Leadership through customization in Blown Film Technology

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Stewart Oliver
6 years ago
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1 Leadership through customization in Blown Film Technology

2 jrukdjs ;qt;r,o jrue~ A & dkfynkl Best of the Gems come from deep churning of the Oceans L a y e r s & m o r e We Customize Co-ex Blown Film Lines through Proven World Class technology MAMATA EXTRUSION SYSTEMS PVT. LTD., (formerly known as Mamata Brampton Engineering Pvt. Ltd.), is focused on manufacturing of the state of art Co-extrusion Blown Film Lines. Mamata Extrusion Systems (MES) a Joint Venture Company established in 1997 in partnership with Brampton Engineering Inc., Canada is now a fully owned company of the Mamata Group since begining of year In 2012, Mamata entered into a new Technology license Agreement & Strategic Business Alliance Agreement with BE, Canada. Over last decade & half MES has evolved itself as a company to set New Standards In Blown Film Technology by :- By Having Devloped Capabilities to Cater to Global Markets through rich experience of 15 Years of JV. By gaining rich experience of supplying / commissioning 3 L / 5 L / 7 L Blown Film Lines. MES Successfully demonstrated Best Price to Performance Ratio to the Industry. MES is a dedicated Blown Film Extrusion Systems manufacturer with a focused approach towards processors requirements. We Offer Customized Solutions as under :- Non Internal Bubble Cooling(IBC) blown film lines upto Three Layers offering very low conversion costs without compromising Film Quality and Outputs. State Of The Art, Three Layer Blown Film IBC Lines for High Outputs for Critical and Customized application requirements. Barrier Blown Film Lines for Five and Seven Layer Films. We offer world renowned Stream Lined Co-Extrusion Die (SCD) technology from BE, Canada World Class Technology at your door step Launched at PLASTINDIA 2012, Mamata becomes sole owner of JV, Enters in to New Technology License Agreement & Strategic Business Alliance Agreement with BE, Canada 7 th Barrier Film Plant with Brampton s SCD / Die Technology Line installed in India st wider width 2895 mm Ultra High output 800 kg/hr 3 Layer Line Installed th Line Installed 1 st Line supplied to Australia Historical Milestones st 3 Layer Line Exported to Europe st wider width 2375 mm higher output 500 kg/hr 3 Layer Line Installed th Line Supplied st 3 Layer Line export to Far East & Middle East st ever 7 Layer Line installed in India 1 st 3 Layer Line Export to West Africa & Russia th Vegaflex concept Line sold within one year of launch 2001 Introduction of Vegaflex concept line - A new standard of excellence for Industry to follow st ever 5 Layer SCD Line Manufactured & Installed successfully in India st Line delivered :50 Joint Venture Between Mamata Machinery Pvt. Ltd., India & Brampton Engineering Inc., Canada 02 03

is A New Standard in Three Layer Co-extrusion Blown Films Technology High output without IBC Excellent thickness & GSM variation without expensive automation

PA, EVOH, SURLYN, EVA, Acid Copolymers etc.

Customized screw design suitable for polymers to be processed Gear Boxes : Custom designed gearboxes, specifically designed for extrusion processes.

Drives : AC Vector Flux Closed Loop Drives provide optimum energy efficiency and precise speed control even at very low screw rpm.

Due attention is given at each stage of die manufacturing, which ensures production of high quality films with tight gauge tolerances, right gloss and

Customized die design as per applications Manufactured from AISI 4340 Alloy Machine Steel The Taper Lock Body & Mandrel Assembly Design Eliminates the

$temperature controls to avoid melt fractures The Eliminator Air Ring The UNI-FLO Eliminator Air Ring allows processors to achieve targets for gauge$

