8/9/2019 Blown Film Manual

1/20

BLOWN FILMCOEXTRUSION LINES

8/9/2019 Blown Film Manual

2/202

Ever since its establishment in 1947 by Luigi Bandera, it hasproved to be a dynamic company focussed on innovation – the

perfect ingredients for a pioneer of the extrusion line sector inItaly and worldwide.

Today, Bandera designs and manufactures a complete range ofextrusion lines based on two major applications: blown lm , andsheet and foil with at die technology.

Over the yearsBandera has earned a

sound reputationworldwide

thanks to its integrityand top quality standards

8/9/2019 Blown Film Manual

3/20

8/9/2019 Blown Film Manual

4/20

8/9/2019 Blown Film Manual

5/205

Blown lm extrusion lines for exiblepackaging, converting and laminating

Undoubtedly, lm coextrusion represents the most consolidatedtechnology for the production of standard multipurpose packagingsolutions.

Today, the three-layer coextrusion lines are the preferred option.The standard conguration comprises a mid high-capacity extruder,arranged with two smaller extruders intended for the outer layers .

Bandera three-layer coextrusion lines combine top quality andquantity standards .

Building on strong customisation, Bandera extrusion lines arecharacterised by production need orientation, top versatility andsafety, combined with minimised power consumption .

The brand new 3-layer series

8/9/2019 Blown Film Manual

6/206

The 5-layer conguration is perfect for customers needing highproduction exibility to process PE lm as well as barrier lm .

The 5-layer Techno Flex plus extrusion line has been designed for theproduction of technical lm with outstanding top quality mechanicalproperties .

The 5-layer Techno Flex plus series production range is denitelywide, and comprises, among others:

Film used in top performing converting lines

Film with specic characteristics intended for industrial applications

Barrier lm intended for food as well as medical and pharmaceutical

applications.

The 5-layer series

APPLICATIONS

5-LAYER

PE

Functional layer

PEFunctional layer

PE

5-LAYERPE

TIE

PA/EVOH

TIE

PE

5-layer PE lm recipes – an example

5-layer barrier lm recipes – anexample

Technical lm

MAJOR ADVANTAGES

Reduction of the thickness of the lm Major exibility Hourly production increased Ennobling of the formulations High quality lm at competitive cost

8/9/2019 Blown Film Manual

7/207

The 7/9-layer coextrusion lines are intended for customersmanufacturing top-notch high-barrier technical lm for food,medical, pharmaceutical and several mechanical (e.g. automotive)applications .

The 7/9-layer lms have a double and triple barrier, respectively, withan EVOH central layer combined with PA middle layers, thus offeringa high performing barrier against gases and water vapour.

Also, Bandera offers extrusion lines capable of ensuring minimisedcurling effect in cases of asymmetric lm structures.

The brand new 7/9-layer series

APPLICATIONS

7-LAYER

PE

TIE

PA

EVOH

PA

TIE

PE

9-LAYER

LLDPELDPETIEPAEVOHPATIELDPE

LLDPE

7-9-layer simmetrical recipes - an esample

8/9/2019 Blown Film Manual

8/208

Blown lm extrusion linesfor FFS industrial bags

HDB FLEX – the new series

Industrial bag market growth is remarkable.Initial focussed on offering extrusion lines pursuing excellentmechanical characteristics, weldability, processability and printability,today the market trends require minimised lm thickness aimed atmaximising production capacity .Bandera has taken on this new challenge nding specic solutionsto meet its customers’ needs, thus conrming – once again – itsoutstanding customer satisfaction orientation.Specically, innovative solutions have been applied in each and everyextrusion line section. The most outstanding ones are:

Triple-ow cooling ring , which offers a strongly enhancedproduction capacity when combined with Bandera design extrusionheads Specic haul-off units with cutting-edge lm cooling system fora better crease free lm surface – a solution setting the pace ofinnovation in HDB lm eld Integrated thickness controlFully-automated winding station , either by contact or by axialwinding

