Home > Blown Film > BXL Blown Film Lines
BXL Blown Film Lines
Macro's BXL Series of blown film coextrusion lines are designed to produce high performance barrier, printing and laminating films in an efficient and cost effective manner. The BXL Series is available up to 9-layers and is built using the latest technology, highest quality materials and superior workmanship. Every line is a versatile system capable of producing a variety of structures using different combinations of resins and layer configurations. Our unique die designs provide the needed flexibility to satisfy today's continuously evolving customer demands.
Applications
Typically, Macro's blown film systems are used in the production of films for converting, food packaging and medical applications. Common applications include lamination films, barrier films for vacuum packaging, thermoforming and skin packaging, milk/beverage/wine packaging films, stretch films, stretch hood films, heavy duty sack films, medical films, geomembrane films, greenhouse films, and agricultural films.
Typical materials processed on BXL lines include LDPE/LLDPE, mPE, HDPE, EVA, PP, PETG, PS and SBS Copolymers, PVC, Nylon, EVOH, PVdC, Ionomers, Surlyn, Acid Copolymers and Tie Resins
Extruders
MacroPlastTM Extruders are designed to provide superior melt quality and throughput for a wide range of polymers of varying rheology. They are available in both smooth bore or groove feed configurations. All extruders come standard with either air or water cooled barrels and a direct drive; however, gearless drives are available in certain applications. MacroPlast extruders are available in sizes ranging from 25 mm (1 inch) to 203 mm (8 inch).
Coextrusion Blown Film Die
Depending on the requirements of the line, it will be equipped with either a MacroPackTM or CentrePackTM die. Both dies are characterized by Macro's unique conical mandrels.
The CentrePack die can be used in lines up to 5-layers, but typically restricted to 3-layer lines where the films produced are used mainly for printing and laminating, and where gauge uniformity is critical. The CentrePack is a center fed, stackable, spiral die that can be used to produce polyolefin based films with superb thickness uniformity without the use of automatic gauge control. It contains a large diameter passage through its center for effective use of IBC.
The MacroPack die is a side fed, stackable, spiral die for 5, 7 and 9-layer lines. It is typically used for producing a wide range of barrier films, but is also effective in the production of printing and laminating films. MacroPack dies posses many unique features that set it apart from any comparable die in the market, including compact size, unrestricted number of spirals, the fewest number of parts and the lowest wetted surface area. Like the CentrePack die, the MacroPack is designed with a large diameter passage through its center for effective use of IBC.
Air Ring
The BXL Series of blown film coextrusion lines are equipped with Macro's D10 Dual Lip Air Rings to ensure the best output rates attainable. The superior bubble stability provided by the D10 and its easy adjustments assure simplified startup and high productivity over a wide range of blow-up ratios. The chamber provides high volumes of uniform cooling air, which is supplied through multiple supply ports along the perimeter of the air ring. The chamber is insulated to prevent condensation on its surface. Its patented lipset design combined with quality materials and precise manufacturing tolerances guarantee superb gauge uniformity.
Macro's D10 Air Ring is the only air ring available in the market with which the operator can make bottom lip adjustments while the bubble is up.
Internal Bubble Cooling (IBC)
The BXL series is provided with state-of-the-art IBC systems that utilize advanced modeling control to ensure the size, shape and thickness of the bubble remains stable and precise. BXL Lines can be equipped with stackable or conical IBCs.
Automated Gauge Control
To enhance the gauge of the product, any BXL line may be equipped with Macro's automatic gauge controlling equipment. This equipment can be equipped with either a layflat scanner or a scanner that rotates around the bubble. Macro provides a variety of gauge sensors including gamma backscatter, capacitance, infrared, X-ray and air gap.
Automatic Air Ring System
The patented design of Macro's D10 PRO Automatic Dual Lip Air Ring delivers the desired improvement in gauge uniformity while preventing any loss in cooling efficiency. Its operating principle assures a quick response time to any input for thickness correction. All these features make the D10 PRO the most advanced, efficient and versatile automatic gauge control air ring available in the market.
Automatic Die System
With Macro's die-based automatic gauge control system, the ACCUPRO system, the die lip is supplied with closely spaced cartridge heaters around its perimeter. These heaters are used to by the gauge control system to make melt temperature adjustments at distinct points around the die's perimeter to compensate for film thickness deviations.
Bubble Stabilizing Cage
The BXL Series is equipped with a low friction, multi-level bubble stabilizing cage that provides enhanced bubble stability for optimum layflat and gauge uniformity over a wide range of bubble diameters.
Collapsing Frame
The BXL's collapsing frames provide superior handling of the extruded bubble. They are fully adjustable from top to bottom. To ensure quality during collapsing, the frames are available in a variety of collapsing surfaces to suit the needs of your specific film. These surfaces include carbon fibre rollers, maple or pearl slats, aluminum rollers. Shallow and deep gusseting is also available.
Randomizing Haul-Off
All BXL lines come standard with a horizontal oscillating haul-off system to ensure proper gauge randomization for excellent roll quality. For special configurations, Macro also provides vertical oscillating haul-off arrangements.
Edge Guiding
Macro supplies edge guiding equipment from the industry's best suppliers. Any line may be upgraded to include Macro's Compact Edge Guide, which uses turning bars to correct the position of the flattened tube in a frictionless and space saving manner.
Winders
To complete the line, the right winders are needed. Macro provides both surface winders and turret winders for its blown film lines. With over three decades of experience, we'll help you decide which winder is best suited to the application. Macro's AUTOMAX winders provide flexibility and guarantee perfect roll symmetry with automated roll changeovers and tension and pressure tapering control for the best control of roll hardness. A variety of upgrade options are available including gap winding, bidirectional winding, and sophisticated roll and shaft handling systems.
Supervisory Control System
To make operation simpler and enhance operational safety, all BXL lines come equipped with Macro's SUPERCOM Supervisory Control System. The SUPERCOM System is designed to assist the operator during start-up, troubleshooting and normal operation. It minimizes the operator's involvement to avoid errors and quality issues. The operator is only required to set film parameters, such as desired film thickness and width (layflat), output, individual layer ratios, formulation for each extruder, and density of each resin. From here the SUPERCOM will automatically control the line's equipment, such as extruder rpm, positioning the bubble cage and setting the appropriate line speed, to produce film that matches the operator's inputted set points.
The operator's touch screen provides convenient access to line parameters such as temperatures, speeds and tensions. The screens also provide various troubleshooting features to help find the source of a problem, should one arise. Recipe options are also provided to store specific production set points to facilitate quick startups and product changeovers.
Upgrades
Encapsulation Package
Macro's patented Encapsulation technology can be incorporated in any BXL line with a MacroPack die to allow the processor greater flexibility to process barrier resins such as PVdC, EVOH and Nylon. Through encapsulation it is also possible to create 7-layer structures using a 5-layer die and 9-layer structures on a 7-layer die.
High Output Package
If high output is a must, critical line components can be enhanced to increase output by up to 50%. The high output package consists of:
- Low Melt Temperature Screws
- Low Pressure Die
- Efficient Cooling for Air Ring and IBC
- High Speed Winders
- Cooling Rollers on the Primary and Secondary Nips
Depending on the application, the addition of Macro's Binary Air Ring System with special IBC can also be integrated to boost output.
