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Tradition of Excellence
High Density Blown Film Systems
Growing Use of High Density FilmDemands Greater Quality, Higher Rates
At the same time, theseimproved properties ofHDPE have also made itmore attractive for lessdemanding applicationsbecause it permits downgauging without sacrificing performance. In order to achieve theseproperties, however, theblown film system used toproduce it must provideabsolute consistency and high reliability whileoperating at today’s higherproduction speeds.
Battenfeld Gloucester hasresponded to this challengeby integrating individuallyoutstanding componentssuch as extruders, dies,hauloff systems andwinders into a highly efficient production system. By optimizing the performance of everycomponent of the system,we are able to assure youof high volume, top qualityoutput, day after day.
Demand for High MolecularWeight High DensityPolyethylene (HMWHDPE)film continues to grow as new applications requireever-higher volumes. Once relegated to lessdemanding applications infavor of more expensive,higher performance materials, today’s high stalkfilms have the strength anduniformity to handle moredifficult jobs.
Higher molecular weightsand the availability of multi-layer films permit use ofHDPE in industrial applica-tions requiring high strengthand durability, in food packaging applicationsrequiring excellent barrierand heat sealing properties,even in hygienic films used indisposable baby diapers andadult protection products.
Battenfeld Gloucesteroffers a unique combinationof technological leadershipand blown film industryexperience that makes usuniquely qualified to offer an outstanding productionsystem. Whether your product is a simple mono-layer or complex multilayerconstruction, we will fully
integrate our reliable, highperformance equipmentwith a process control system designed by extrusion experts for extrusion applications. The result will be a reliable,easy to use system that will provide you with yearsof productivity.
From initial conceptthrough engineering, construction, assembly andstartup, your BattenfeldGloucester blown film system is a fully integratedsystem that will provideyou with years of trouble-free, profitable operation.
Gloucester engineers haveyears of experience withblown HDPE film — including the newer, higherperformance grades — and truly understand notonly every processing variable, but also the wayindividual components function together and affect both each other and the process itself.
As a result, not only do individual components ofthe system utilize the mostadvanced technology, but the entire line is optimized for long life and low maintenance.
Gloucester engineers setup your line using a proventwo-part strategy.
System EngineeringUsing rigorous systemsengineering techniques,Gloucester engineers integrate the mostadvanced, fully proven innovations in feeding,extrusion, dies, bubble control and cooling,hauloff, winding and totalprocess control to maxi-mize production of thehighest quality blown film.
Profit EngineeringUsing proven project management techniques,Gloucester engineers bringthe system on line rapidly,maximizing uptime and life cycle, minimizing maintenance requirements,and assuring top qualityand high yield for maximum profitability.
Every Type of Final ProductThe following are only afew examples of the kindsof final products that arecurrently being producedon Gloucester lines:
• Merchandising bags
• Industrial bags
• Clothing bags
• Retail bags
• Grocery sacks
• Multilayer food packaging
• Hygienic films
• Agricultural film
• Reclaim and PCR films
• And many, many more.
Systems are currentlybeing commissioned andinstalled to run specialmaterials and film struc-tures. Others are beingadapted to meet the special needs of new high density applications.
An Integrated Approach To Blown Film Production
Like the production lineitself, Gloucester’s team of experienced specialistsis completely integrated.Design engineers, techni-cians, process engineers,system consultants, service specialists and support personnel all workclosely together to assumecomplete single sourceresponsibility for selectionand installation of:
• Gravimetric or volumetric feeding and blending systems
• Extruders and screws
• Precise barrel tempera-ture control systems
• Specially designedscreen packs
• Minimum resistance HD-specific dies
• Gauge control withInternal Bubble Cooling(IBC)
• Layflat, collapsing, oscillating hauloff
• Comprehensive processcontrol
• Large diameter, highspeed winders
A Team Approach toImplementing Blown HighDensity Film Technology
Before and during installation, Gloucester specialists not only applytheir extensive, highly practical knowledge ofblown HD film to your production line, but alsoteach it to you and yourstaff. Even after installa-tion, they remain availablefor training, consultation,and problem solving.