PROCESS MATERIALS

HDPE LDPE LLDPE Mldpe PP

8/9/2019 Blown Film Manual

9/209

MAJOR ADVANTAGES

Unrivalled exibility in HDPE and bioresinlm production

Cost effectiveness

“Made in Italy” - “Made in Bandera”

User-friendly line management

Sturdiness and performance

Blown lm extrusion lines forretail and industrial applications

The brand new HYBRID FLEX series

The brand new Hybrid ex range comprises single-layer extrusionlines and coextrusion lines for the production of HDPE andbiodegradable/compostable resin blown lm .Pursuing on its commitment for environmental protection and powersaving, and conforming with the latest European laws about retailmaterials, Bandera has designed a multi-material extrusion line. Thebrand new Hybrid ex extrusion lines can process:

Compostable materials

Biodegradable polymersHDPE LDPE

The brand new Hybrid ex extrusion lines have been designed toensure top performance regardless of extruded products.A standard Hybrid ex extrusion line conguration comprises thefollowing :

Dosing system for 4 materials Extruders with bimetallic barrel and no-wear coated screwFixed extrusion head arranged with IBC system and high efciencycooling ringRotating haul-off unit, atteners equipped with either hard woodenslats or aluminium rolls; rollers specically designed for thin lm

processing Automatic single- or double-station winding unit, by contact

Each extrusion line can be customised to meet the customer’sneeds. Thanks to the consolidated partnership with the largestItalian bioresin and compostable resin producer, Bandera three-layerextrusion lines are accurately tested with different products.

8/9/2019 Blown Film Manual

10/2010

Over the past two years, Bandera has launched its Smartex project.Aimed at designing fully customer-need-oriented extrusion lines ata competitive price , the series pursues:

Quality Flexibility Top performanceReliability Low power consumption Low environmental impact

The achieved cost savings do not come from component qualityreduction indeed from series production . All general costs are splitinto a large number of lines thus generating an economy of scale atprocurement stage.

MAJOR ADVANTAGES

Excellent mid- and long-term yield

Optimised production regardless of processtype

Excellent cost effectiveness

“Made in Italy” - “Made in Bandera”

Unrivalled user-friendly line management

Multi-purpose extrusion lines forconverting and exible packaging lm

The new seri es

T T

T T

Winding unit series W 400, by contact

8/9/2019 Blown Film Manual

11/2011

The Smartex range comprises two congurations:

Bandera Smartex projects include standardised extrusion lines fullyarranged to be implemented according to customers’ requirements .

Smartex extrusion line production includes:

Packaging lm (food and non-food lm) Thermoretractable lmLamination lmStretch hood lm

SMARTFLEX 16 SMARTFLEX 22

Useful width 1600 mm 2200 mm

Extruderconguration

1 x 65 ø mm2 x 50 ø mm

1 x 75 ø mm2 x 65 ø mm

Extrusion head range 180÷350 mm 300÷500 mm

Haul-off unit Oscillating1800 mmOscillating2400 mm

Winding unit By contactOpen width: 1800By contact

Open width: 2400

PROCESS MATERIALS

LDPE

LLDPE

mLDPE

EVA

MDPE

HDPE

PP

FORNIRE FOTO

Standard Smartex 22 layout

8/9/2019 Blown Film Manual

12/2012

Bandera agrilm coextrusion line exibility and versatility isincreasingly appreciated by customers, considering that, generally,agrilm is a seasonal product.

With the same coextrusion head and minimised set-up times, Bandera

coextrusion lines can produce agrilm as well as thicker lm (e.g.waterproong geomembrane ): a valuable chance to have an all-year-round protable coextrusion line, regardless of agrilm seasonality.

Bandera is a pace setter in agrilm extrusion lines.

Today, agrilm production is predominantly obtained bymulti-layer

coextrusion lines while single-layer lm application is increasinglyintended for a limited and low target market.

