As the cornerstone technology of modern plastic processing, film blowing has greatly promoted innovation in packaging, agriculture and industry. ABA Series Film Blowing Machinesvarious blowing equipment stand out as the mainstream choice for high-end membrane blowers because of its unique multi-layer co-extrusion structure and efficient production capabilities. This paper systematically analyzes the core working principle of ABA Series Film Blowing Machines through four key stages of material plasticization, multi-layer co-extrusion, bubble inflation and cooling device, and demonstrates the technical advantages of ABA Series Film Blowing Machines through practical application.
1. Material Plasticization: precise control of the Screw Extrusion System
ABA Series Film Blowing Machines are driven by their screw extrusion system system, which combines materials science and hydrodynamics. The system Typically consists two independently controlled screw extruders (configuration A/B/A) for feeding, melting and homogenizing outer, middle and inner materials, respectively, and operates as follows:
1.1 Segmented Screw Design
Each screw is divided into feeding zone, melting zone and metering zones. compression ratio design is used in feed area to ensure uniform material conveyance. barrel heat transfer and presoftening in barrel are used on pellet surfaces. The melting zone is achieved by gradual reduction of screw pitch and viscous flow temperature (e.g. 105-135°C in PE and 164 – 175 ° C°C in PP) by a combination of mechanical shear and thermal conduction. The measuring area is maintained at a constant temperature to ensure uniform melt viscosity in subsequent co-extrusion.
1.2 Temperature Gradient Control
The system achieves zoning heating and cooling along the screw axis to establish a precise temperature gradients. The feeding temperature of PE materials is between 50 ° C and 90°C, the flow temperature in the melting zone area gradually increases to viscous temperature, and the flow temperature in the measuring area is stable. The mold contact area should be 10–30°C cooler to prevent the membrane from cracking. This dynamic temperature control strategy ensures the fluidity of the material while reducing the risk of thermal degradation.
1.3 Enhanced Mixing Capability
For recycled materials or mixes with a lot of filler, the screws are built with barrier or pin structures. These structures make the melt shear more often. This helps spread the color masterbatch and antistatic agents evenly. In one real case, using reinforced stirring screws let the maker raise the calcium carbonate filler content from 30% to 60%. At the same time, the surface still met ISO 3 finish standards.
2. Multi-layer co-extrusion: engineering breakthrough in pipeline design
The big new idea in ABA Series Film Blowing Machines is their three-layer co-extrusion die structure. This structure uses fluid mechanics to make functional composite films.
2.1 Spiral Flow Path Design
The die employs a spiral distributor channels to guide A/B/A melt flow into a separate spiral channel. Compared with traditional molds, the design extends the melting residence time by 40%, achieves dynamic equilibrium of interfacial tension between layers and eliminates stress concentration. Experimental data show that helical grooves can enhance interlayer bonding strength to more than 2.5 N/15 mm.
2.2 Layer Thickness Ratio Adjustment
By adjusting die channel outlet gap (adjustable 0.1 – 3.0 mm), the system achieves a flexible layer thickness ratios of 1:3:1 to 1:11:1. For food packaging films, 80% recycled material + 20% LLDPE middle layer formulation combined with 100% original outer layer reduces costs while maintaining printability.
2.3 Material Compatibility Expansion
Die assembly made of 38CrMoAl nitrided steel is ultra-precision machining to achieve a Ra0.2 μm surface roughness, which is compatible with PE, PP, PA, EVOH, and other materials. One example of an enterprise application demonstrates that, with parameter adjustment, a single mold could produce between 0.008 mm of barium 0.008 mm保鲜膜 (preservation film) and 0.2 mm of industrial packaging film.
3. Bubble Inflation Molding: Synergistic Control of Fluid Mechanics and thermodynamics
The transition from melt extrusion to film formation involves complex rheological and thermal changes during bubble inflation and traction.
3.1 Blow-Up Ratio Control
Compressed air goes in through the mandrel. This makes the bubble grow. The bubble diameter becomes 2.5 to 4 times the die diameter. This is called the blow-up ratio. The closed-loop pressure control system changes the air pressure by itself (0.1 to 0.5 MPa). It does this based on how stretchy and thick the material is. This keeps the thickness variation across the film at or below 3%. For making 0.015 mm CPP film, the blow-up ratio is controlled precisely. This gives a longitudinal to transverse tensile strength ratio of 1:1.2.
3.2 Draw Ratio Optimization
traction rollers induces molecular chain orientation by stretching bubbles 4 – 6 times the extrusion speed (tensile ratio). The servo-driven dual-roller differential traction device adjusts roller speed ratio (1:1.02) to eliminate internal stress. The experimental results showed that optimized draw ratios improves the impact strength of the film darts by 18% and heat seal strength 15%.
3.3 Bubble Stability Enhancement
To address bubble oscillation during high-speed production (production line speed >100m/min), the system integrates IBC (Internal Bubble Cooling) technology. The annular air duct send cooling air to the inside of the bubble at 15–25°C, reducing frost line height by 60%. This increases the rate of production by 30% while maintaining thickness variation within ±1.5%.
4. Cooling Setting: Phase Change Control Precision Engineering
The physical properties of the films depend on cooling process, and the crystal structure is controlled by the ABA series of machines using a multi-stage cooling system.
4.1 Dual-Air Ring Cooling
The upper ring provides cooling air at 45°C and the lower ring provides air at 40°C at 15° C to relieve internal pressure. The temperature differential control maintains crystallization 35 – 55%, satisfying different light transmission and toughness requirements.
4.2 Water-Cooling Assistance
For high barrier films, optional water-cooled rollers control surface temperature (20–40°C) and exposure time (0.3–0.8 s), resulting in a 20% increase in crystallinity of EVOH barrier layer crystallinity. This reduces oxygen permeability to less than 0.5 cm3/(m2·24h·0.1MPa).
4.3 Online Thickness Monitoring
Integrated β-ray or infrared thickness gauges provide real-time monitoring (sampling frequency >1,000 times/min). In a closed-loop quality control system, when the deviation exceeds set value, the system automatically adjusts the displacement (accuracy 0.001 mm) or traction speed of the die bolt. Production line data showed that the Cpk values increased from 1.0 to 1.67 after implementation of the project.
V. Technological Advantages and Application Scenarios
The core value of ABA series machine tools lies in balancing performance and cost through structural innovation:
5.1 Material Cost Optimization
The intermediate layer can be made of 80 per cent recycled material, protected by virgin outer layers, reducing raw material costs by 10–15%. One food packaging enterprise reportedly produces 50,000 tons a year, saving more than $280,000 a year.
5.2 Functional Portfolio Capacity
Layer combinations also has high barrier (EVOH), high toughness (POE) and anti-static (carbon black masterbatch) properties. For pesticide packaging films, the PA/EVOH/PE structure water vapor transmission to 0.2 g/(m2·24h) while also resisting chemical corrosion.
5.3 Production Efficiency Improvement
Three-layer structure, material changeover time reduced by 70%, automatic rewinding, 24 hours non-stop operation. One case study demonstrated that Overall Equipment Effectiveness (OEE) increased from 65% to 82% with ABA.
Conclusion:
ABA series blower achieves high efficiency, precision and flexibility through the collaborative innovation of screw extrusion, multi-layer co-extrusion, bubble inflation and cooling system. The main idea of this technology is to put together materials science, fluid dynamics, and control engineering. This helps meet strict packaging needs. It also helps support the circular economy and sustainable development. As bio-based materials and nanocomposites keep improving, ABA technology will keep moving forward. It will aim for better performance and lower energy use. This will shape the future of film making.
