Optimized Extrusion TechnologyE X T R O N U P T O 1 0 L AY E R S B L O W F I L M L I N E S

High technological knowledge and know-how, along with long time experience in the field of developing machinery for plastic industry, and customer oriented approach ensure than Extron is the right company to base partnership with.

We apply our best effort not only to provide you with state of the art new machinery, but also will offer you solutions for modernization and upgrading your existing lines. Our relatively small organization

with little red tape makes it easier to make strategic decisions or apply last minute changes to developing projects at hand.

We provide our customers with up to date machinery and latest technologies through all the history of our company, trying to step with new and answer the challenges of the changing world. We were the first to deliver 10 layer line in 2001.

Along with outstanding quality of our production lines we supply our customers with technological services, making their life easier.

We test and try different recipes for our customers so they can run the most suitable products for their lines with high efficiency. We help you to modernize your machinery and lead you to the new age technology. We help you to update any kind of machinery from any supplier, ensuring that it will work smoothly and carelessly.

Our professional personnel is available 24/7! You can call us or you can ask us to come on site.

Partnership

Extron Engineering:Results On Every Layercompany offering advanced technical solutions in extrusion and techniques for the plastic industry.

Extron has nearly 30 years of experience in designing and building of high-tech machinery for the major companies of the world in plastic, multi- and monolayer films as well as plastic piping. Extron machines and complete turnkey production lines are supplied to meet the exact requirements of the customers as well as top-level usability. The company policy is based on customer approached constant and continuous technical updating and active search for even more advanced technical solutions and innovation in extrusion. Optimum design and engineering of plastics processing machinery is based on the wide theoretical

knowledge and practical experience to find and complete customer-proven solutions. Computer-aided engineering, extensive know-how and highly qualified staff are our background to meet the future challenge of the plastics processing industry, especially in the field of co-extrusion. We also provide installation; start up and after sales technical and technological services.

Profitable Partnership

Tailored professional service, strong technical know-how, reliability and flexibility are our keys to true customer orientation and profitable partnership.

The Extron Customer Promises

• Reaction time 24/7. Our technical personnel is available all the time for your contact. We provide online monitoring of the problem via internet and offer you a solution to it.

• The Extron machines and complete turnkey production lines meet the exact specific customer requirements.

• We always find the solution for arising problems offering various possibilities for modernization of existing lines.

Security For Your Business

• The optional Expanded Warranty gives more security for your business. Customer receives annual technical support along with spare parts for the line to ensure the proper workability of the machinery.

• Fast connections to the customer’s factories.

• Experienced personnel of Extron will help you find a solution to you problem.

2

is an innovative

Extron Engineering

3

Multi Layer Blown Film Line

LLDPE

EVA

TieEVOHTie

LLDPE

PP

EVA

PPPP2

TiePAPA

PATiePP

PPmPE

EVA

mPE

STRETCH HOOD

SAUSAGE PACKAKING

DEEP THERMO FORMING

Name of lineLayers / Die ø., mm /

Web Width, mmOutput, kg/h

3 / 200 - 500 / 1200 - 2600 200 - 700

5 / 300 - 500 / 1200 - 2600 300 - 600

7 - 10 / 300 - 500 / 1200 - 2600 300 - 500

Blow film lines with 10 layers are the perfect solution for high standard film, with outstanding thermoforming, stability, durability, gas permeability, chemical stability and other barrier qualities.

Extron blow film lines for 10 layer films allow the relatively cheap manufacturing of such films in single process using combinations of materials of different nature such as mixes of polyolefins (LDPE and HDPE), adhesives, GPPS, SBС, EVOH, PA6/66, PETG, PVDC, COC, PAA and Nano particles.

Blow film line range of Extron and applications:

• Rane III – 3 layer lines manufacture sillage, stretch, shrink, lamination, foamed and pearlised films

• Rane V – 5 layer lines manufacture twist wrap and barrier films

• Rane X – 7-10 layer lines manufacture high barrier films with EVOH, EVA, PA, etc.

4

5

Real-Time Monitoring, Real-Time Value

Gravimetric control system (GCs) monitors the raw material consumption in real-time mode and compares it to the haul-off speed.

If any deviation of actual metric weight from its calculated value occurs, GCS corrects the speed of the extruder or the speed of the haul-off unit.

According to the Customer’s demand and requirements, the GCS instrumentation and software are delivered either for single-flow or multi-flow monitoring. A basic GCS is comprised of following components:• feed hopper• weighting hopper• metering valve and frame• PLC with single user interface• line speed measurement with

closed loop control• screw rotary speed

measurement• measurement of screw output

per one revolution (gr/r)• interfaces for upper level

control and printer (optional).

• Centralized vacuum pump, filtering system and additive material handling station

• Transportation from storage silos to day silos.

Raw material transportation

6

TYPE EX-18 EX-35 EX-50 EX-60 EX-70 EX-90 EX-120 EX-160

Screw diameter mm Ø 18 Ø 35 Ø 50 Ø 60 Ø 70 Ø 90 Ø 120 Ø 160

Length/diameter ratio L/D 24 30 30 30 30 30 30 30

Motor power kW 1,5 13,2 30 55 75 160 250 355

Single Screw Extruders: Ultimate Productivity and UsabilityBased on decades’ of experience, Extron have developed a range of high output single-screw extruders to cover the majority of extrusion applications.

The standard features include heavy-duty gear, electronically controlled AC-drive using the latest digital technique and PLC (programmable logical control) enabling complete diagnostics of machine and process parameters.

A combination of grooved feed section, removable sleeve and precise temperature control of cooling water guarantees constant output without pressure variations. Barrier screw designed for customer’s raw materials gives high output with excellent melt homogeneity and exact melt temperature.

