Die Gap Optimization in Blown Film Extrusion | XinYe Solutions

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High-Performance Blown Film Extruders | Precision Film Manufacturing Solutions

Empower your film production with cutting-edge Blown Film Extruders. Blown Film Extruders provide an efficient, reliable, and versatile platform for manufacturers wanting to produce high-quality polyethylene (PE) films, from durable agricultural sheeting and construction films to flexible packaging liners and shrink films.
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advantages of blown film extruders

Unmatched Production Flexibility.

Blown film extruders can accommodate a wide range of polymers (LDPE, LLDPE, HDPE, PP) and change from one application to another with minimal effort – from high-clarity packaging films to UV-stabilized agricultural sheets. Simply change resins and/or make minor adjustments to produce custom film widths (5cm to 5m+) and thicknesses (5–250 microns). Perfect for brands looking to expand their current offering or serve multiple markets.

Exceptional Cost Efficiency & Material Savings.

With advanced auto gauge control and IBC (Internal Bubble Cooling) system, you can produce films with ultra-consistent thickness, with only ±2% variance, resulting in 10–20% material waste reduction. With energy-efficient DC drives, and the latest screw designs, blown film extruder operators will realize the highest output per kWh, dramatically reducing production costs while improving ROI.

Multi-Layer Barrier Capabilities.

Co-extrusion blown film lines (3–9 layers) produce engineered films that can provide: - High-barrier structures (EVOH/PA) for food/pharma packaging. - Puncture-resistance films, using recycled-core layers. - Custom sealant/abuse layers in a single pass. Post-production lamination is unnecessary, lowering the total cost of ownership.

Scalability & Future-Proof Operations.

Modular systems allow for simple improvements, including: - Adding screen changers to reduce downtime. - Transferring to automated winders or gauging systems. - Upgrading from monolayer to co-extruded films without replacing the line. Smart PLC controls with recipe memory ensure repeatable quality during high-volume runs.

Industrial Blown Film Extruders | High-Efficiency PE/PP Film Production Lines

ABA Mini Film Blown Machine VIEW DETAILS

ABA Mini Film Blown Machine

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Computer Control Film Sealing and Cutting Machine

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XinYe 2025 Automatic Plastic Film Extrusion Blown and Offset Printing Machine

Industrial Blown Film Extruders: Precision Film Production Solutions

Engineered for Versatility, Efficiency & Quality
Transform Raw Polymers into High-Performance Films Drawing on PE, PP and specialty resins, our blown film extrusion lines produce high-strength, ultra-thin films with unmatched consistency. Our systems are designed for ease to operate 24/7 and fast ROI with 30% more output efficiency and ±1.5% thickness tolerance so we do not waste film when conforming to international quality standards (ISO, CE and UL).

FAQ

Can your blown film extruders handle recycled materials like PCR plastics?

Yes, our blown film extruders will run almost any recycled content. In fact, our extruders utilize a twin-screw design with melt filtration (optional automatic screen changers) specifically engineered for recycled content! Our extruders can process resin content as high as 100% PCR (LDPE, LLDPE, HDPE) while maintaining : > - Bubble stability > - ≤5% haze for clarity films > - Dart impact strength ≥400g > - As a real-world example, Pack Eco Ltd. successfully used 40% PCR in retail films with no impact to property.
Most clients experience ROI within 12–18 months. Our clients are seeing ROI through: > - 30–50% lower scrap rates (using IBC cooling and auto gauge control) > - 20–35% energy savings (varying degrees of consistent quality using DC drives and heat recovery) > - 15–40% increased output (computing screw designs specific to their resin)
Yes, our modular blown film systems allow for seamless upgrades: > - Up to 7 additional extruders can be added to create new barrier/sealant layers > - We can also add IBC systems or automated winders without modifying or replacing the base line. > - Retrofits will typically take <2 weeks and have minimal production > Tip: Begin with a 3-layer set-up to allow for flexibility with barriers on the film.

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What Our Client Are Saying?

Rajiv Mehta

Our legacy extruder was a product of its time, and had 9.2% material waste on agricultural films. After installing their 5-layer line with IBC cooling to their specifications we were producing films with ±1.8% thickness consistency. Scrap on agricultural films went from over 9 percent on the previous extruder to 6.1% immediately after, and then reduced further to a remarkable 4.9%, after running through the startup optimization stage. The energy recovery modules saved us an astonishing $7,200/month.

Dr. Elena Vogel

There are no words to explain how the 7-layer co-extrusion has revolutionized our operation. We have gone from producing barrier films on all of our Ethanol-based substrates (EVOH/PP) for sterile packaging that can pass ISO 13485, to two and even three passing. It made a lot of difference to production, where we went from 180kg / hr on 25μm films, to producing 320kg/hr doubling our throughput. We received a return on investment within 14 months.

Chinedu Okeke

A majority of their customer base are pharmaceutical products. The volatility of the voltage in our Nigerian facility per day before we installed their DC-drive extruders, is a story on its own. However, with surge protection, their DC-drive extruder continued to operate continuously through the blackouts that caused three (3) competitors operational lines to stop because of voltage. Last quarter we recorded 98.7% uptime - and did not sustain screw damage on recycled HDPE when fluctuating feed stock/film cultivars.

Sarah Chen

We had to establish that we had environmentally sustainable credentials in order to collect another client in the EU for a large retailer. The twin-screw system with a melt filtration was crucial in transitioning to processing 40% PCR-LDPE, while sustaining a dart impact above >450g, and most of all, our film still had a clarity with a benchmark of 92% haze. Collectively this one line secured our ASDA Walmart contract.

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30% Higher Output Efficiency

30% Higher Output Efficiency

High-Precision Screws with (L/D 30:1-36:1) + Large DC Drives = output 500 - 2,200 kg/h capacity - ±1.5% Film Thickness Consistency vs ±5% Industry standard - Result: Green Shield Agro Films increased output in 3 months by 34%.
Future-Ready Material Flexibility

Future-Ready Material Flexibility

- Process virgin, recycled (100% PCR), or bio-resins (PLA & PHA) - Melt filtration + Automatic screen changers preserve the integrity of films.
Intelligent Co-Extrusion Capability

Intelligent Co-Extrusion Capability

3 - 11 layer barrier films (EVOH76/PA76/EVA1-2) as one pass Military-rated IBC cooling generates consistent medium temperature stabilizing bubbles at 250m/min line speeds

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