Blown Film Extrusion Could Help You Lower Costs and Stand Out in a Crowded Market
From food-safe bags to industrial films, blown film extrusion has transformed how businesses produce high-quality packaging materials at scale. It provides superior strength, customization options, and more. This has made it a go-to solution for manufacturers worldwide. In this blog, we’re breaking down the benefits of blown extrusion and how it could help elevate your packaging.
What is Blown Film Extrusion?
Blown film extrusion is one of the most common processes for the production of packaging films. This method involves putting plastic pellets into the extruder, where they are melted down using a carefully controlled melt profile. The pellets gradually go through “extruder barrel zones,” which are set to increasingly higher temperatures. This ensures proper melting and a higher-quality final product. A process engineer and the quality control department will record these settings for future run uniformity.
Once melted, the polymer goes through the “screen pack,” consisting of a few layers of metal screens. They act as a filter, holding back any unmelted pellets or chunks of contamination. After going through the screen pack, the material is pushed around a tube or sleeve called “the mandrel” and between the round “die ring.” The molten material will then form a tube, which operators tie off like the lip of a balloon as it exits the die. The tube is then inflated with air, pulling the hot bubble upwards.
From there, the material will be gathered up the extrusion tower so the whole mass can be pulled back down over idler rollers and toward the winders. The bubble of molten material begins to cool fairly quickly, typically about 30 inches above the top of the die as it exits the extruder. You can see the material change from hot and crystal clear to a kind of hazy or frosty appearance; this is called the “frost line.”
Next, a “collapsing frame” or “air-bearing ladder” will gradually flatten the tube. It then turns downward and heads back toward the ground. If the final product is tubing, the operators will wind the flattened bubble or tube onto the core. If the final product is sheeting, the operators set blades at each fold in the tubing and slit it off. They recirculate the trim back into the extruder, where it will be re-melted and blown again.
Lastly, the material will go through the “corona treater,” as it’s being wound up. This machine creates an electrical discharge which achieves three things:
- It polarizes the surface of the poly
- It roughens the surface
- It burns off any surface contamination
The treatment makes the surface ideal for ink or adhesives, making the final product easier to stand out in retail environments.
Advantages of Blown Film Extrusion for Packaging
Cost-Effectiveness
Blown film extrusion is one of the most cost-effective packaging creation methods because of its high material efficiency and fast production speeds. This process is perfect for creating thin, flexible films that reduce material usage while still creating large surface areas. Additionally, the automated nature of the process minimizes labor costs and increases throughput, which is why many businesses choose it for large-scale projects.
Customization
This type of packaging is highly customizable, making it highly sought after by companies in a range of industries. The process allows organizations to choose from a range of varying thicknesses, strengths, and barrier properties. It can also include adjustments to things like puncture resistance, moisture and oxygen barriers, and more. Additionally, businesses can choose additives or coatings like anti-static agents, UV inhibitors, or colorants.
Sustainability Advantages
Blown film extrusion can be used to make more sustainable packaging options than ever before. Not only does this lower your business’s carbon footprint, but it allows you to cater to the growing number of eco-conscious consumers. At PPC Flex, we can create blown film packaging out of a range of sustainable materials. This includes recyclable and compostable plastic options, and more.
Work with PPC Flex for Your Packaging Needs
If you’re looking for blown film extrusion packaging, we’re here to help. PPC Flex is a leading provider of flexible packaging, offering a comprehensive range of products and services to meet diverse packaging needs. With a focus on innovation and consumer satisfaction, we’ve emerged as a trusted partner for businesses seeking high-quality, purposeful packaging solutions.
We can help you design and manufacture your packaging, taking all the complexity and stress out of the situation. With an in-house graphics department, we excel in delivering exceptional speed to market while maintaining high standards of service, quality, and technology. The rest of our experienced team uses an integrated approach for seamless collaboration, resulting in packaging that enhances brand visibility and consumer appeal.
When you choose PPC Flex, you gain access to a team of dynamic packaging professionals who are dedicated to your success. With a focus on sustainability, innovation, and customer satisfaction, we’re well-positioned to help your business grow through powerful packaging solutions.
Let’s Get Started
Want to learn more about what we can do for you? Reach out to our team for an initial consultation.