2 Layers Blown PE Film Extruder Plastic Film Machine
Overview of PE Plastic Film Machine
PE plastic film machine, also named film blowing machine, PE film making machine or PE film extruder etc.
1. Barrel and screw of PE plastic film machine are made of high quality alloy steel with optimum hardness and durable service after precision finishing and nitrogen treatment.
2.PE plastic film machine high pressure type dies are accuracy made and also therefore are pricey however their life span is considerable.
3.Each die head will have a working range of die inserts at different diameters to fit the needed application. Different die gaps can also be specified relying on the material being extruded.
4. Main Motor coupling connected with gear box, reduce the power consumption.
5.Winder and utting unit adopts torque motor to keep proper tensions and make rolling even and easy to replace.
6.Pneumatic up and down mobile, surface friction winder, equipped AC motor with frequency conversion.
7.The auxiliary machine of PE plastic film machine has a platform working table for making operation easy and is equipped with bubble stabilizing ring.
8. High efficiency dual lip air ring cooling system , SSR +PID temperature controller.
9.The plastic film procedure is a continual procedure, as such the machinery has to be designed to cope with both the high speeds involved and have the ability to operate on a 24 hour basis.
Usage of PE Plastic Film Machine
1. 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. Blown film extrusion can be used for the manufacture of co-extruded, double-layer or multi-layer films for high barrier applications such as food packaging.
2. Industry packaging (e.g. shrinkable film, stretch film, bag film or container liners).
3. Agricultural film (e.g. greenhouse film, crop forcing film, silage film, silage stretch film).
4.Consumer packaging (e.g. packaging film for frozen products, shrinkable film for transport packaging, food wrap film, packaging bags, or form, fill and seal packaging film).
5. 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.
6.Laminating film (e.g. laminating of aluminum or paper used for packaging for example milk or coffee).
7.It is used for blowing plastic film of PE, i.e. Polyethylene.
8.Which is used for all kinds of plastic membrane and packaging bag, for food, medicine, beer bottle, material bottle, box, case, cloth reel, floor, glass, all size of trays, pottery, tissue, etc.
Packing list of PE Plastic Film Machine
Part 1. Electrical parts of PE Plastic Film Machine
1.1.Heater of PE Plastic Film Machine
1.1.1. Cast aluminum heater features:
Conditions: the environment temperature 20 ºC ~ + 60 ºC; relative humidity< 80%
Electric strength: passed by 1500V50HZ sinusoidal AC voltage withstand voltage test, when the pressure reach to 1M1N, no breakdown phenomenon.
Leakage current: < 0.5 MA
Insulation resistance: 2MΩ
Grounding resistance: < 0.1 Ω
Power deviation: + 5% ~ -10%
Heat resistance: installed on the machine surface temperature almost up to 400 ºC.
1.1.2. Stainless steel heater features
1. Cr20Ni80 mica heater or thermal system is the heating element, adopt natural mica powder or synthetic mica plate for insulation, outer metal is stainless steel.
2. It is portable mica heater but warming faster.
3. Mica heater shell is made of 0.3 ~ 0.5 mm stainless steel plate, and the middle core the is made of high insulation resistance and anti-high-temperature mica plate, in which evenly around a variety of standard specifications of nickel-chromium alloy resistance wire as a heating element, be processed into various shape by the molding machine.
4.According to the connection mode of user demand, voltage from 110 v, 180 v, 220 v, 380 v, the highest power load reach to 3.5 W per square cent meter.
5. The sintering infrared radiating surface save electricity 35%. Mica stainless steel heater Is ring type.
6. It is simple, reliable and easy to use, feature fast temperature rise, high thermal efficiency, small power consumption and long service life etc.
5.1.3. Cooling fans with heater
The screw and barrel are equipped with cooling fans.
1.2.Main motor of PE Plastic Film Machine
If your motor overheat phenomenon occur, it might be caused by 2 reasons:
1. The motor is overload, power is not enough.
2. The motor fan wiring is wrong, the fan motor correct wiring is separated from the main motor wiring, whenever the main motor speed is low or high, the fan power is strong power enough, otherwise, if the fan motor wiring is from the same connection of power supply, fan motor speed and main motor speed work synchronously, the main motor certainly overheat.
All of our fan motor wiring is separated from the main motor.
