Home > Cast Film > CXL Cast Film Lines

CXL Cast Film Lines

Macro's CXL Series of Cast Film Lines are the ideal solution for processors seeking to take their barrier film capabilities to the next level.  Each line is designed to produce high performance barrier films in an efficient and cost-effective manner.  A versatile system, the CXL Series is capable of producing a variety of structures using different combinations of resins and layer configurations.

For certain applications, cast films offer advantages over similar films created with a blown film system. Cast films typically provide improved clarity, especially for PP, higher gloss, lower haze, better gauge uniformity, unequalled flatness, enhanced thermoformability, including deep draw forming and better flexibility in barrier resin selection (PP, PA, EVOH, PVdC).

Applications

Typical applications of the CXL Series include high performance barrier films with combinations of PA and EVOH for food packaging and medical applications.  In addition to these traditional barrier films CXL lines are capable of producing barrier films with PVdC, by means of PVdC encapsulation.  Other applications include the production of cast polypropylene (cPP) films, stretch films, thermoforming films and specialty films with tacky layers.

Typical materials processed on CXL 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

MacroPlast Extruders are designed to provide superior melt quality and throughput for a wide range of polymers of varying rheology.  All extruders come standard with either air or water cooled barrels and with 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).  A gear pump can be incorporated to prevent surging with reclaimed material.

Coextrusion Die

All CXL lines are outfitted with a variable geometry feedblock featuring a selector plug that can be used to redirect individual extruder flow to different layer positions in the film. 

Each line is equipped with an autogauge cast coextrusion die, carefully selected to match the application(s) and supplied by one of the industry's best manufacturers.  Internal deckles are included with each die to allow changes to the film width.

To save costs associated with edge trimming waste, the CXL Series includes the option of edge encapsulation, which extrudes the film edges using a single resin, typically lower cost LDPE.  With this option the edge trimming is done in two steps: the first step is the trimming of the LDPE edge, which can be recycled; the second step involves trimming the small remaining edge composed of more expensive resins, such as barrier and tie resins, that goes to waste.

Through layer encapsulation, PVdC can be incorporated as the barrier resin.

A dual chamber vacuum box is connected to the die body to boost output, improve the film quality and reduce condensation on the cast roll surface.  The vacuum box has its own independent adjustable blower to allow enhanced control of air removal.

Film Casting Unit

The film casting unit is used to cool the melt after it leaves the die by passing it over two independently driven cast (chill) rolls. The temperature of these cast rolls are kept uniform by circulating chilled water through their interiors.  The cast rolls surface speed is set higher than the melt leaving the die to reduce both the width and thickness of the film as it is formed. 

The CXL Series is outfitted with a versatile film casting unit featuring exceptional standard features along with a wide range of options.  A range of surface treatments is available for the cast rolls, including chrome and anticorrosive treatments.  An air knife is provided to press the film surface against the main cast roll with a continuous blast of air.  This eliminates quality problems that can arise from trapped air between the film's surface and the cast roll.  The air knife features adjustable lips and an independent, adjustable blower.  Edge pinning by high voltage electrodes is also included to ensure the film's edges are necking properly.  The unit is designed and pre-drilled for an optional third cast roll.  For embossing applications, a pressure rubber roller can be added as an option. The film casting unit comes standard with a cleaning roll to remove condensed gases expelled from the raw materials.  The cleaning roll can be upgraded to a three-roll cleaning system with adjustable positioning.

Automated Gauge Control

To enhance the gauge of the product, any CXL line may be equipped with automatic gauge control system comprising of a flat scanner with a beta, infrared, or X-ray sensor.

Trim and Slitting

Each CXL Series line is equipped with an edge trimming/slitting station to remove edge trim and for creating multiple rolls.  Trim removal is performed via venturi system or trim winders.  Optional repellitizing system is also available.

Winder

To complete the line, the right winder is needed.  Macro provides top of the line center-turret winders for its cast film lines and with over 30 years of winding experience, we'll help you decide which winder is right for your applications.

All CXL Series lines come equipped with a fully automatic AUTOMAX-T center turret winder that delivers high quality finished rolls.  The winder is equipped with a gap winding feature with a linear lay-on roll.  It also includes a bidirectional winding feature that allows rolls to be wound either with the treated side in or out.

Programmable taper tension control is provided to allow the operator to establish specific tension profiles during roll buildup.  A specially designed flying knife mechanism assures clean and perfect cuts every time. 

Macro's AUTOMAX winders provide flexibility and guarantee perfect roll geometry 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 sophisticated roll and shaft handling systems.

Supervisory Control System

To make operation simpler and enhance operational safety, all CXL 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, 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 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.