Cast Film Production Line consists of a screw extrusion system, a high-precision die head, a spiral cooling roller, an online printing unit, a film guide system, an online trimming and recycling device, an automatic winding device, a tension control system, and a central control platform. It is a set of highly integrated automation equipment that integrates cast film extrusion, online printing, and automatic slitting.

Highly integrated design: one-time molding, coherent and stable

Cast Film Production Line realizes the three functions of cast film-printing-slitting on one line, avoiding the repeated handling and clamping of traditional film rolls between equipment. Taking Cast Film Production Line as an example, the film width is 2200mm and the maximum winding diameter can reach Φ1000mm. The whole machine runs continuously, eliminating the time required for the intermediate process and improving production efficiency by more than 30%.

High-precision molding: precise matching of die head and extrusion

The die head width supports up to 3000mm, and with the Ф150mm+Ф90mm twin-screw co-extrusion system, the film material weight range is 14-60g/㎡, and the thickness control uniformity is better than ±5%. It can realize co-extrusion of single-layer, double-layer and three-layer structural film materials to meet the needs of different functional films.

Energy-saving operation: significantly reduced operating costs

The whole line adopts low-energy-saving drive and thermal control system, and the energy consumption is reduced by more than 20% compared with the traditional three-stage process equipment. Cast Film Production Line occupies a compact area, effectively reducing the workshop area and the number of manual configurations, and is particularly suitable for efficient and intensive production bases.

Flexible adjustment: fast switching of multiple varieties

The system supports online replacement of key indicators such as printing color group, film width size, thickness parameters, etc., to meet the market needs of multiple categories and small batches. 1-2 color online printing configuration makes it possible to quickly change the printing content, greatly improving the flexibility of product delivery.

Online intelligent system: visualization of the entire process

Optional MES digital system, automatic thickness detection system, defect monitoring system, to achieve real-time monitoring of production status, data traceability and automatic warning. The online trimming and recycling system of edge materials further improves the utilization rate of finished film, which can reach more than 95%.

High-speed production line for baby diaper bottom film

Cast Film Production Line is deployed in the Nan'an plant of Hengan Group to produce PE bottom film for baby diapers. Cast Film Production Line integrates printing and slitting functions, effectively reducing the material damage rate caused by intermediate transfer, achieving zero failure rate for continuous 8-hour operation, and adapting to the high-beat packaging line of Hengan Group.

Color printing film for sanitary napkins

Cast Film Production Line is used in P&G OEM factories to manufacture packaging films for the Always series of sanitary napkins. The built-in 1-2 color printing unit meets the brand printing needs, while maintaining the stable matching of printing and casting processes, and the consistency of product heat sealing performance is improved by 15%.

Cast bottom film for pet pads

This production line is used to manufacture PE bottom film for pet urine-absorbing pads, supporting the stable production of thin and light film materials below 14g/㎡. According to feedback from OEM factories cooperating with Hartz, the film thickness fluctuation of Cast Film Production Line is controlled at ±3%, ensuring the stable adhesion of the product's high-absorption layer structure.

Medical gasket impermeable packaging film

In the medical industry, Cast Film Production Line is used to manufacture the outer film of disposable mattresses for hospitals. Cast Film Production Line has strong stability and low foreign matter rate, supports production environments with high cleanliness requirements, and can be connected to online defect identification systems to ensure the consistency of batch quality of medical materials.

Food-grade transparent film substrates

In the food packaging production line of Saudi Arabian cooperative customers, this production line is used to produce frozen food packaging base film. The customer selected a Φ1000mm large-diameter winding configuration to facilitate docking with the back-end coating line, improve the efficiency of film roll replacement, and increase daily output by 40% compared with the original system.

Extrusion system maintenance: periodic inspection and lubrication control

The screw wear and melt pressure changes need to be checked every 500 hours of operation, and the system should be cleaned with standard cleaning materials; it is recommended to replace the lubricating oil of the main reducer every 2000 hours to ensure transmission efficiency and system life.

Die head system maintenance: cleaning frequency and temperature control management

The die head lip needs to be manually cleaned every week to prevent carbide accumulation from affecting the uniformity of the film material. The die head heating system regularly detects the resistance of the heating rod and the response speed of the thermostat to ensure uniform heating and avoid thickness instability caused by temperature difference.

Printing unit maintenance: color group replacement and ink path management

When using the printing function, the printing plate, scraper and ink pump system need to be cleaned every day to prevent pigment deposition or adhesion from causing printing failure next time; the ink filtration system should replace the filter element once a week.

Slitting and winding system: tension calibration and shaft maintenance

The tension sensor of the automatic winding system should be checked and calibrated once a month to avoid film wrinkles and film breaks caused by tension fluctuations. The surface of the air shaft should be kept free of scratches, and the sealing ring should be replaced immediately if it is damaged to prevent affecting the efficiency of film roll removal.

Electric control and safety system: periodic inspection and software update

The main control system recommends checking the tightness of the wiring in the electric cabinet every quarter and cleaning the dust inside the cabinet; the software side, such as the MES system and the detection module, needs to be updated according to the manufacturer's upgrade cycle to keep the control logic compatible with the latest process.