1.3.Inverter of PE Plastic Film Machine
Inverter feature
1. Inverter can smooth speed regulation in a certain range, by adjusting the rotational speed of main motor, traction motor to produce different film products;
2. Smooth start and stop, because the plastic extruder is the constant torque load, smooth start and stop is to avoid too much of a mechanical shock, on the other hand also can reduce the start-up process of unqualified products;
3. Run a single direction of motor;
4. Stable performance, reliable work.
1.4.K type thermocouple
K type thermocouple refer to nickel chrome - nickel silicon thermocouple, which is a type of inexpensive thermocouple to measure high temperature.Because of this alloy has good high temperature oxidation resistance, can be applied to oxidizing or neutral medium.It can measure the high temperature of 1000 degrees for a long time, short-term measurable to 1200 degrees.
It cannot be used for reducing property medium, otherwise, it will be corroded soon, in this case can only be used under 500 degree measurement.
It is much cheaper than other thermocouple, its repeatability is very good, the thermoelectric potential is large, thus the sensitivity is high, and it has a good linear property. Although the measuring accuracy is slightly low, but can satisfy completely the requirements of industrial temperature measurement, so it is the most commonly used on industrial thermocouple.
1.5. Solid state relay(SSR)
5.5.1. Our switch adopt Chint and Delixi etc famous brand in china.
Solid state relay (SSR)with isolation function that is non-contact electronic switch, no mechanical contact parts in the process of switch, so solid state relay is also compatible with logic circuit besides has the same function as electromagnetic relay, resistance to vibration and mechanical shock, install location is unrestricted, has the good performance of moisture-proof, mildew corrosion resistance, the performance in terms of explosion-proof and prevent ozone pollution is also good, small input power, high sensitivity, small control power, good electromagnetic compatibility, low noise and high working frequency etc.
5.5.2. Advantages of solid state relay
(1) Solid state relay feature high life and high reliability. There are not mechanical parts or mobile parts in solid-state relay contact, so they can work stably in high shock, vibration environment, due to the inherent characteristics of composition of the solid state relay components, determines that they are long life and high reliability of the solid state relay.
(2) The solid state relay feature high sensitivity, small control power and good electromagnetic compatibility. Since solid state relay has featured wide input voltage range, low driving power, solid state relay can be compatible with most of the logic integrated circuit which does not need to add buffer or drive.
(3) Rapid transformation: solid state relay switching speed can be from a few milliseconds to a few microseconds because of using solid state relay.
(4) The electromagnetic interference is small.
5.5.3. DC motor regulator and DC motor. We can offer the high quality DC motor and DC motor regular.
1.6.Air ventilation of PE Plastic Film Machine
Air ventilation controller micro mobile parts is fixed on the bubble shelf which is equipped a lot of film shaping guide roller, air ventilation controller is connected with main motor of wind ring. Micro sensor is fixed on the top of the blown film. Micro mobile parts of air ventilation controller need to get a fixed pole.
Film air bubble size is related with internal inflatable pressure of tubular film, and has nothing to do with external cooling.
Cooling air volume is related with the position of blown film air bubble which located up and down. The bigger of cooling air volume, the blown film air bubble down the farther. The smaller of cooling air volume, the blown film air bubble up the farther.
1.7.Optional device of PE Plastic Film Machine
Auto loader material vacuum device is automatic material feeder loader, which mix HDPE, LLDPE, Pigment well and auto load.
Part 2. Gearbox of PE Plastic Film Machine
2.1.Overview of gearbox
Our extruder gearbox series is designed for screw extrusion equipment of high precision, hard tooth face with thrust transmission device.Product design USES various technical specifications provided by JB/T9050.1-1999.
2.2.Gearbox main features
1, the gear reducer for high strength steel alloy & carburizing steel, gear grinding after carburizing and quenching heat treatment processing, 6 levels of precision, high precision gear, gear hardness HRC54-62, low transmission noise.
2, equipped with high bearing capacity of thrust, reliable performance and can bear big axial thrust.
3, in addition to the individual small specifications products, all configuration has forced lubrication and water cooling system.
4, series gear box body are processed in the six sides.
5, the gearbox transmission efficiency, low noise, can run for a long time.
6, bearing adopt chinese famous Wafangdian brand almost 100 years brand.
Part 3. Rotating die head & air ring of PE Plastic Film Machine
3.1.Rotating die head
3.1.1.Rotating die head features
1.Temperature control sensor: 2 points
2. Material: it is made of medium carbon steel S45
3. Adopt strict and tempering heat treatment process and the CNC lathe precision machining, to ensure that each part of die head processing precision is high.