Nowadays, three-layer coextrusion lines are preferred as they satisfythe current requirements for agrilm. Nonetheless, future trends aretoward 5-layer line conguration ( with the possibilities to have 7-layerconguration).

The multi-layer lmensures an enhanced management of raw processmaterials and optimised additive distribution in every layer , thusincreasing lm physical and mechanical properties as well as light andheat transmission: as a consequence, the lm life cycle is increased.

New extrusion lines for theproduction of agrilm

AGRIFILM APPLICATIONS Greenhouse lm

Thermal lm

Diffusive lm

Photoselective lm

Fumigation lm

Mini tunnel lm

Silo lm

Mulching lm

Solar lm

8/9/2019 Blown Film Manual

13/2013

Bandera coextrusion lines are equipped with cutting-edge peripheral andancillary systems, whose control and display functions are integratedinto the Bandera line supervision system in order to ensure automated

line operation : Haul-off units, up to 8500mm open width

Power-driven gusseting units

C- and V- folders for easy reel stocking and handling

Winders up to 5500mm, available in gap winding mode

The classical conguration of agricultural systems are:

Coextrusion line Extrusion head Open width

3-layer Up to 2300mm Up to 24m

5-layer Up to 2200 mm Up to 22m

7-layer Up to 2000 mm Up to 18/20 mt

8/9/2019 Blown Film Manual

14/2014

Complete extrusion lines forgeomembrane

WATERPROOFING GEOMEMBRANEINTENDED FOR

Landlls Tunnels Collection tanks Water basins Irrigation channels Extraction mines Motorways Strengthening works at river and marinewater ows

Dam protectionsFish farming

THICKNESS RANGE

Min thickness : 0.5 mmMax thickness : 3 mm

USEFUL WIDTH

Useful width : from 6 ÷ 8 m

PROCESS MATERIALS

HDPE Black(carbon black)/white Masterbatch

Geomembrane is the most peculiar product in the tubular blown lmsector, with unique characteristics.

Geomembrane target market growth is ongoing, especially inemerging economies where rapid development has increased thedemand for geomembrane.

Bandera offer comprises complete extrusion lines with up to1200kg/h production capacity, with lm thickness up to 3 mm.

3-LAYER GEOMEMBRANE EXTRUSION LINE STANDARD CONFIGURATION

Dosing system

The standard conguration comprises a high-capacity extruderfor the inner layer and two smaller extruders intended for theouter layers , arranged with bimetallic barrels and no-wear coatedscrews

Coextrusion head (die up to 2300mm) equipped with internalbubble cooling system (IBC)

Fixed haul-off unit, suitably designed for production needs

Fully-automated winders , 8m width, with automatic shaftextraction and reel downloading

Geomembrane can be textured on one or both sides; a plain strip canbe obtained to ease welding.

This product can also be processed with 5 –layer extrusion head forthe production of Agrilm .

Bandera geomembrane extrusion lines can be customised accordingto Bandera customer’s needs.

8/9/2019 Blown Film Manual

15/2015

Bandera winding units are denitely worth detailing.

Fully automatic and equipped with safety devices .

Winding cycle control by touch screen user interface connected withcentral PLC.

Winders are offered in three operating modes:

By contact (peripheral winding), single- and double-stationconguration; lm tension control by top sensitivity load cells

By contact and with shaft axial control , single- and double-stationconguration. Two winding modes are available:

- by contact - by axial control on winding shaft axis,

- a.c. servomotors

Top quality winders featuring the following operation modes:

- by contact- with axial control arranged on winding shaft axis by AC servomotor- with gap control

- combined winding, with control arranged on winding shaft axisand by contact on the rubberized pressure roller

- by counter-rotation - shaft accelerator.

Larger pressure roller size allow for top-quality faultless reels,whose diameter can exceed 1500 mm.

