Rajoo - Extrusion Training Programme PDF

Training on Basics of Plastics Processing - Extrusion
Venue: Rajoo Innovation Centre LLP, Rajkot

Duration: 23rd to 24th July 2018
Report Prepared By:
Manish Soyal
Officer- PADC
Product Application & Development Center

Established in 1986 by founder Late Shri C. N.Doshi
Turnover as on March 2017 : 125 Crores
Total branches in India: 05
Rajoo Collaboration & Joint Venture
Rajoo Technical Collaboration Rajoo Joint Venture
British
company
Went
public
Rajoo
Rajoo
Hosokawa
Commodore
Bausano
Alpine AG, Rajoo
Germany
Inc. U.S.A. Extrusion
Pvt. Ltd
Bausano &
Figli S.P.A.
– Italy
Techno
Coating Eng.
Italy

Product portfolio
(Monolayer Film ) (Multilayer Film) (Foam Extrusion Lines)
(Downward Extrusion Blown (Extrusion Sheet Lines) (Thermoforming)

Film Lines)

Product portfolio
(Lab Equipment-Sheet line or blown
(Extrusion lines for nonwoven fabric)
film line)
(Twin Screw PVC Pipe Plant) (Drip Irrigation Pipe Plant)

FOILEX - Monolayer Blown Film Lines
Output Range: 40 kg/hr to 700 kg/hr

Lay-flat widths Range: 25 mm to 3200 mm
Thickness Range: 10 micron to 200 micron
Suitable For: LDPE, LLDPE, HM - HDPE, PP
Applications:
1. PE general purpose films 2.HDPE pick-up bags 3. shade-net film
4. PE lamination films 5.HD twist wrap films 6. stretch and cling films
7. shrink films, 8. Anti-rust films

MULTIFOIL- Multilayer Blown Film Lines

Applications:
1. Barrier Packaging 2. Swimming Pool liner 3. Diaper
4. Garment Bag 5. Milk & Water Pouch 6. Mulch film
7. Oil & Food Packaging, 8. Retort Pouch

FOMEX - PS/PE Foam Extrusion Lines
PS Foam Sheet Extrusion Line

Thickness Range: 0.09 mm to 6mm
Suitable: PE, PS, PP and EVA
Applications:
1. Thermofomable sheet
2. Packaging of Electrical item
3. Bottle cap Liner
4. Table mats
5. Wall Calendar
PE Blown film Extrusion Line
AQUAFLEX - Downward Extrusion Blown Film Lines

Widths Range: 800 mm to 1500 mm
Suitable: PE, Nylon, PP and Elastomer
Applications:
1. Beverage Packaging 2. Garment Packaging 3. High Impact Stretch Film
4. Fruits Packaging 5. Lamination Film

LAMiNA - PS/PP/ABS/rPET/EVA Sheet Lines
Output Range:
150 kg/hr to 1000 kg/hr
Widths Range:
700 mm to 800 mm
Thickness Range:
0.25 mm to 15 mm
Suitable:
PE, PA, PC, ABS, PMMA,
EVA and EVOH
Applications:
1. Sheet for stationary files 2. Cosmetic packaging 3. lamp shades
4. Refrigerator liner 5. Disposable Containers for food packaging

DISPOCON- Electro- Hydro- Pneumatic plug Assist Thermoformer Container
Applications:
1. Blister Packaging 2. Fast Food Packaging 3. Lids for cold beverages
4. Biscuit Tray 5. Yogurt cups

FLOWEX - Twin Screw PVC Pipe Plant

Pipe Dia: 15mm to 1000 mm
L/D Ratio: 30:1
Applications:
1. Conduit/ Ducting
2. Casing Pipe
3. Construction pipe
4. Irrigation Pipe
5. Plumbing Pipe

PENTAFOIL & HEPTAFOIL
PENTAFOIL
5 layer Co- extruded blown film line

7 layer Co- extruded blown film line

HEPTAFOIL
WORKSHOP TRAINING ON PLASTIC PROCESSING (BLOWN FILM EXTRUSION)