3 is A New Standard in Three Layer Co-extrusion Blown Films Technology High output without IBC Excellent thickness & GSM variation without expensive automation Low cost of conversion Low wastage L a y e r s & m o r e Extruders For All Blown Film Applications Suitable For : LL, LD, mll, HDPE, MDPE, PP, PA, EVOH, SURLYN, EVA, Acid Copolymers etc. Our customized screws with plain barrel technology help in getting best possible quality melt at lowest possible temperature for better quality film at higher outputs. Feed Screw : Bimetallic Barrier Screw & Bimetallic Barrel for improved life High throughput with lower energy consumption and hence lower operating costs Customized screw design suitable for polymers to be processed Gear Boxes : Custom designed gearboxes, specifically designed for extrusion processes. Reduced energy consumption and maintenance. Drives : AC Vector Flux Closed Loop Drives provide optimum energy efficiency and precise speed control even at very low screw rpm. 3 Layer Spiral Mandrel Dies Our Die Heads are characterized by selection of the right quality steels with in house CNC machining. Due attention is given at each stage of die manufacturing, which ensures production of high quality films with tight gauge tolerances, right gloss and desired mechanical properties. Customized die design as per applications Manufactured from AISI 4340 Alloy Machine Steel The Taper Lock Body & Mandrel Assembly Design Eliminates the mechanical interference fit associated with spiral mandrels Ensures excellent concentricity between the spiral mandrels and the die body Streamlined Polymer Flow having No Stagnation and Dead Points Increased Yield due to lesser gauge variation Capability to handle Critical Layer Ratios Separate inner & outer lip temperature controls to avoid melt fractures The Eliminator Air Ring The UNI-FLO Eliminator Air Ring allows processors to achieve targets for gauge uniformity, output and physical properties of blown film. The Eliminator has the superior capability in terms of enhanced cooling efficiency by virtue of its design and can be used for the cooling of all PE structures, PP & coextrusion structures containing PA & EVOH. The Eliminator Air Cooling Ring Advantages : Improved cooling efficiency Ease of operations Better lock in over a wider range of operating conditions which results in significant improvement in gauge consistency even at higher output rates Enhanced blow up ratio range More useful for wide range of material melt strengths 04 05

1 2 3 4 5 6 7 L a y e r s & m o r e Customized High Output Three Layer Co-extrusion Blown Film Lines with IBC 4+1

AC Drives offers the advanced cooling efficiency even for polymers having high MFI and low melt strength while

The processors will gain maximum advantage with 4+1 Pancake IBC for normal and sophisticated coextrusion applications.

the four pancakes from fully open to fully closed allows for a gradual increase in air velocity for maximum heat

of film Control system to allow the operator to precisely control the air exchange to maintain balanced bubble Haul

randomization each having their own advantages.

rollers mounted on platform for full 360º oscillation for uniform gauge distribution & excellant roll geometry.

through full 360º oscillation Horizontal Oscillating Haul Offs : Keeps the film path horizontal & achieves

4 L a y e r s & m o r e Customized High Output Three Layer Co-extrusion Blown Film Lines with IBC 4+1 Pancake IBC System The 4+1 Pancake IBC System along with separate air inlet & air outlet blowers controlled through AC Drives offers the advanced cooling efficiency even for polymers having high MFI and low melt strength while maintaining ease of operations. The processors will gain maximum advantage with 4+1 Pancake IBC for normal and sophisticated coextrusion applications. The 4+1 Pancake IBC delivers uniform airflow to ensure consistent gauge The adjustable air flow through each set of the four pancakes from fully open to fully closed allows for a gradual increase in air velocity for maximum heat transfer and bubble stability Non Contact ultrasonic sensing technology has no dependency on the colour or thickness of film Control system to allow the operator to precisely control the air exchange to maintain balanced bubble Haul Offs - Vertical & Horizontal MES offers two choices for Haul Offs - Vertical or Horizontal type for gauge randomization each having their own advantages. Vertical Oscillating Haul Off : Provides the provision to make film path vertical through set of turn bars & idler rollers mounted on platform for full 360º oscillation for uniform gauge distribution & excellant roll geometry. Uniform gauge distribution No wrinkles No scratches on the film Excellent roll geometry Perfectly flattened films through full 360º oscillation Horizontal Oscillating Haul Offs : Keeps the film path horizontal & achieves differential oscillation of set of turn bars to complete the gauge randomization process. Gauge randomization by turning the film at 0º to 180º in both directions to achieve full 360º Oscillation Economical System as compared to Vertical Oscillating Haul Off Compact system Uniform gauge distribution through the product rolls 06 07

1 2 3 4 5 6 7 L a y e r s & m o r e Barrier Film Lines 5 to 7

your recipe costs Minimize your cost of conversion 5-7 Layers

coextrusion die offers most modular and versatile die design

range of resins to make structures with the required

Temperature isolation between layers Streamlined melt

Automatic Surface Winders Fully Automatic roll change over

finished roll Variable surface pressure between the wound roll

Bowed spreader roll just prior to the winding drum to ensure

5 L a y e r s & m o r e Barrier Film Lines 5 to 7 Layers Engineer your films with built in flexibility Optimize your recipe costs Minimize your cost of conversion 5-7 Layers Streamlined Coextrusion Dies From BE The streamlined coextrusion die offers most modular and versatile die design to allow processors to harness the characteristics of a wide range of resins to make structures with the required properties. Temperature isolation between layers Streamlined melt distribution Easy upgrades due to modular design Fully Automatic Surface Winders Fully Automatic roll change over requires operator only to load new core shaft and remove finished roll Variable surface pressure between the wound roll and the drum allows roll hardness to be precisely controlled Bowed spreader roll just prior to the winding drum to ensure wrinkle free film Surface drum driven by (field oriented control) Encoder feedback, load cell feedback AC Vector Flux drives for precise tension control 08 09

Automations for Enhanced Efficiency Mamata Extrusion can offer a wide variety of automation options starting from resin handling to finished roll handling.

quality and repeatability The accuracy considerably reduces the raw material costs, in fact and the ingredients are metered without any wastage.

