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DMT, Complete BOPP Film Production Line, 1998, 6500mm, 1400 kg/h, 3-Layer Coextrusion

DMT, Complete BOPP Film Production Line, 1998, 6500mm, 1400 kg/h, 3-Layer Coextrusion

Description

  1. Overview
    1. Complete line for the production of biaxially oriented polypropylene film.
    2. Product: biaxially oriented polypropylene film plain, two- or three layer coextruded.
    3. Line capacity: 1400 kg/h of coextruded film 3 layers A-B-C.
    4. Film width: 6500 mm on winder.
    5. Thickness range: 12 - 50 μ.
  2. Film Configuration
    1. The equipment is capable of producing all the range of film presently available on the market. Specially following configurations are possible:
    2. Standard coextruded film with two heat sealable faces: ABA.
    3. One side heat sealable coextruded film: ABB.
    4. Plain film with possible modifications of face layers: BBB.
    5. Coextruded film with individual faces layer structure: ABCD.
    6. Plain and coextruded perlized film.
    7. Plain and coextruded mat film.
  3. Film Thickness Range
    1. Plain film: 12 - 50 μ on mill roll winder.
    2. Coextruded film: 15 - 50 μ on mill roll winder.
  4. Film Width
    1. Unoriented film (at die exit): 920 mm.
    2. Biaxially oriented film (trimmed on winder): 6500 mm.
  5. Stretching Ratio
    1. MDO (mechanical): 1:1 - 1:10.
    2. TDO (mechanical): 1:4 - 1:10.
  6. Line Speed (Mechanical)
    1. Slow section: 5 - 60 m/min.
    2. Fast section: 20 - 250 m/min.
  7. Nominal Throughput on Winder at Full Width, Trimmed (Mill Roll)
    1. The throughput is based on simultaneous use of the main and satellite extruders.
    2. Thickness 12 μ: speed 160 m/min, throughput 674 kg/hr, annual capacity 4852 ton/year.
    3. Thickness 15 μ: speed 180 m/min, throughput 948 kg/hr, annual capacity 6825 ton/year.
    4. Thickness 20 μ: speed 230 m/min, throughput 1614 kg/hr, annual capacity 11 620 ton/year.
    5. Thickness 25 μ: speed 200 m/min, throughput 1750 kg/hr, annual capacity 12 600 ton/year.
    6. Thickness 30 μ: speed 166 m/min, throughput 1750 kg/hr, annual capacity 12 600 ton/year.
    7. Thickness 40 μ: speed 125 m/min, throughput 1750 kg/hr, annual capacity 12 600 ton/year.
    8. Thickness 50 μ: speed 100 m/min, throughput 1750 kg/hr, annual capacity 12 600 ton/year.
  8. Test Run Throughput on Winder at Full Width, Trimmed (Mill Roll)
    1. Thickness 12 μ: speed 140 m/min, throughput 589 kg/hr, annual capacity 4246 ton/year.
    2. Thickness 15 μ: speed 160 m/min, throughput 842 kg/hr, annual capacity 6065 ton/year.
    3. Thickness 20 μ: speed 200 m/min, throughput 1400 kg/hr, annual capacity 10 000 ton/year.
    4. Thickness 25 μ: speed 160 m/min, throughput 1400 kg/hr, annual capacity 10 000 ton/year.
    5. Thickness 30 μ: speed 133 m/min, throughput 1400 kg/hr, annual capacity 10 000 ton/year.
    6. Thickness 40 μ: speed 100 m/min, throughput 1400 kg/hr, annual capacity 10 000 ton/year.
    7. Thickness 50 μ: speed 80 m/min, throughput 1400 kg/hr, annual capacity 10 000 ton/year.
  9. Actual Throughput
    1. The actual throughput obtained with a given product may vary from the above nominal data depending on materials processed, desired quality parameters and other such requisites.
  10. Raw Material
    1. Core layer: isotactic polypropylene homopolymer, BOPP grade.
    2. Density: 0.900 - 0.905 ASTM D 1505.
    3. Granule bulk density: 0.500 - 0.550 kg/L ASTM D 1895.
    4. Melting point: 160 - 168°C (DSC) ASTM D 3415.
    5. Melt flow index (MFI): 1.5-4 ASTM D 1238 L (2.5 kg, 230°C, 10 min).
    6. MFI variation from batch to batch: 5%.
    7. Ash content: < 300 ppm.
    8. Atactic content minimum: < 6% > 3.5% solubility in xylene.
    9. Moisture content max.: 0.1% weight.
    10. Skin layer: polypropylene random copolymer, BOPP grade.
    11. Density: 0.900 - 0.905 ASTM D 1505.
    12. Granule bulk density: 0.500 - 0.550 kg/L ASTM D 1895.
    13. Melting point: 127 - 140°C ASTM D 3415 (DSC).
