Coextrusion system for the production et 5,7 and 9 layers blown film

FLEXIBLE - MODULAR - EFFICIENT

The history of the production of bar-
rier films, is mainly associated to
three-layer co-extrusion lines, with
a barrier of nylon, bound to the
structural polymer by means of the
interposition of a tying layer.
While being suitable for required
purposes, these early structures
showed a strong tendency to curl
(curling effect), made even worse
by the substantial thickness of the
layer required to ensure that the
barrier was sufficient. This intrinsic
defect was the main driving force to
quickly move towards the production
of geometrically balanced structures,
bringing the nylon in the core central
position, thus developing a five layer
symmetric structures, produced by
three extruders, which universally
and definitively opened and devel-
oped the barrier film industry.
The arrival of EVOH, together with
the development of more performing
tie resins in the application fields,
gave way to the design of the first
asymmetric structures, with a seal-
ing layer different from the main
structural body. Systems with four
extruders and one head with five
layers were the almost standard line
layout, which remained a benchmark
of setup.
At the same time there were devel-
opments and improvements as far
as packaging was concerned, with
the consequent need to extend the
application range of available films.
Above all, sterilising treatment in
autoclave identified the limits of a
single barrier products, whether PA
or EVOH, in terms of sensitivity to
moisture and relevant drop in the
oxygen barrier values.
Macchi had to give an answer to a
number of requirements to be faced
in the same time:
- need to produce a barrier structure
made by the simultaneous usage
of both PA and EVOH
- process strongly asymmetrical
structures
- produce structures using two or
three different barriers to optimise
the film performance and allow fur-
ther thickness reduction
Briefly, these are the reasons which
have led us to the present produc-
tion of five, seven and nine layer
machines, along with the develop-
ment of extrusion screws, innovative
head concepts and a total re-design-
ing of the entire system, from take-
off units to winding systems.
Complete line for barrier film
The main feature of this technology
is that the residence time of the melt
inside the head was highly reduced.
The density of the assembly, the
moderate volume with the additional
advantage that this design allows for
the same flow-path on all the layers,
offer an excellent flexibility for the
choice of polymers which can be
used and also leading to an improve-
ment of the time requested for prod-
uct changeover, with a significant
reduction in the purging process.

The word barrier film immediately
brings to mind the food packag-
ing sector, whilst there are many
non-food applications, like the phar-
maceutical-medical, automotive or
industrial specialities.
And it goes without saying that,
besides the extrusion process,
these kinds of expensive films must
be wrapped and transformed in per-
fectly wound reels with the degree
of attention and technology that they
deserve. Macchi has a full array of
technology-oriented devices to fully
complement such very dedicated
production systems.
Double station BOPlus automatic winder
Thickness control system detail
9 layer die head scheme
Decurling tank
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Macchi S.p.A. - 21040 Venegono Inferiore (VA) Italy - via Papa Paolo VI, 5 - Tel. +39 0331 827.717 - Fax. +39 0331 827.750
Service Hotline +39 0331 866.427 - email: macchi@macchi.it - www.macchi.it
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9 layers
7 layers 5 layers
Extruders configuration