4. Electroplating: the whole die head with environmentally friendly alloy electroplating, plating is more uniform, ensure that the die no dead Angle, die flow easier to clean up, die head is more durable, and the production of thin film surface brighter and higher quality (or according to customer requirements, the hard chromium electroplating).
3.1.2.Rotating die head process
Blown film die head is made up of die bodies (die core, die barrel and die ring) and heater (heating coil).
1. select right material, it is to choose the corresponding materials, for example middle carbon steel S45 .
2. forging, forging the ingredients into a mold of coarse embryos, as part of the more compact the molecular structure of the forging parts of the embryo.
3. The lathe processing, according to the die design drawings of the die head, a lathe processing, as far as possible with high precision lathe, and master skilled lathe technicians.
4. polished the flow way part of the mould after machining by lathe, the better smooth of surface of flow way, the better blown film quality, and the less the defect lines of film.
5. hard chrome electroplating in flow way after polishing, which increase the wear resistance and corrosion resistance, and make the mould is not easy to damage and not easily get stranded.
6. finally, install the die head, combined with heating coil parts.
Blown film co-extruder die head contrast test many times to choose optimal shapes, feature large inner pressure, uniform extrusion stability, better performance of strength of film, no slot with extruder etc. And changes of the proportion of mixture and the recycle material, blown film extruder do not need to replace the die head.
3.1.3.How to adjust the die head of blown film extruder
1. If the die head is covered from top to bottom, loose or release the screw on the thick edge, and tight the screw on the thin side.
2. If the die head open under bigly, and put the die head in above, loose the screw on the thin side, and tight the screw on the thick edge.
3. Die head with four or six adjustment bolt which generally is hex socket, adjust on the edge of upper part of the die head.
3.1.4. How to clean the die head of blown film extruder
Step No. 1. Paint the die head with available paraffin or methyl silicone oil.
Step No. 2. Wipe the paste waste material gently with 1000 mesh sand paper until clean.
Step No. 3. According to the material property, adjust temperature while changing different material because of heating temperature difference of virgin and recycle material, increasing extrusion amount to extrude paste material after replacement of the filtering screen.
Step No. 4. The key is to add methyl silicone oil into the hopper in the process of production within a week, which lubricates the screw, barrel and die head, also clear die head meanwhile.
3.2. Rotating die head
Rotating die head with double tuyere air ring, wind pressure is very strong, the wind ring is cooling fast, so you can speed up the main motor and increase production, also has benefit of thickness deviation.
Part 4.Rewinding parts of PE Plastic Film Machine
4.1.Film shaping guide roller of PE Plastic Film Machine
Film shaping guide roller is made up of shaping ring and shaping bar. And shaping bar of shaping guide roller is adjustable , and stabilizing bubble frame structure has big adjusting range. It is convenient to operate and adjust, with stable bubble tubular film, create conditions for winding roller.
4.2.Clip board of PE Plastic Film Machine
Tractors of extruder is made up of towing, clip board or nip bar, traction roller and traction motor, the unit of traction adopts electromagnetic slip type mechanism, driven two pairs of drawing roller through gear parts, and the rewinding roller meanwhile. Clip board or nip bar is fixed on the shelf, the adjustment of inclined angle of clip board or nip bar can be adjusted freely according to the blown film thickness.
4.3.Film rewinding system of PE Plastic Film Machine
4.3.1. Overview
Film thickness is controlled by changing the proportion of the speed of the motor, inverter steady speed is precision, leading to speed stability, and uniform film thickness. Two clip roller and winding roller adopt tension control, the tension of different materials requirements is different, the tension of the rollers should be adjusted independently. Rewinding axis is leaning on the winding roller, relying on the winding roller's friction to drive the rewinding axis rotation, thus the material tension has nothing to do with the coil diameter
4.3.2. Benefit
The tension is produced by differential speed and frequency converter work under the mode of open loop vector control speed, fast dynamic response, overcome the smaller torque motor speed tension and larger deceleration tension.
The motor constant torque output as speed control. While the linear velocity and tension is constant, the winding roller speed keep constant too, will not be changed by the changing of coil diameter and load line, so overcome faults of constantly adjusting the motor output torque from empty to full volume process, in order to maintain a constant tension.
System is easy to manipulate.
4.4.Rubbe roller of PE Plastic Film Machine
Nitrile rubber roller which will have deep lines so that it opens LDPE film during work. It is equipped with a few such rollers on my machine. If the film is very thin and it can not get together during work.
