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Blown Film Lines

Systems to manufacture blown film have formed part of ALPINE's product range since 1955. The reliability of these film blowing lines is well known, just as are the long years of experience we have had in the design and manufacture of such complex production equipment.

Our three testing centres - in Augsburg, USA and Japan - are equipped with state-of-the-art machines and components, and are used for both customer and development trials. Test series using the laboratory equipment can be carried out under as-real conditions so that the results fully reflect Alpine's capabilities.

Products

ALPINE Extruder Type HX

Today's extruders function in accordance with the Solid-Bed Feeding Principle and are equipped with grooved feeding sections which display the following design characteristics:

Longitudinal grooves which are tapered in the feeding direction
Intensive water cooling of the grooves
Thermal isolation between the grooved feeding section and the screw barrel

The extruders are designed to ensure high outputs whereby the output is proportional to the screw speed over a wide range. ALPINE HX extruders are compact, robust and highly efficient. The individual components are characterised as follows:

Extruder type	HX 50	HX 65	HX 75	HX 90	HX 105	HX 120
Srew diameter mm	50	65	75	90	105	120
Screw length L/D	25, 30	25,30	25,30	30	30	30
Maximum drive rating kW	45	80	105	140	200	260
Approx. output (PE-LD) kg/h	105	180	250	330	470	600

ALPINE Film Die Heads

Series X (patent pending)
The X series combines very successfully the technology of standard spiral distributor systems with experience gained from multi-layer plate die heads.

Characteristics:

Short melt channels
Optimised rheology
Low pressure drop
Completely coated melt channels
Excellent air distribution for IBC applications
Excellent temperature distribution
Effective insulation between IBC parts and the die head body
Optical working height
Long life
Fast and easy cleaning

Mono die heads

Type	BF 10-25 K2	BF 14-35 K2	BF 40-63 K2
Die diameter (mm)	100-250	140-350	400-630

Three-layer die heads

Type	TBF 16-32 X	TBF 25-50 X	TBF 56-71 X
Die diameter (mm)	160-325	250-500	560-710

Five-layer die heads

Type	FBF 16-32 X	FBF 40-55 X
Die diameter (mm)	160-325	400-550

Seven-layer die heads

Type	SBF 16-40 X	SBF 40-55 X
Die diameter (mm)	160-400	400-550

Nine-layer die heads

Type	NBF 40-56 X
Die diameter (mm)	400-560

ALPINE Cooling Systems

The output performance of the Hosokawa Alpine blown film lines could be considerably enhanced by the perfectly coordinated inner and outer cooling. In general Hosokawa Alpine cooling systems require the use of calibration baskets. All systems are available for the standardized tool diameters and different raw materials. The fan performance depends on the required output performance of the blown film line. The following 3 cooling systems are used as ideal solution for the respective requirements:

Operation mode: short neck

Hosokawa Alpine cooling ring CR with duallip, insert AX and cooling tower IBC that is adapted to the short neck operation mode.

Operation mode: long neck

Hosokawa Alpine cooling ring CR with duallip, insert LX and cooling tower ICS that is adapted to the long neck operation mode.

Highest output performance

The highest output performance is expected from precisely defined film programs. Hosokawa Alpine realized the highest output performance through the use of a double cooling ring CCR. The outer cooling of the blown portion is thus even more efficient and the output performance significantly increased. The Hosokawa Alpine double cooling ring CCR cooperates directly with the inner cooling IBC, which is specifically adjusted to this increased output performance. For optimum adjustment of the cooling performance the upper cooling ring of the double cooling ring CCR can be height-adjusted through the use of a motor.

External cooling rings

Type	CR 32	CR 50	CR 71
Output performance kg/h	until 360	until 500	until 710
Outer cooling fan kW	15	22	31
IBC-fan supply air kW	7,5	11	11
IBC-fan exhaust air kW	7,5	11	11

Bubble Control – BDC

Modern blown film systems are in general equipped with an inner cooling system. They continuously exchange the air in the film bubble and the blow control ensures that the diameter of the film bubble does not change. The new BDC system is another important step towards automated and continuous control of the processes in blown film lines.

ALPINE Film Take-off units

Take-off systems

ALPINE offers various take-off systems which can be equipped for the required layflat widths and take-off speeds:

Oscillating take-off unit with horizontal turning bars type AON
Oscillating take-off unit suspended type AHR

Take-off speeds

As standard the systems are equipped for take-off speeds up to 150 m/min.
Take-off speeds up to 220 m/min. and more are optionally available.