The product range comprises extruders with screw diameters from 18 to 160 mm.

General characteristics:

Barrier screwNitrated steel, HV 950 – 1000

Grooved feed bushUsed with a barrier screw enables high plastification rates and low melt temperature

Extruder barrelNitrated steel, HV 950 – 1000 Temperature control zones, heating/coolingHeating zones of extrusion die flange and die head flang

7

Blown Film DiesAll blown film dies are computer modelled for optimum melt flow channel configuration and rheological compatibility. The spiral distributor is designed to provide a balance between minimum residence time, reduced sensitivity

to resin changes and uniform polymer flow. Dies are available as oscillating or stationary model. Extron also delivers versatile side fed dies for barrier films consisting of sophisticated multi layer structure.

Cooling Systems

Bubble Basket

High output blown film lines have both external and internal bubble cooling. The IBC-system with precise adjustment of the bubble diameter guarantees an exceptionally wide BUR-range and excellent gauge uniformity especially on thinner films. A

combination of external and internal bubble cooling, an extra cooling section between collapsing frames and water cooled nip rollers guarantees optimum cooling, excellent lay flat quality and minimized line height.

The frame construction with motorized height adjustment gives needed stability to the bubble.The adjustment for the bubble diameter is motorized and centralized. All segments move radially together, towards bubble centre. The bubble basket provides a one-touch adjustment to the sizing arms allowing quick and easy control of the bubble. Teflon

rollers on the sizing arms provide an “easy-slip” surface for the film, minimizing drag.An automatic widht control is connected tot the diameter adjustment through PLC. Non-contracting, accurate ultrasonic sensors with IBC (internal bubble cooling) systems assure just the right lay-flat of the film.

8

Haul-offThe Extron haul-off units are manufactured with emphasis on quality, the strong construction guarantees long life operation.

The nip-roller and the collapsing frame operate integrally ensuring that the film comes out full-width without any wrinkling problems. The collapsing frames are motorized making adjustments of them very easy. In addition, the centralized provision for adjustment enables repeatable positioning according to specific product recipes. Motorized

side guiding frames or side gusseting assemblies are easy to add to this system. The compression force of the nip can be adjusted accurately and corrected according to the film during production.

The haul-off can be equipped with double cooling rolls, which cool the film evenly from both sides. Even and double sided cooling guarantees high production rate and wrinkle-free film.

The production program of Extron includes both horizontal and vertical oscillators, combining

the haul-off with an oscillator ensures perfect geometry of the film reel. Based on our long experience we usually recommend HFO (Horizontal Film Oscillators), which enhances product quality and eliminates problems with film wrinkling and lateral movement.

In all haul-off units we use AC-Servo motors for nip rollers and oscillating units. The servomotors are controlled with accurate servo drives that are connected to the RTS (Real Time Systems) process control.

9

Rewinding Technology: Extron WindersFor winding of tackifiered films, like stretch film, Extron delivers double decked winders with independent winding stations on top or back to back type center winders.

A wide selection of Extron winders ranges from basic surface models to fully automatic center winders with gap winding option.

High speed winders with multiple inline slitting capability, automatic roll change and integrated robotic system for handling of winding shafts, winding cores and finished rolls are features of Extrons modern winding technology. The Extron winders are highly automated by using PLC, and latest digital drive systems which make it easy to follow up and to analyze the

process. The Corona Treating Unit has been selected on the basis of our long-term experience. The properties of the Corona Treating Units are defined according to the customer’s needs.

10

Total Control - Always in Real-TimeThe control system constantly monitors every stage of the manufacturing process and corrects current production parameters. The process control system of an extrusion line is PLC-based. And usually the PLC-unit of an extruder serves the entire production line. BASIC CONTROL SYSTEM provides the following services to the manufacturing process:

• Speed control of all installed drives of the production line.

• Temperature control and adjusting to the set point.

• Monitoring of melt pressure temperature.

• Web width control and monitoring.

• Thickness control and monitoring.

• Raw material flow control.• Alarm reporting and diagnostics

Integrating the GRAVIMETRIC CONTROL into the basic control system of an extrusion line enables enhanced process monitoring and run mode optimization. Due to the effective process management, the operating control system optimizes the pipe manufacturing process and saves raw material and other resources.

The Extended Operation Control SystemThe operation control system of a single extrusion line can be connected to a PC based upper level control system, which integrates and administers control systems of all installed production lines of the factory. The configuration of the system enables effective and comprehensive

process control, including operation security and coordination. The extended operation control system enables automation of the manufacturing process.

An automatic width control is connected to the diameter adjustment through PLC. Non-contacting, accurate ultrasonic

sensors with IBC (internal bubble cooling) systems assure just right lay-flat of the film.

For tacky surface films we have special Non-contacting basket with air cushion segments. When using rotating (oscillating) basket for oscillating die, the die- and basket oscillating are synchronous.

After Sales ServicesWe provide our customers with extended warrantee for three years. Extended warrantee guarantees smooth and careless functioning of the production line. We offer our clients one year service pack, which includes all the filters and oil for gear boxes, die and extruder

cleaning, checking and adjusting the equipment, all the necessary accessories and tools for the work, 24/7 response and remote support via internet, as well as information link.

We also provide our customers with various services such as

delivery of spare parts, possible constant monitoring of the lines, technical support in case of emergencies, modernization of the lines, technological support when customer changes the recipes and other related services.

11

Extron Engineering designs and manufactures machinery and provides advanced technology for the plastics industry.

Extron-MecanorTalttatie 4FI-37800 AkaaFinland

T +358 20 778 7800F +358 20 778 7937W www.extron-mecanor.com

Optimized Extrusion Technology