Automatic winding units

W 400 series:

Contact mode

Contact mode combined with axial control

Top ESR 9000 series

8/9/2019 Blown Film Manual

16/2016

As far as agrilm is concerned, Bandera winding unit rangecomprises single- and double-station versions :

Useful width from 2500 to 5000 mm

Fully automated for jumbo reels

Shaftless to wind agrilm on cardboard and PVC cores

Bandera offers geomembrane automatic winding units withautomatic steel shaft extraction and reel download.

Winding units for agricultural lmand geomembrane

Geomembrane automatic winding unit

8/9/2019 Blown Film Manual

17/2017

Made in “Bandera” – a synonym forqualityIn-house manufacture of the most critical and complex extrusioncomponents:

Screws : they are designed on the basis of process materialrheological characteristics in collaboration with raw materialproducers.

Extrusion heads : conceived with the support of the most up todate and precise design systems, taking into account customers’process material rheological characteristics. Bandera offers itscustomers the widest range on the market, with dies from 30 to2300 mm . Bandera extrusion heads ensure top quality productsand minimised melt residence time inside the extrusion head , thusallowing accurate temperature control and offering the chance toprocess the most thermosensitive materials.

Cooling rings : cutting-hedge double-ow cooling rings forextremely accurate bubble stability control and top performancewith minimised thickness tolerances. They ensure trouble-freeintegration into top-quality automated thickness control systems.

Cutting-edge haul-off units , either oscillating or xed: designedand manufactured in compliance with product requirements andline production range. Useful widths comprised between 800 mm(for the production of industrial heavy bags) and a 8500 mm (for theproduction of agrilm and geomembrane).

8/9/2019 Blown Film Manual

18/2018

Why choose Bandera as a technological partner?Over the past years Bandera has strengthened its leading position in its reference markets worldwide of packaginglm, agrilm and waterproong geomembrane sectors.Among its customers Bandera lists major packaging item suppliers of food industries, and major agrilm andgeomembrane producers.Why choose Bandera?

Unrivalled expertise in manufacturing complete blown lm extrusion lines Worldwide appreciationPace-setting know-how from the collaboration of leading packaging companies and expertise in small-, medium-and large-sized blown lm extrusion heads manufacturing Wide extrusion head range, from 30mm to 2300mm Extended expertise in winding unitsIts rooted collaboration with tested reliable sub-suppliers Timely and efcient aftersales service ISO 9001:2000 certication

EXPRESSCUSTOMER

SERVICESUPPORTED BY

BANDERA STAFFUNRIVALLED EXPERTISE

IN PROCESS MECHANICS/ ELECTRONICS

COSTEFFECTIVESPARE PARTSPACKAGES

4 SERVICECENTERSFOR A WORLDWIDEASSISTANCE

OVER 24-MONTHWARRANTY

UPON REQUEST

SCHEDULEDINTERVENTIONSFOREXTRAORDINARYMAINTENANCE

CUSTOMISEDON-SITE TRAINING

FOR NEWAPPLICATIONS

RECLAIMING OFEXISTING MACHINESAND REVAMPING OF COMPLETEEXTRUSION LINES

8/9/2019 Blown Film Manual

19/2019

R&D

Facts & gures: latest turnovers

A new Research & Development area is going to be fully operational by 2014to test complete extrusion lines

Com i n g S o o n

8/9/2019 Blown Film Manual

20/20

PLASTICS MACHINERY

EXTRUSION TECHNOLOGY SINCE 1947

Costruzioni Meccaniche Luigi Bandera SpACorso Sempione, 120 - I-21052 Busto Arsizio (VA) Italyt +39 0331 398111 - f +39 0331 680206lbandera@lbandera.com - luigibandera.com

R E V 2 / F I L M / E N / 0 9 / 1 3

For details about Bandera technology, visit us at luigibandera.it

h l d d f ll l d

http://www.luigibandera.net/bandera/en/prodotti/lm-in-bolla.html

Visit our website andlearn about our products

EXTRUDERSFOIL SHEET PIPE COATINGEXTRUDERS

GRANULATION

b r i e n g l a b

. c o m