BLOWN FILM EXTRUSION PROCESS

Process:
 Plastic Pellets are successively compacted and melted, then forced or extruded,
through an annular die.
 Melt emerging from extruder is inflated by air pressure (5 to 7 kgs/cm2)depending
upon machine size.
 The bubble is inflated by air pressure contained in between the die and the seating
provided by the nip rolls.
 Bubble is properly stabilized and cooled with the help of internal bubble cooling
system (IBC) & thickness profile controller.
 The bubble is flattened by a pair of collapsible frames before it passed through
 the nip rollers.
 Wind on the winder

The film blowing operation can be accomplished theoretically in any of the following
conditions:
1. Horizontal
2. Vertically Upward
3. Vertically Downward
• The horizontal direction is very rarely used.
• The vertical upward blowing is preferred, e.g. for PE, Nylon and EVOH.
• The vertical downward blowing is used for the manufacture of high clarity PP as
well as Nylon films.
• This process requires water quenching of the bubble for fast cooling which is
rendered convenient by vertical downward blowing.

BLOWN FILM TERMINOLOGY
Blow up Ratio (BUR) = Bubble diameter/Die Diameter

Blow ratio indicates the maximum amount of
stretching in the crosswise direction for a particular
material. For LLDPE BUR = 2.5 : 1.
Lay Flat Width = Width of the flattened lay flat tubing
Frost Line Height: The height from the die face at

where melt freezes.
The frost line height affects the optical property of the film since molecular relaxation
takes place at frost point, thus:
1. Higher the frost line height, poor will be the optical properties.
2. Lower the frost line height Brittleness of the film increases.
Generally setting of frost line height depends upon material thickness , and width of
the film to be extruded.
Standard value for frost line height is 1.2 to 2 times the diameter of the die for LLD
based blown film.
BLOWN FILM : Process Variables
Process Variables BLOWN FILM APPLICATIONS

Melt Temperature • General Packaging Films
Back pressure • Lamination Films
Internal Air pressure • Surface Protection Films
Efficient cooling • Barrier Films for Food Packaging
Single lip/Dual lip cooling ring • Agriculture Films – Green-house
Take off speed films/Mulch Film
Blow Up Ratio (BUR) • Heavy duty shipping sacks
1. Typical Converter film 2 : 1 • Stretch Wrap film
2. Typical Barrier Film 1.8 : 1 • Shrink Film
3. Shrink film 4 : 1

BLOWN FILM DIES
Advantages:
1. Low initial Cost
2. Adjustable die opening
3. Will handle low flow materials
Disadvantages:
1. Mandrel deflects with extrusion rate,
necessitating die adjustment
2. Die opening changes with pressure
3. Non-uniform melt flow
4. Cannot be rotated
5. One weld line in film

BLOWN FILM DIES
Advantages :
1.Positive die opening
2.Can be rotated
3.Will handle low flow resins
Disadvantages:
1.High initial cost
2.Very hard to clean
3.Two or more weld lines in film

BLOWN FILM DIES
Advantages:
1.No weld line in film
2. Positive die opening
3. Easy to clean
4. Can be rotated
5. Improved Film Optics
Disadvantages:
1. High head pressure
2. Will not handle low flow resins
without modification

