POLYMER PROCESSING DESIGN LAB

POLYMER & PROCESSING DESIGN LAB

REPORT NO:

02 (Blown Film Extrusion Line)

SUBMITTED BY:

WAJAHAT GHULAM RASOOL

REGISTRATION NO:

2016-PE-12

SUBMITTED TO:

SIR ENGR.MUZAMIL HAMZA

GROUP NO:

UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE

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 POLYMER PROCESSING DESIGN LAB

Blown Film Line

Objective:

To study the working of blown film extrusion and analyze the effect of
processing parameters on the properties of thermoplastic.

Equipment Required:

Blown film extrusion line, Vernier Caliper, Thickness gauge,

measuring gauge.

Material Required:

HDPE (Grade 912) and LLDPE (Grade 1018 Sabic)

Introduction:

Blown film extrusion is a technology that is the most common method to

make Plastic films, especially for the packaging industry. The process involves extruding a tube
of molten polymer through a die and inflating to several times its initial diameter to form a thin
film bubble. This bubble is then collapsed and used as a lay-flat film or can be made into bags.
Usually polyethylene is used with this process, and other materials can be used as blends with
these polymers. A typical blown film (upward) is shown in fig 2.1.[1]

Fig 2.1 A schematic diagram of blown film (upward)

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A combination of HDPE and LLDPE was used to perform the experiment. Typically,
blown film extrusion is carried out vertically upwards, however horizontal and downward
extrusion processes are now becoming more common.

Procedure:
 Processing parameters were set on the control panel of extrusion blown film
 Combination of LLDPE and HDPE was used in the hopper as feed
 Three different temperature were set according to three zones respectively,
190oC, 200oC and 220oC
 Molten material was then allowed to pass through die and parison was allowed
to move in and upward direction.
 Air was blown from downward to blown up the parison
 Blown material was then forced to pass through the folding rods
 Material was then passed through nip rollers that controls the thickness of the
material.
 After passing through nipping rollers, material was then pass through
conveying rollers
 Finally, it was winded up on the nipping rollers.
 Thickness and width were measured for each sample

Results and Discussions:

The effect of processing conditions on the thickness and width of plastic bag was observed as
shown in table.

Observations Speed Levels Revolution Thickness Lay Flat Blow Up

Per Minute Width(mm)
Values (mm) Ratio

01. Low 50 0.03 165 2.0609

02. Moderate 54 0.02 168 2.0984

03. High 56 0.014 175 2.1733

It was observed that thickness of the material was decreasing as shear rate increases due to
increase in screw rotation (RPM). The opaqueness in the product appears if the thickness of the
product is too high due to the hindrance in light rays to pass out the sample.

Calculations:

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 POLYMER PROCESSING DESIGN LAB

Bubble Diameter 0.637 × Lay Flat Width

Blown up ratio = =
Die Diameter Die Diameter
Die Diameter = 63mm = 2.5 inch

For sample 1
0.637 × Lay Flat Width 0.637 ∗ 165
Blown up ratio = = = 1.668
Die Diameter 63

For sample 2
0.637 × Lay Flat Width 0.637 × 168
Blown up ratio = = = 1.6986
Die Diameter 63
For Sample 3

0.637 × Lay Flat Width 0.637 × 175

Blown up ratio = = = 1.769
Die Diameter 63

Questionnaire:
Q:
Suggest the troubleshooting steps that can be taken to remove the surface characteristics
observed during the blown film extrusion of HDPE+LLDPE?
Ans:
Die lines and melt fracture effect the surface properties of HDPE+LLDPE during blown film
extrusion. Die lines can reduced by cleaning the die properly and refinishing the rough flow
surface. Melt fracture can be reduced by lowering the viscosity of the melt which is done through
increasing melt temperature.
Q:
Address the importance of the blown film extrusion of HDPE+LLDPE in industry and how
the objective of this lab relates?
Ans:
Blown film extrusion of HDPE+LLDPE is very important in the industry as it is widely used in

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the packaging industry to make shrink, stretched and plastic bag film. It is also used in the
consumer packaging to make packaging bags. All these applications require control thickness
and other various parameter that are studied to improve the quality of the product. These
parameters are studied during this laboratory.
Q:
What are dispersive and distributive mixing?
Ans:
Process where particle clamps are broken down during mixing with polymer with high shear
rate is called dispersive mixing. Distributive mixing is however carried out by repeatedly
straining, stretching and rearranging of layers. Distributive mixing leads to the uniform
homogenous mixing of minor component into the polymers.

Q:
List the advantages and disadvantages of single screw extruder?

Twin Screw Extruder

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Conclusion:
This process was carried to make plastic bags of different thickness. The
parameters effecting thickness and width were observed and blown up ratio was calculated by
different thickness of plastic bags. LLDPE and HDPE were used to carry out the process.
Applications:

Blown film can be used either in tube form

o Plastic bags.

Typical applications include Industry packaging.

o Shrink film.
o Stretch film, bag film or container liners.
o Consumer packaging (e.g. packaging film for frozen products, shrink film for transport
packaging, food wrap film, packaging bags, or form, fill and seal packaging film).
o Laminating film (e.g. laminating of aluminum or paper used for packaging for example
milk or coffee).
o 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).
o Films for the packaging of medical products, Agricultural film (e.g. greenhouse film, crop
forcing film, silage film, silage stretch film).

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Reference:

 [1] Introduction is retrieved from

http://www.appropedia.org/Blown_film_extrusion

 [2] Applications are retrieved from

http://www.bpf.co.uk/Plastipedia/Processes/Blown_Film.aspx