    14. Melt flow index (MFI): 5-7.5 ASTM D 1238 L (2.16 kg, 230°C, 10 min).
    15. MFI variation from batch to batch: 5%.
    16. Moisture content max.: 0.1% weight.
    17. Additives: major additives are anti-blocking and slipping agent on PP homopolymer matrix and PP random copolymer matrix. Specifications of additives used depend on film type made and actual end use.
    18. Recycled material: the equipment is designed to accept in the core layer up to 40% (depending on film thickness) of recycled material in form of ground edge trim (reprocessed in line) and regranulated film scraps.
  11. Process Definition
    1. The equipment is designed to produce high quality BOPP film by use of the best state of the art process.
    2. The main process steps are coextrusion of primary film by triple manifold die, followed by symmetric quenching of extruded film on chill roll with outside water bath, sequential MD and TD stretching, edge trimming with in line reprocessing, corona treatment and winding.
    3. A fully integrated monitoring of all process parameters by computerized process control (C.P.C) combined with in line thickness measurement and automatic die control (A.D.C) provides outstanding consistency of the film properties and improved thickness tolerance.
    4. Because of its versatility, the equipment is capable of producing all the ranges of film presently available worldwide in the thickness range and throughput indicated in the present description.
    5. Full process technology as well as detailed information on the main formulations are available for our customers.
    6. The adjustment range of all important process parameters is wide enough to be adapted to almost all known process conditions. Customers having their own process may therefore use the equipment without changing their process parameters and will benefit of the extremely high production reliability and consistency of the film properties resulting from the equipment design.
    7. They will note that even when using the same raw material formulation and the same process conditions as on their other lines, the film produced with our equipment will show higher mechanical properties, better transparency, improved thickness tolerance and lower shrinkage value. The production yield will be improved, production period without film break up to 5 days may be achieved. After film break, standard running conditions will be re-established within few minutes, allowing a perfect functioning of the automatic die control system.
    8. The consumption of energy will be lower than with their existing lines.
  12. Manufacturing Principle
    1. Because a film line incorporates a very large number of individual components using different manufacturing technologies, the optimum manufacturing approach is to have a large percentage of the components sub-contracted or procured from specialized makers before being assembled in individual machines or complete turn-key line.
    2. The selection of sub-contractors and/or suppliers having high quality standards, appropriate machines, a wide experience of this type of line, is therefore essential for the quality of the provided equipment.
  13. Sub-Contractors
    1. All the components produced on our own proprietary drawings are made by a permanent network of manufacturers having been selected for more than 10 years and having manufacturing experience of similar components used in more than 100 film lines around the world. All these sub-contractors are equipped with the most modern specialized machines capable of manufacturing:
    2. Casting roll (max. ∅ 5000 mm).
    3. Max. width: 9000 mm.
    4. Clips: max. yearly production: 100,000 pieces.
    5. Oven: max. 12 000 mm.
    6. Winder frame max. width 8500 mm (film).
    7. Pull roll stand frame (max. width: 9900 mm).
    8. For some sensitive pieces, such as large size filter body, melt pipe, casting roll outside shell or monorail for the TDO, specially made allied steels are necessary. These materials are supplied.