BLOWN FILM: PROCESS TROUBLE SHOOTING
PROBLEM OBSERVED POSSIBLE CAUSE POSSIBLE CORRECTIVE ACTION
1. Reduce Melt Temperature
2. Increase Cooling, neck height,
1. High Melt Temperature
3. BUR
1. Low Dart Impact 2. Inadequate cooling
4. Correct the material
3. Incorrect selection of Recipe.
combination with high impact
material.
1a. Increase BUR
1. Too Much film orientation 1b. Decrease Die Gap
1c. Increase Frost line height
2. Low MD Tear / Split Film 2. Resin Density too high Use a Lower density Resin
3a. Decrease Melt Temperature
3. Thermal Degradation of the
3b. Add an antioxidant master
polymer during extrusion
batch
1. Low Extrusion Temperature 1. Increase Melt Temperature
2. Improper die gap 2. Increase/Decrease die gap
3. Excessive friction at Die lip 3a. Lower processing rate
3. Melt Fracture 3b. Add processing aid to reduce
COF
4.Resin MFI too low for Extrusion 4. Use higher melt flow resin
conditions or equipment
1. Melt Temperature too high 1. Reduce melt temperate
2.Too Much or too little
2. Adjust cooling air(IBC/OBC)
cooling air
4.Poor Bubble stability 3. MFI too high for process 3. Lower processing rate
4. Output rate too high / too
4. Reduce/Increase output rate
low
5. Misalignment of nip rolls 5. Realign nip rolls
1. Check for contamination in
1.Contamination silos, transfer systems, colours
and other master batches
2. Stop or reduce the ratio of
2. Excessive regrind or
regrind material until problem
reprocessed material
improves
5. Gels, Holes, Bubble Breaks
3. Clean screw and die plus
3. Dirty screw, die or screen
change
pack
screen pack
4a. Check screw
4. Poor mixing 4b. Check heater bands and
1a. Clean screw and die plus

1. Dirty screw, die or
change screen pack
6. High Gauge variation screen pack
1b. Clean Die
2. Uneven Cooling 2a. Check air flow
1. Dirty or damaged die lip 1. Clean or repair die
7. Die Line 2. increase purge time
2. Insufficient purging
between transition
1a. Use resin with a higher
1. Resin viscosity too high
MFI
for die design
1b. Use a processing Aid
8. Port lines 2. Reduce temperature
2. Die and melt
differences between die
temperature off
and polymer melt temp.
3. Melt temperature too low 3. Increase the melt Temp.
1a. Reduce melt temp.
1. Melt Temperature too 1b. Check external cooling
9. Low Extruder Output
Product Application & Development Center high 1c. Check extruder screw
Multi-Layer Plastic Film

Type of Plastic granules in Multilayer
Basic Polymer LDPE, LLDPE, HDPE, MLLDPE
Specialty Polymer Inomers, EVA, EAA, PA, EVOH, PVDC
anti-oxidant, UV, anti-block, slip additive, color

Additive & Master Batch:
pigmented, bio-degradable, anti-fog, cling

Basic Granules

LDPE
Properties:
•Basic polymer
•Easy to process
•Moderate MVTR
Applications:
•General purpose packaging
Consumption: •Food grade packaging
Used normally 10% to 40% with LLDPE for •Heavy duty packaging
manufacturing of PE films. •Lamination purpose
•Pharmaceutical purpose
LLDPE
Properties:
•Basic polymer
•Easy to process
Co-monomer types of LLDPE: •Good mechanical props.
Butene LLDPE – C4
•Moderate MVTR
Hexene LLDPE – C6
Octene LLDPE – C8
Applications:
Used normally 50% to 80% for manufacturing •Heavy duty packaging
of PE films. •Lamination purpose
•Pharmaceutical purpose
HDPE
Properties:
•Processing in moderate
•Better physical &
•mechanical properties
•This & ultra-thin film can be
processed
•Good MVTR
Applications:
Used extremely in mono-layer & Multi-layer •Heavy duty packaging
Barrier film
•Stiff Film

mLLDPE
Types of mLLDPE: Applications:

• Hexene based • Heavy duty packaging
• Octene based
• Lamination film
Properties: Consumption:
• Very good mechanical Props. Used normally 10% -30% with PE
• Good sealing properties material for enhancing mechanical
• Faster hot tack, and has & sealing properties.
better down-gauging
properties, which allows for
thinner films and packaging.