HIGH DENSITY BLOWN FILM SYSTEM
In Line Cylindrical Screen Changer Model 1021Winder
80mm HG Contracool® Extruder
IBC Blower Supply
Extrol with Autoprofile™
Production of high qualityHDPE film requires theextruder to feed a constantmelt at a high volumeagainst high head pressure.To assure this, we use ourexclusive Variable LeadBarrier (VLB IV) screw,which separates the molten polymer from the pellets as melting proceeds to
Because of their long experience with blown film systems, BattenfeldGloucester engineers knowthat heated air vented fromthe extruder can cause fluctuations in the tempera-ture around the bubble thatcan, in turn, cause gaugebands in the film. To preventthis, the innovative design of our Contracool® Extrudersdirects heated air away from rather than toward the bubble.
HG FEED SECTION
HG CONTRACOOL®AIR-COOLED EXTRUDER
Superior HDPE Film Begins With Superior Extrusion
maximize efficiency andreduce screw wear. In combination with a uniquelygrooved proprietary alloyfeed liner, the VLB IV screwprovides the required high output and, togetherwith precise temperaturecontrols, maintains a stable, consistent melt.
CONTRACOOL® EXTRUDER COOLING SYSTEM
EXTRUDER GEAR BOX ASSEMBLY ADAPTER / SCREEN ASSEMBLY
Low Speed Gear TaperedRoller ThrustBearing
Low SpeedPinion Gear
Cast Iron Housing
High Speed Gear
High Speed Pinion Gear
Extractable Screen Assembly
Inner CylindricalBreaker Plate
plish this, the material mustbe thoroughly filtered, yetmaintain maximum homo-geneity to prevent gaugevariations. The Gloucestercylindrical in-line screen packprovides over five times thefilter surface area of conven-tional screen packs whilesimultaneously homogenizing the melt. These innovativescreen units are also carefully designed for minimum residence time to prevent polymer degrada-tion. The block and adapterare machined alloy steelforgings with electrolessnickel-plated flow surfaces.
Longevity and ReliabilityBecause longevity and reliability are critical considerations, the massivegearbox is designed foryears of reliable operation.Hardened gears and highcapacity thrust bearingsthat meet the torquerequirements of HDPE serveto reduce operating noise.
Unique Screen PackPermits Thinner GaugeBecause of its superiorstrength compared withlower density polymers,HDPE is frequently extrudedin thinner gauges. To accom-
For maximum uptime, thepack is easily accessible for cleaning.
Battenfeld Gloucester’s stationary HDPE dies arespecifically designed to handle high density materi-als. Computer determinedspiral flow channels withport inserts minimize residence time to preventpolymer degradation. Theyalso maintain a high shearrate that prevents gelbuildup and speeds productchangeovers.
The mass of each componentof the die is optimized to provide thermal homogeneityand maximum deflectionresistance throughout the die for dimensional stabilityyielding exceptionally uniformflow rate and consistentgauge control.
Precision Dies DesignedSpecifically for HDPE
Three-layer die has single-levelmaterial entrances for easyextruder placement.
Die parts are machined fromdrop-forged, through-hard-ened, stress-relieved steelwith precise uniformity toprevent warping during heat-ing and cooling cycles. Allflow surfaces, including feedport passages, are electro-less nickel-plated to resistabrasion and corrosion.Other flow surface treat-ments are optional.
For maximum uptime,Gloucester’s innovativetaper-lock self-aligning dieparts can be assembled anddisassembled quickly andeasily, and the die diametercan be changed withoutchanging the entire die.
