 mm max
Line speed: upto 250 m/min
Tension control: N, 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
Central/surface/gap winder

118. Winder technology

119. Film tower

120. Thank you for your attention!

121. Internal bubble cooling(IBC)
Simulation of typical IBC system

122. Internal bubble cooling(IBC)
Simulation of typical IBC system
Heat transfer coefficient profile for original and modified designs

123. Improved grooved barrel/screw system
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

124. Experiment result
Throughput vs. screw speed for grooved and smooth extrusion system

125. Experiment result
Throughput and melt temperature vs. screw speed

126. Experiment result
Back pressure and grooved bore pressure vs. screw speed