Specialty Polymers
Polymer Name Company Properties
Inomers DOW 1. Provides clarity, formability, and scratch
resistance
2. Provides low-temperature seal initiation,
excellent hot tack strength, and puncture
resistance.
Ethylene-vinyl acetate( EVA) RIL 1. Exhibits good flexibility, good
transparency
2. Enhances clarity and sealability of olefins
Ethylene Acrylic Acid Copolymer Dupont 1. Excellent adhesion to aluminum, nylon
(EAA) (Nucrel) and paper
2. Excellent hot tack strength, toughness,
and low-temperature seal initiation
Nylon Film GSFC & BASF 1. Excellent mechanical strength,
transparency, thermoformability and
barrier
Ethylene-vinyl alcohol (EVOH) EVAL & 1. Act as Oxygen barriers
Sornal
Polyvinylidene chlorides DOW 1. Superior gas and moisture barrier
(PVDC) properties,
2. Excellent heat sealability.
Additives & Master Batch

Feeding/mixing of raw materials
Types of Feeding/Mixing
1. Mixing by hand
2. Mixing in tumbler mixture
3. Volumetric feeding system
4. Gravimetric feeding
system

Processing of Polymers

Processing of Polymers

Types of Multi-layer films
General purpose film

Food packaging film
 Multi layer barrier speciality film
 Lamination grade film
 Vaccum packaging film
 Shrink film
 Stretch wrap film

Running Machines at Rajoo center during Training Time

HEPTAFOIL (7 layer) -Plant & Machinery & Parameter setting:
1. Multi-layer blown film is the

extrusion of multiple layers of
material simultaneously
which utilizes two or more
extruders to melt and deliver
a steady volumetric
throughput of different
viscous plastics to a single
extrusion head (die) which
extrude the materials in the
desired form.
2. The layer thicknesses are
controlled by the relative
speeds and sizes of the
individual extruders
delivering the material.

Observed the manufacture of seven layer 30μ film (non barrier) in HEPTAFOIL
Extruder Description Feed Output (kg/hr) Film t (μ)
C1: Exxon LL 1001AV
Φ = 70mm; C2 & C3: -
A 42.9 2.96
5 comp. feeder C4: RIL LD 22FA002
C5: A.Schulman AMF 705 HF
C1: Exxon LL 1001AV
Φ = 60mm;
B C2: RIL LD 22FA002 42.8 2.95
4 comp. feeder
C3 & C4: -
C1: Exceed LL 1018MK
Φ = 50mm; C2: Exxon HD HTA 108
C 58.6 3.94
3 comp. feeder C3: Exxon LL 1001BU + RIL
LD1005FY20
D 58.9 3.95
LD1005FY20
E 58.6 3.99
LD1005FY20
Extruder Description Feed Output (kg/hr) Film t (μ)
Φ = 60mm;
F C2: RIL LD1005FY20 72.1 5.01
4 comp. feeder
C3 & C4: -
Φ =70mm;
C2 & C3: -
G 5 comp. feeder 101.3 7.03
C4: RIL LD1005FY20
C5: A.Schulman AMF 705 HF
Other process parameters and output:
A - 36/200/205/210/212/215
B - 35/200/205/210/215
C - 37/200/205/210
Extruder temperature (°C) D - 36/200/205/210
E - 40/200/205/210
F - 37/200/205/210/215
G - 35/199/205/210/212/214
IBC/EBC temperature (°C) 10/20 Haul off speed 61.5 m/min
Thickness of film obtained 29.86µ Weight of film 117.91g/m
Width
Product of film
Application obtainedCenter
& Development 2149.4mm Output of machine 435.3 kg/hr
Cylindrical Spiral Die: The circular dies have spiral pathways for the polymer melt flow and are
assembled one over the other circumferentially.

Double lip cooling: To achieve thickness control and optical properties, the bubble is blown
using cold air from inside (IBC - Internal bubble cooling) and external of the bubble (EBC -
External bubble cooling)
Bubble is properly stabilized and cooled with the help of
• IBC temp – 10°C internal bubble cooling system (IBC) & thickness profile
controller.
• EBC temp – 12°C
Film thickness measurement

unit: Film thickness
measurement unit measures
the thickness of the film
throughout the circumference
of the film and feeds back to the
‘PLASTCONTROL’ system for
corrective action and achieve
desired thickness of the film.
Oscillating haul off unit: Oscillating haul-off unit oscillates 359° over the turn bar and allows
minimum web tension that eliminates wrinkle or bulge problem.
Web aligner : To align the film by reducing slip and make the film distribute evenly over the roll.