MONOLAYER HDPE IBC DIE / AIR RING ASSEMBLY
Monolayer IBC Die
IBC Air RingSingle Lip Air Ring
Bubble Stabilizing Rings
IBC Return Air Stack
Horizontal ScreenChanger Assembly
To assure maximum bubblestability with minimum operator intervention,Gloucester utilizes a uniqueInternal Bubble Cooling (IBC)system. The patentedDigisonic non-contact ultrasonic sensor systemaccurately controls bubblediameter. Cooling rate andlayflat are manipulated witha simple touch of the key-pad. Smoothly flowing airguides the polymer stalk,cooling it from the inside inits most critical area.Additional film orientation is provided by a multipleinternal ring structure. Asthe film is blown, the bubblediameter is controlledthrough the exhaust blowerand damper. This arrange-ment immunizes the IBCfrom the effects of normalbubble sway or atmosphericconditions and allows it tohold a consistent diameterfor improved layflat control.
Gloucester’s latestPolycool® 900 Series Air Ring and Autoprofile™
System provide additionalstabilization of the bubble.The air ring precisely controls air flow to eliminatefilm chatter and provide sufficiently high air volume to support the requirementsof high density films. TheAutoprofile™ system usesstandard film thickness measuring devices and theExtrol microcomputer toeliminate thickness variationsby directing thermally corrected airflow to the proper areas, resulting in theflattest film in the industry.
A Cool, Stable BubbleAssures Smooth Operation
POLYCOOL® 900 AUTOPROFILE™ AIR RING
Air Ring Body
Upper LipFinned Heaters
While a cool, stable bubbleis critical to producingsmooth, flat film, yourBattenfeld Gloucester blownfilm system includes severalother subsystems that bringunprecedented precision to the collapsing, flatteningand hauloff needed forsmooth film winding.
Automatic LayflatControl (ALC)The patented Digisonic™ IBCcontrol uses highly accurateelectronic sensors to con-stantly measure the truediameter of the blown tube. It immediately compensatesfor even the slightest devia-tion from your setpoint byadjusting blower speeds and air flow. Since there areno major layflat variations,edges can be trimmed clos-er to the final web width for minimal scrap and reclaim.
Slat Collapsing FrameThe interlacing side guidesof Gloucester’s SlatCollapsing Frame providethe proper geometry to collapse non-extensible highmolecular weight films without wrinkles or creases.To further reduce drag andresulting bagginess, a lowfriction plastic slat cover isavailable. Segmented rollerand airboard collapsers arealso available for specialapplications.
An Integrated Systems Approach To Flatter and Smoother Film
The Traversanip® OscillatingHauloff shown eliminates theneed for rotating dies.
Oscillating Turning Bar
Stationary Turning Bar
Stationary Vertical Idler Roll
Exit Bowed Idler Roll
Tower Idler Rolls
Double Vertical Idler Rolls
Oscillating HauloffThis proprietary hauloff system provides 100 per-cent randomization of gaugebands through its continuous720° oscillation. It assuresultra-smooth, randomizedfilm that can be easilywound into large diameterrolls that make high speedconverting profitable. It alsoeliminates the expense andmaintenance requirements ofrotating dies, and the floorspace needed for special extruder platforms.
Battenfeld Gloucester Series1000 Winders offer virtuallyevery configuration you willever need, including singleand multiple rolls up to 60”in diameter. More important-ly, they are specificallydesigned to producesmooth, uniform rolls ofHDPE film.
Strong and StableSeries 1000 Winders featuresolid, durable constructionand heavy, solid frames.This provides not onlymechanical stability andreduced vibration for higherquality rolls with clean slitfilm edges, but also lowermaintenance and a longerlife cycle.
Converter QualityWinders ProduceHigh Quality Rolls
MODEL 1021 WINDER
MODEL 1020 WINDER
New Core Shaft
Load CellTension RollBowed Roll Infeed Nip
Precise ControlBattenfeld Gloucester buildsprogrammable logic controlinto all Series 1000 Winders.Roll quality is monitored atevery moment using presetcontrol points and alarms tomaintain consistency andhigh yield over long produc-tion runs. Series 1000Winders can also be integrat-ed into the blown film system’s overall scheme. As an added bonus, the soft-ware based controls can beeasily customized to yourspecific application and justas easily reprogrammed toaccommodate different applications.
