Breathable Film Casting Machine adopts a modular structure, mainly composed of a twin-screw feeding system, a high-precision die head, a casting cooling roller group, a fully automatic center winding device, an online detection system, and an optional laminating and slitting unit. It is an industrial equipment designed for the production of high-performance breathable films.

1. Efficient plasticization

The core of Breathable Film Casting Machine adopts a twin-screw feeding system with a screw diameter of φ75mm and an L/D ratio of 36:1. It is designed for high melt index polyethylene and polypropylene materials. Its screw groove structure is a multi-stage distributed shear zone, which can achieve continuous plasticization and stable output. Driven by a high-torque drive motor, the melt plasticization uniformity is increased by more than 30%, and bubbles and crystal points are significantly reduced. It is suitable for precision casting of high-transparency and high-barrier film materials.

2. Uniform casting

The main cooling roller adopts a spiral flow channel design, with a roller diameter of φ800mm and a length of 2600mm. The Breathable Film Casting Machine is equipped with a built-in circulating water constant temperature system, and the temperature control accuracy can reach ±0.5℃. This design effectively avoids uneven cooling and local ripples, making the surface of the film material smoother and more delicate, and the air permeability distribution is uniform, which is particularly suitable for the manufacture of baby diapers and medical protective materials.

3. Intelligent winding

Equipped with an automatic center winding system, the maximum winding diameter can reach 1200mm, equipped with tension closed-loop control technology, and the adjustment accuracy is ≤±2N. The automatic roll-changing mechanism adopts servo positioning, the roll-changing time is less than 15 seconds, and the continuous operation is uninterrupted, which effectively reduces the generation of waste and improves the efficiency of the production line. An auxiliary pull-out shaft system is also available to facilitate quick unloading and save human resources.

4. Energy-saving and efficient

Breathable Film Casting Machine uses a frequency converter to intelligently control the power consumption of the heating zone and the drive zone, and cooperates with the heat recovery system and the roller insulation structure to achieve an overall energy saving rate of more than **18%**. The heating zone is equipped with a 9-segment PID intelligent temperature control module with a control accuracy of ±1°C, which is not only energy-saving but also prevents thermal degradation of raw materials.

5. Multi-dimensional detection

The online defect detection system can be integrated to realize real-time monitoring of film surface damage, black spots, and crystal points; with the online thickness detection device, the thickness control accuracy can reach ±0.002mm. At the same time, it supports the MES production line management system, with functions such as order scheduling, data statistics, and remote fault diagnosis to realize digital factory operation.

6. Function expansion

According to customer needs, the online black metal tape laminating system can be optionally equipped. The Breathable Film Casting Machine is suitable for manufacturing food packaging or disposable medical dressing backing film; it can also be equipped with an online embossing device with adjustable pattern depth to enhance the aesthetics and tactile properties of the film material.

1. Baby Diaper Production Line

The breathable film casting machine is widely applied in baby diaper production, ensuring the backsheet maintains excellent breathability and softness. This application helps Hengan Group enhance its premium baby diaper series, improving comfort for infants and reducing the risk of skin rashes.

2. Adult Incontinence Products

In adult care hygiene, breathable films provide superior moisture control and leakage resistance. Windeed utilizes this machine to upgrade its adult incontinence product lines, offering better dignity and comfort to long-term users.

3. Feminine Hygiene Pads

The breathable film casting machine is critical for manufacturing sanitary napkin backsheets. Qifeng has integrated this technology to achieve lighter, thinner, and more breathable feminine hygiene products that enhance user experience.

4. Medical Protective Films

Breathable films are also used in surgical gowns and medical drapes, combining liquid resistance with high air permeability. Huahan applies this equipment to expand its healthcare-grade material production capacity.

5. Household Hygiene Products

For table covers, mattress protectors, and disposable household hygiene materials, breathable films offer an economical yet comfortable solution. Zhuangda Material leverages this application to serve the domestic consumer goods market.

6. Packaging Industry

Breathable films are also applied in packaging where vapor control is essential. Quanta-gold Boat incorporates these films into special packaging lines, ensuring freshness retention for sensitive goods.

7. Industrial Nonwoven Laminates

Breathable films laminated with spunbond or meltblown fabrics form strong yet breathable composites. Xinsanhe applies this technology in nonwoven material production, serving both hygiene and industrial needs.

8. Disposable Protective Wear

For protective clothing, breathable films maintain comfort by reducing heat accumulation. Xinghuo uses the machine to develop breathable PPE materials for industrial safety.

9. Customized Hygiene Solutions

With flexible design options, breathable films are tailored for different regional markets. ACHOICE focuses on delivering customized breathable film applications to meet diverse consumer preferences.

Regular Cleaning and Calibration of the Screw System

As the core component for plasticizing and pushing raw materials, the screw requires thorough cleaning every 500 hours of operation to remove carbonized residue and prevent contamination of subsequent products. It is recommended to use a dedicated screw cleaner and relubricate the screw after cleaning to prevent gap abnormalities caused by thermal expansion and contraction. Precision calibration is also required every six months to maintain uniform feeding.

High-Precision Maintenance Mechanism for the Die

The die head, with a width of up to 4200mm, requires daily temperature disassembly and wiping after operation to prevent film residue from clogging the flow channel. Hot runner inspections are performed monthly to ensure smooth flow. If uneven film spraying is observed, the hot plate temperature zones must be checked immediately and the PID parameters readjusted to ensure uniform and smooth film discharge.

Cooling System Circulating Water Quality Management

Maintaining cleanliness of the cooling roller's internal water channels is crucial. It is recommended to replace the softened water and check the circulation pump's function monthly to prevent scale accumulation that can affect cooling efficiency. Regularly inspect the cooling roller's bearings and seals for wear. Replace any unusual noises or dripping components immediately.

Automation System Software Maintenance and Upgrades

For equipment equipped with MES systems and modules such as defect detection and thickness measurement, it is recommended to perform quarterly software updates and sensor calibration to ensure data accuracy and system compatibility. A regular backup mechanism can be set up to prevent data loss and production disruptions caused by unexpected downtime.

Replacing Components in the Winding and Traction Systems

The winding shaft and auxiliary traction system are subject to mechanical wear. It is recommended to inspect the rubber pressure rollers and friction shafts every eight months and replace them promptly if signs of wear or fatigue deformation are present. Non-slip foot devices must be kept free of oil and contamination to prevent slippery surfaces that could affect operator safety.