Thickness can be measured by capacitive / nuclear based devices, contact or non-contact devices, prior to collapsing frame or post primary nip depending upon non-barrier /

Brampton Engineering s Heated Lip gauge control system is an accurate and easy to use system to reduce gauge variation in blown film.

Auto Width Control Provides an instant readout of the actual layflat eliminating the need to wait for the film to reach the winder.

Supervisory Control & Data Acquisition System (SCADA) The SCADA system facilitates the total line control from a single point giving the operator the flexibility of easy

Auxiliaries / Utilities List of some of the out sourced Auxiliaries / Utilities which can be offered by MES along with the line to facilitate supply of entire line as a package.

6 Automations for Enhanced Efficiency Mamata Extrusion can offer a wide variety of automation options starting from resin handling to finished roll handling. Single / Multi Component Gravimetric Blending & Dosing The system functions independent of the bulk density variations of the material to be metered guarantying constant quality and repeatability The accuracy considerably reduces the raw material costs, in fact and the ingredients are metered without any wastage. Online Thickness Measurement System Online rapid and accurate measurement of film thickness allows the film production process to be tightly controlled. Thickness can be measured by capacitive / nuclear based devices, contact or non-contact devices, prior to collapsing frame or post primary nip depending upon non-barrier / barrier film nature. Auto Gauge Cotrol Systems In Segmented Air type system the gauge is controlled through air flow from Segmented Air Ring. Brampton Engineering s Heated Lip gauge control system is an accurate and easy to use system to reduce gauge variation in blown film. Based on feed back of film thickness measurement profile, the individual heaters of heated Die Lip correct the gauge variation and control the profile continuously. Auto Width Control Provides an instant readout of the actual layflat eliminating the need to wait for the film to reach the winder. Reduces the time required to get bubble on size and helps reduce layflat changes from long term process variations. It helps to make trimless film winding. Supervisory Control & Data Acquisition System (SCADA) The SCADA system facilitates the total line control from a single point giving the operator the flexibility of easy control and monitoring the complete line performance. Auxiliaries / Utilities List of some of the out sourced Auxiliaries / Utilities which can be offered by MES along with the line to facilitate supply of entire line as a package. Web Guides Corona Treaters Chilling Plants Electrical Distribution panel Testing Equipments etc. Complete Turn Key Project for Coex Blown Film Line from concept / configuration of the line to the commercial production on request is also possible. Infrastructure MES has well designed large Assembly area with Special high ceiling bay, for assembly of towers and set up to complete lines for demonstration and testing spread across 1,40,000 Sq.feet. A full CNC machining facility for manufacturing of critical components including dies

Customize your line from the Range of System Elements we offer No of Layers : 2 to 7 Width : 1000 mm to 3000 mm Output Range : 180 kg/hr to 1000 kg/hr Extruders : 50 mm to 150 mm Die : 180 mm to 850

7 Customize your line from the Range of System Elements we offer No of Layers : 2 to 7 Width : 1000 mm to 3000 mm Output Range : 180 kg/hr to 1000 kg/hr Extruders : 50 mm to 150 mm Die : 180 mm to 850 mm - Spiral Mandrel / Streamlined Coextrusion Dies (SCD) through BE, Canada Cooling Ring : The UNI-FLO Eliminator Air Ring IBC : 4+1 Pancake IBC Auto Gauge Control Systems : Heated Die Lip Type / Segmented Air Type Cage : Roller type Haul Off : Vertical Oscillating Haul Off with discharge nip & PLC controlled operation / Horizontal Oscillating Haul Off Winder : Surface Winders up to 3125 mm width Structure : Prefabricated tower Controls : Panel type line controls / Computerized SCADA controls Others : We can also offer turnkey solutions All other automations / auxiliaries / utilities upon request. The details mentioned here by are for reference purpose only and the technical data and specifications given are subject to change without prior notice. Kindly refer your customized offer for scope of supply and other details. Configure a Line to produce what you want to sell... MAMATA EXTRUSION SYSTEMS PVT. LTD. (Formerly known as Mamata Brampton Engineering Pvt. Ltd.) 5/1/1A/1, Phase-1, G.I.D.C., Vatva, Ahmedabad , India. Phone : Fax : sales@mamata.com Website : 01/2013 marg

Blown Film Lines with water cooling

EXTRUSION LINES FOR MEDICAL APPLICATIONS Laboratory machines for the processing of polymers Blown Film Lines with water cooling The new and reliable system for the production of sterile multi-layer-tubes