Corona treatment - A potential of about 12000V is applied on the film to make the
film surface printable, to reduce the coefficient of friction and to impart slip properties
to the film. (Not in operation during the observation).
Slitting system - To slit the film at edges/centre as desired.
Winding system :
• Proper tension must be maintained to achieve good winding and hence the entire
roll of the film can be used 100% of the length during application.
• If required, printing (Rotogravure/Flexographic printing) is carried out in printing
machines over the film.

Sheet Line-Plant & Machinery & Parameter setting:
Observed processing RIL PP H050MN for the manufacture of sheets in RS3X-1430-20/300 K

sheetline
The machine has four

extruders and all the
extruders were fed with RIL
PP H050MN. Output from
the first extruder forms the
top and bottom layer of the
sheet.

Sheet Line-Plant & Machinery & Parameter setting:
Parameters Values
A – 250/260/270
Temp profile. B – 238/248/260
Extruder (A to D, °C) C – 238/248/260
D – 240/250/260
Screen changer temp, °C 264

Adapter temp., °C 264
Chill rolls temp, °C 15.9/19.8/43.5
Stacker speed, MPM 2.7
Take off speed, MPM 2.5
Winders speed, MPM 1.3

WPC/PVC foam board and WPC profile lines

Rajoo Bausano’s exclusive WOODPLEX technology uses wood powder upto 80% to
manufacture WPC (Wood Plastics Compostie) profile and upto 50% to manufacture
furniture board, with machine outputs ranging from 200kg/hr to 1500kg/hr. L/D: 36/1
to 36/1 to allow sufficeitn residence time for excellent homogenization of natural
fibres with polymers and offers a large surface for optimal heat transmission.


Rajoo - Extrusion Training Programme PDF

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Rajoo - Extrusion Training Programme PDF

Caricato da

Copyright:

Formati disponibili

Training on Basics of Plastics Processing - Extrusion

Venue: Rajoo Innovation Centre LLP, Rajkot

Product Application & Development Center

Rajoo Technical Collaboration Rajoo Joint Venture

Product Application & Development Center

(Downward Extrusion Blown (Extrusion Sheet Lines) (Thermoforming)

Product Application & Development Center

(Twin Screw PVC Pipe Plant) (Drip Irrigation Pipe Plant)

Product Application & Development Center

Output Range: 40 kg/hr to 700 kg/hr

Product Application & Development Center

Output Range: 80 kg/hr to 1200 kg/hr

Product Application & Development Center

Output Range: 80 kg/hr to 800 kg/hr

Output Range: 80 kg/hr to 400 kg/hr

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Output Range: 250 kg/hr to 2000 kg/hr

Product Application & Development Center

Output Range: 80 kg/hr to 1200 kg/hr

7 layer Co- extruded blown film line

Output Range: 300 kg/hr to 1200 kg/hr

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Blow up Ratio (BUR) = Bubble diameter/Die Diameter

Lay Flat Width = Width of the flattened lay flat tubing

Frost Line Height: The height from the die face at

Process Variables BLOWN FILM APPLICATIONS

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

1a. Clean screw and die plus

Product Application & Development Center

Basic Polymer LDPE, LLDPE, HDPE, MLLDPE

Specialty Polymer Inomers, EVA, EAA, PA, EVOH, PVDC

anti-oxidant, UV, anti-block, slip additive, color

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Types of mLLDPE: Applications:

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

Product Application & Development Center

General purpose film

Product Application & Development Center

Product Application & Development Center

1. Multi-layer blown film is the

Product Application & Development Center

Thickness of film obtained 29.86µ Weight of film 117.91g/m

Product Application & Development Center

Film thickness measurement

Product Application & Development Center

Product Application & Development Center

Observed processing RIL PP H050MN for the manufacture of sheets in RS3X-1430-20/300 K

The machine has four

Product Application & Development Center

Screen changer temp, °C 264