Collapsing frames

To ensure optimal collapsing can be achieved for all applications 3 versions are available:

Roller collapsing frames none driven
Wooden collapsing frames
Combined collapsing frames

Adjustment of the collapsing geometry can be effected manually or electrically.

Collapsing rollers

Steel-rubber-covered pair. The steel roller is driven by a frequency controlled servomotor.
Tempering is available for both rollers

Working widths in meters

Type	1.0	1.3	1.6	2.0	2.5	3.0	3.5
AON	x	x	x	x	x	x	x
AHR	x	x	x	x	x

ALPINE Film Winders

Alpine’s new state-of-the-art Winding technology is a perfect compliment to our Extrusion technology to produce consistently perfect rolls of converter grade film.

Alpine’s new generation winders produce perfect, uniformly wound film rolls which maximize converter efficiency.

FEATURES

Cylindrical film rolls
Perfectly straight edges; single or multi-lane
Precisely controlled winding tension
Highest conversion

LAYOUT OPTIONS:

Single station winder
Dual winders (Face-to-Face or Back-to-Back configuration)
Secondary nip between primary nip and winders can be mounted on:
- Winder frame
- Tower mezzanine
- Floor level between winding stations

SPECIFICATIONS:

Servo controlled contact pressure
Longitudinal slitting for multi-lane operation
Option for driven rollers (heated or cooled) for web tempering

WORKING WIDTHS

4 working widths between 1.3 m and 2.5 m

ALPINE Film Orientation Line MDO

ALPINE supplies monoaxial gap orientation lines (MDO) as downstream equipment in the film manufacturing process. MDO enables processors to modify properties such as shrinkage, tear, and density for their specific end-use application. These property enhancements are achieved with reduced raw material consumption.

Application examples for oriented films:

transparent mailing envelopes, lamination film for example for stand-up pouches, label films, shipping sack films, breathable films.

Characteristics

Working widths up to 2500 mm
Exit speeds up to 200 m/min
In-line operation with a blown film line or cast film line or out-of-line operation from roll to roll

Technical Data

Heating units

Large circumferential contact for efficient heat transfer
Tempering with oil or water
Two tempering units number 1 for heater roller 1, number 2 for heater rollers 2 and 3
Independent drive and control on each heater roller
Lay-on rollers on the first and second heater rollers

Orientation unit

Orientation ratio stepless up to 10:1
Tempering with oil or water
Independent drive and control for each steal roller
Two tempering units one for each steal roller
Pneumatically operated rubberised rollers

Tempering unit

Tempering with oil or water
Independent drive and control for each tempering roller

Cooling unit

Large circumferential contact to ensure efficient film cooling
Cooling medium water
Lay-on roller on the first cooling roller
Cooling unit for all cooling rollers

General

Independent drive and control of each cooling roller

ALPINE Process Control

ExVis is the basic software of the ALPINE Process Control

ExVis – Extrusion Visualisation Program

This high performance software enables the collation, visualisation and filing of extrusion process data.

The complete extrusion line is displayed on the monitor. ALPINE equipment is controlled by means of Siemens PLC equipment which intercommunicate via a Siemens profibus. Entry of data is effected via a touch-screen and a keyboard. Operating data are prepared of bus-data transfer via defined interfaces. The display of all data is effected either graphically or numerically. Alarms and error messages are displayed in the same way.

ExVis contains a database which enables all data to be displayed in a diagram as a function of time. Evaluation and analysis of data is thus much simplified. Trends, film formulations etc. can also be stored.

OrVis – Orientation Visualisation Program

OrVis is a software for the control and visualisation which was developed to control the orientation process in ALPINE monoaxial orientation lines. It works autonomously in out-of-line units or under ExVis on in-line units where the data are supplied to the ExVis databank.

ProVis – Profile Visualisation Program

ProVis is software developed to control the POS system which improved the film thickness profile. It can operate autonomously or under ExVis.

POS – Profile Optimisation System

The POS system consists of the following hardware components:

PCS – Profile Control System

To ensure optimum film quality. The film profile is measured, controlled, visualised and documented.

PMS – Profile Measuring System

Profile measurement is effected with sensors in contact or optionally without contact to the film. Depending upon requirements the sensor is either mounted on a reversing unit or in the film collapsing system.

CRS – Segmented Cooling Unit

The CRS is an additional cooling ring with an independent blower. The air exiting from the cooling ring is divided into segments. Stepless solenoids regulate the amount of cooling air which effects the film thickness in the independent segments.

TRS – Segmented Heating

The TRS is an alternative to the segmented cooling ring. Independently controlled heater cartridges control the temperature profile around the circumference of the die.