Blown film extrusion line

Macchi E18

GENERAL DESCRIPTION:
The Macchi 3-Layers E18 is a high-capacity blown film co-extrusion line designed for the production of general-purpose films where high film width and output rates are required. It processes LLDPE, LDPE, mLLDPE, MDPE, HDPE, and, in its upgraded configuration, also PP. This system features a 700 mm three-layer die head and achieves an output capacity of up to 900 kg/hour, depending on the formulation.

EXTRUSION GROUP:
• Extruders: 80 mm + 100 mm + 80 mm
• Infrared heating
• Hydraulic screen changers
Detailed upgrade specification:
• One Plastex 100/30D extruder (center layer B)
• Two Plastex 80/30D extruders (layers A and C)
• Bimetallic barrels
• Nitrided screws
• Water-cooled grooved feed sections
• 5 heating zones with IR heaters and blowers
• Motors:
- 150 kW DC motor (100 mm extruder)
- 100 kW DC motors (80 mm extruders)
• AC motor system with digital control (IP55) for reduced energy consumption and harmonic distortion

DIE HEAD:
• Model TE505
• 700 mm die diameter, die gap 1.8 mm
• 4+4 heating zones with ceramic heating bands (total 19 + 35 kW)
• Mounted on a die cart with integrated air distribution manifold
• Insert range 600–800 mm
• Equipped with IBC system

COOLING SYSTEM:
• Dual-lip carbon fiber Karat air ring (K-Design)
• ASR4 Double Flux Cooling Ring, 15 kW blower
• Jet-7 IBC cooling control system:
- 15 kW inlet blower
- 18 kW exhaust blower
- Bubble diameter sensor
- Air balancing valves
- Variable-speed inverters

TAKE-OFF UNIT:
• Take-off width: 3200 mm
• Oscillating nips
• Optional tower-mounted secondary nip with load-cell control

WINDING SECTION:
• Double automatic back-to-back winder
• Automatic roll change
• Maximum winding width: 3150 mm

FILM SPECIFICATIONS:
Film width range (with 700 mm die): 2000–3100 mm
Thickness: 15–200 μm
Output example: 3000 mm width, 100 μm LDPE → 800 kg/h ±10%

LINE SPECIFICATIONS:
Installed power: 550 kW, 415 V, 3-phase + neutral
Screw speeds:
80/30D extruders: 0–130 RPM
100/30D extruder: 0–120 RPM
Cooling water consumption: 6 L/min
Compressed air requirement: 6 bar
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Standard color: White RAL 9003 / Green RAL 6010

ADVANCED CONTROL & MEASURING SYSTEMS:
• Doteco gravimetric dosing system Grado
• Thickness profile systems (EC Plus modules):
- S2 Automatic Die Control
- S3 Rotating Capacitive Thickness Scanner
- S4 Track Scanner
- Q1 Serial communication (extruder/gravimetric values)
- Q11 Printer module
- Q12 Online modem diagnostics
- Q7 Power consumption monitoring
• K-Design VARIOcool automatic thickness control
• Kundig reversing ring and thickness measurement

AUXILIARY EQUIPMENT:
• Tower
• E+L web guiding system
• Corona treater AFS or 2800 station
• Calibrating basket with optional supporting basket
• Bubble guide GSRC 3200 (6 levels, motorized, IBC-linked)
• Micro-perforation system (FBF cold needle)
• Air shafts (8 pcs)

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