Two pairs of traction roller consists of rubber roller and alloy steel roller, can effectively prevent the air to escape and ensure the smooth progress of the coil rewinding. Traction frame adopts assembly structure, outfit is convenient to tear open, which is advantageous to the transportation loading and unloading. Take-up device adopts the center winding of the effective mechanism, and keeping the constant tension, friction piece is driven by sprocket, and the big gear is driven by friction piece, to drive the winding shaft, so as to ensure the re-winder works smoothly while the winding diameter changes from small to big, the friction force can be controlled by adjusting the spring-loaded of edge.
We adopt nitrile rubber roller, also you can choice the Polyurethane and Silicone rubber roller, but we recommend nitrile rubber, because it is of high quality and inexpensive.
The motors have separate cooling fans with 380V. These are more powerful motors of fans. They are of high quality.
Our fan motor wiring is separated from main motor.
Part 5. Screw and barrel of PE Plastic Film Machine
5.1.Overview of screw and barrel
Production of all kinds of screw, barrel, strict selection of high quality alloy steel as raw material, using the latest technology and elaborate processing and testing equipment, to ensure the production of precision and quality, and has long service life and good abrasion resistance, corrosion resistance.The barrel is equipped with water cooling system.
5.2.Screw and barrel main features
The screw material: 38CrMoAl Nitride / 42CrMo intermediate frequency quenching + electroplating
42CrMo bimetallic PTA + electroplating.
Barrel material: 38CrMoAl Nitride / 42CrMo bimetallic alloy PTA inner hole casting.
Surface roughness:Ra0.4 um
Nitriding hardness: HV ≥900 , alloy layer thickness≥ 2 mm
Hardness: HRC58, Nitriding depth: 0.5-0.8 mm
Nitride brittleness≤2 level, Chrome plating layer thickness: 0.03-0.05 mm
Characteristic of PE Plastic Film Machine
Main motor and take-up motor are controlled by frequency inverter adjust
Material of screw and barrel: 38CrMoAlA Polished with Nitride Treatment
Hardness of heat treatment: Screw HV≥ 740, barrel HV≥ 900
Depth of hardening: 0.6-0.7mm
Brittleness grade: ≤ 2 grade
Gear box: 250 Involutes cylinder Bevel wheel, cast alloy steel piston, fine grinding hard gear surface
Die material: Steel 45#/surface treatment of flow channel: Hard chrome- plating
Double digital display temperature controller.
Parameters:
|
Model |
SJ-45 |
SJ-50 |
SJ-55 |
SJ-60 |
SJ-65 |
SJ-80 |
SJ-100 |
|
Screw diameter |
45mm |
50mm |
55mm |
60mm |
65mm |
80mm |
100mm |
|
Screw ratio (L/D) |
28:1 |
28:1 |
28:1 |
28:1 |
28:1 |
28:1 |
28:1 |
|
Screw speed |
10-100r/min |
10-100r/min |
10-100r/min |
10-100r/min |
10-100r/min |
10-100r/min |
10-100r/min |
|
Main output |
20-30kg/h |
25-35 kg/h |
35-50 kg/h |
55-65 kg/h |
55-70 kg/h |
70-90 kg/h |
110-140 kg/h |
|
Power of main motor |
7.5kw |
7.5-11 kw |
11-15 kw |
15-18.5 kw |
18.5-22 kw |
30-37 kw |
45-45 kw |
|
Specification of die head |
φ40-80mm |
φ60-120mm |
φ100-170mm |
φ100-170mm |
φ120-220mm |
φ150-300mm |
φ500mm |
|
Rotational mode of machine head |
Continuous rotation |
Continuous rotation |
Continuous rotation |
Continuous rotation |
Continuous rotation |
Continuous rotation |
Continuous rotation |
|
Single-side thickness |
0.01-0.10mm |
0.01-0.10mm |
0.01-0.10mm |
0.01-0.10mm |
0.01-0.10mm |
0.01-0.10mm |
0.01-0.10mm |
|
Max.folding width |
600mm |
600mm |
800mm |
1000mm |
1100mm |
1500mm |
2000mm |
|
Total power |
19.5kw |
22kw |
26kw |
30kw |
42kw |
56kw |
88kw |
|
Weight of machine |
1900kg |
2000kg |
2300kg |
3000kg |
3800kg |
4600kg |
6000kg |
|
Overall dimensions (m) |
4.5*1.8*3.5 |
4.5*1.8*3.5 |
5.5*2*3.8 |
6*2.2*4.2 |
6*2.4*4.3 |
7*2.7*5.8 |
8*3.2*7.6 |
For more infomation, feel free to contact us:
More machine pictures:
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