Series 1000 WindersAll Gloucester Series 1000Winders offer the followingfeatures:
• Roll diameters up to 60 inches
• Load cell tension monitoring and control
• Electronic taper tension
• Floating layon roll
• AC flux vector drives
The large number of com-plex processes that takeplace during HDPE blownfilm production, the speedat which they occur, and theunique requirements of highdensity film make processcontrol a critical part of theoverall operation. That’swhy Battenfeld GloucesterHDPE blown film systemsincorporate the Extrol 6000Integrated Process ControlSystem, the control systemdesigned for extrusionprocesses by extrusionexperts. It gives you singlepoint control of everyprocess function from feed-ing and blending throughextrusion and blowing tohauloff and winding.
The Extrol microprocessor-based control system isincredibly fast, and easy to learn and operate. It constantly monitors everysystem variable and cease-lessly manages all of yourset points and parameters,including:
• Gravimetric blending and feeding
• Autoprofile™ gauge control
• Drives and temperaturezones
• Auto-trending of melt and barrel temperature,melt pressure, drive RPM and amperage
• Alarm and event data logging
• Data links to other computers
• Automated orderly shutdown procedures
• Automatic ramping of every drive (significantin coextrusion)
• On-demand SPC/SQCdata and reports
• Sophisticated safety logic
Complexity of HD Blown FilmProduction Requires HighlyIntelligent Process Control
Extrol Process Control putsyou in absolute and totalcontrol of the profitabilitydesigned into yourGloucester high densityblown film system.
Designed specifically forhigh-volume, round-the-clockproduction of high densityHDPE film, BattenfeldGloucester blown film processing lines feature:
• Gravimetric blending,feeding, scrap reclaimsystem
• Superior extruder andscrew design
• Extended life dies
• Unique screen packassembly
• Automatic layflat control
• Traversanip® oscillatinghauloff
• Highly intelligent Extrolprocess control
• Internal Bubble Cooling(IBC)
• Slat collapsing frame
• Converter quality winders
• Full support and service
Unique Features ofGloucester High DensityBlown Film Systems
Your Battenfeld Gloucesterhigh density blown film system includes the mostreliable and advanced technology available. Our service and support areequally advanced. Gloucesteris your single source for alltechnical and maintenanceexpertise, in addition to theprocess experience thatfrees you to concentrate on the end product. Support includes:
• Fully inclusive processconsultation
• Comprehensive engineering services
• Use of Gloucester’s dedicated TechnicalCenter for material andequipment testing
• Gloucester’s worldwidenetwork of skilled, knowledgeable serviceengineers
• Our extensive inventoryof parts and supplies.
Each Gloucester film line is supported by a computermonitored multi-million dollar parts inventory
Outstanding Service and Superior Support
Battenfeld Gloucester Engineering
From its headquarters inGloucester, Massachusetts,USA, Battenfeld GloucesterEngineering is a worldwideleader in extrusion basedplastics production systems.Gloucester supplies production lines, includingintegrated microcomputercontrol systems, for blownfilm, cast film, foam sheet,rigid sheet, extrusion coating, bag making andreclaim processing.
A member of the BattenfeldGroup, a leading worldwidesupplier of plastics process-ing systems, Gloucester hasled in the development, engineering, manufactureand support of individual production components andcomplete extrusion linessince 1961.
Total production facilities ofalmost 360,000 square feetinclude CAD/CAM/CAE andCNC equipment for precisionmanufacturing of compo-nents such as extrusionscrews and dies. Completeintegration of design andengineering enableBattenfeld Gloucester to stay at the forefront of thelatest technologies.
Battenfeld Gloucester • USA
Battenfeld Gloucester Europe • UK
Battenfeld Gloucester Engineering Co., Inc.Blackburn Industrial Park /Post Office Box 900Gloucester, Massachusetts 01931-0900 USA
Tel: 978-281-1800 Fax: 978-282-9111 www.bge.battenfeld.comSMS Plastics Technology
Tradition of Excellence