Coextrusion system for the production of 3 layer blown film FLEXIBILE MODULAR EFFICIENT

Coextrusion system for the production of 3 layer blown film FLEXIBILE MODULAR EFFICIENT

Film coextrusion is becoming more and more widespread in the packaging industry and is quickly replacing monolayer film production. Today, companies that invest in a new film extrusion system typically choose a 3-layer co-extrusion line with the highest output engineered into the center layer which optimizes productivity and line flexibility. Always in tune with the industry needs, Macchi introduced at the Plast 2000 exhibition in Milan, the innovative series of COEX flex extrusion systems, which immediately met with huge success. Macchi s COEX flex compact extrusion systems are equipped with three extruders, a side-fed co-ex die, tubing and all required connectors. All components are assembled on a custom platform and offer a compact group that is in tune, user friendly, easy to install and economical to transport. One of the great advantages of the COEX flex system is its ability to replace a traditional monolayer extrusion system and still occupy the same floor space. This up-grade has been successfully applied in dozens of applications worldwide. A By virtue of our current level of design technology in dies, air rings and extrusion feed screws, it has allowed the Macchi COEX flex line to achieve a standard manufacturing series production level. The criteria followed for the construction of the platform have always been: devoted attention to detail, choice of first quality materials and the desire to offer the industry a ready-to-use, reliable product incorporating worldwide available quality components. COEX flex Configurations Size Size 1 Size 2 Size 3 Size 4 Size 5 Size 6 Extruders 2 x 45 1 x 55 2 x 55 1 x 65 2 x 65 1 x 80 2 x 65 1 x 80 2 x 80 1 x 100 2 x 80 1 x 100 Die Range mm Min 150 Max 300 Min 180 Max 300 Min 220 Max 400 Min 300 Max 500 Min 300 Max 500 Min 400 Max 600 B Kg/h max 200 / 230 300 / 350 450 / 500 350 / 600 400 / 600 500 / 800 Dimension mm B 4950 B 4950 B 5800 B 5800 B 6800 B 6800 Weight Kg 7200 8500 10500 11200 12000 14000

Primary Standard Components A/C Motors exhibiting low energy consumption, minimum maintenance and a greater quality control Bi-metallic Extrusion Barrels an inherent high resistance to wear and corrosion Infrared Barrel Heating power saving up to 20%, long heater element life and quicker cooling response times Air Ring and IBC Blowers filtered and insulated for noise and dust control. All motors are inverter controlled Technologically Advanced Electrical Components focusing on the main drive speed control, the advantages represent a cleaner and more efficient electrical consumption, keeping in mind a respect for international safety regulations for both personnel and the additional electrical components Control Panel Conditioning Systems designed to maintain an ideal temperature inside the electrical cabinets allowing optimum component performance under the most demanding conditions.

Feedscrew, Screenchanger and Die Technology The feedscrews are a barrier type, designed for optimum performance in processing a wide variety of materials including LDPE, LLDPE, EVA, Metallocenes, PP, PS, PA resins and the major HDPE resins available on the market today. Particular attention has been paid to the consistency of our manufacturing processes and the quality of materials in order to guarantee a long and productive life span. Custom coated bimetallic screws perfected by Macchi after many years of experience are available as an option. The screenchangers are a prime consideration when processing materials that are temperature sensitive. These hydraulic Macchi screenchangers are manufactured to tight tolerances, designed with minimal allowable polymer volume and streamlined flow paths in order to avoid hang-up points and to facilitate material change over operations. The extrusion dies are the heart of the system. Macchi COEX flex dies have proven their flexibility and quality since 1997 with the beginning of their series production. The operating principles and material distribution are distinct and superior to the more traditional bottom fed or multi-level side fed die technologies available on the market today.

This is due mainly to: approximately 30% less material contained inside the die than with standard designs. This leads to quicker and more efficient material changes. lower operating pressures while maintaining maximum output rates. This allows greater flexibility in processing a wider variety of materials even with high viscosity. the integrated IBC system is completely independent from the heated components of the line, allowing for the least amount of heat exchange to take place and reducing any chance of gauge variation due to temperature variables. all layer flow paths are kept independent until combined in the top die zone just below the die lips. This allows for near perfect distribution of the thickness of each layer, regardless of differing material viscosities. Macchi s exclusive die design maintains equal material residence times on each layer, whereby stack die designs engineer a variety of flow paths and time relative to the number of layers.

Application of the Macchi COEX flex Group At present, there exist three different sizes of the Macchi COEX flex unit: small, medium and large. They have been designed also to easily substitute a typical monolayer extruder and transforming the line into a co-extrusion system while limiting the cost of the investment. With this up-grade, improved gauge uniformity due to the new die technology and increased production due to the IBC system present on the medium and large models are guaranteed. The complete line is available in different versions by using various components and configurations due to the remarkable modularity of the elements. Oscillating take-off units Built exclusively in the horizontal version, they are available in 1200 mm, 1600 mm, 1800 mm, 2400 mm. The COEX flex groups have also been fitted on large lines with take-off units up to 2800 mm and 3200 mm widths. Winders Manufactured in various models and dimensions, the most popular types are the Macchi BSA basic automatic winder and Macchi BO Plus. These are part of a line of winders that are considered one of the top performing winders available on the market worldwide. The BO Plus winder can now be equipped with various features such as: winding with gap, pure axial winding and reverse wind capabilities. The top of the line BO Plus winder is protected by 3 different patents. Its final configuration is dependent on the type of film production required.

Modular roboticized systems have been designed in order to entirely automate the production process and to guarantee a safe work place. Gravimetric systems Macchi gravimetric systems have been designed to be compact, practical and easy to integrate with the extruders. Control systems Macchi COEX flex group is complete with world-wide available quality electrical components and operator control console. Many of the operating systems available today can be integrated into these production controls. Modular and expandable, Macchi s EASY CONTROL is one of the most complete production managing systems available today. Film thickness profile control is one of the many systems available as an option.

14500 mm Rev.004-11/05 www.bonobodesign.it 16000 mm Typical layout where the COEX flex group can be fitted on high-tech coextrusion lines up to 3200 mm, or simple lines with BSA automatic winders. 13400 mm 9350 mm The content of this catalogue is for informative purposes only. All data concerning technical specifications and production rates granted depend exclusively on contractual agreements. Macchi S.p.A. - 21040 Venegono Inferiore (VA) Italy - via Papa Paolo VI, 5 - Tel. +39 0331 827.717 - Fax. +39 0331 827.750 email: macchi@macchi.it - www.macchi.it