Cast Film Integrated Production Line consists of extrusion system, cast film die head, cooling and shaping system, automatic printing device, film edge trimming and recycling system, winding module, electrical control system and other modules. The core structure has high integration, modular design and high-strength carbon steel frame. The whole production line realizes the continuous and synchronous automatic operation of the three core processes. It is an efficient and intelligent equipment integrating film casting, online printing.

1. Integrated structure: process optimization, double efficiency

Cast Film Integrated Production Line integrates the three key processes of casting, printing into one device, completely eliminating the transfer and clamping process of film rolls between different devices in the traditional mode. The maximum running speed can reach 150 meters/minute, effectively increasing the overall production capacity by more than 30%. It is suitable for two models, JW-LY2700-Y and JW-LY3000-Y, to meet different production requirements.

2. Save space and resources: small footprint, less waste

The space required for the entire line is about 70% of the traditional three-machine line solution, which can effectively reduce plant investment and labor arrangements. Equipped with an online edge trimming and recycling system, the edge utilization rate of the film is increased to more than 98%. The film weight control range of Cast Film Integrated Production Line is 14-60g/㎡, and the maximum winding diameter of the film roll is Φ1000mm, ensuring long-term uninterrupted continuous production.

3. Refined quality control: strong stability

Cast Film Integrated Production Line uses an online automatic thickness detection system and an automatic defect detection system to ensure consistent film quality per meter; the printing unit supports 1~2 color high-speed synchronous printing, and the overprint error is controlled at ±0.1mm, which is suitable for various patterns and logo printing, avoiding contamination and damage during the roll transfer process, and the overall yield rate reaches more than 98%.

4. Flexible production switching: to meet diverse needs

Cast Film Integrated Production Line adopts a servo control system and a modular setting parameter library, and production specification switching can be completed in just 10 minutes. It supports different width adjustments from 2200mm to 2400mm, and can respond quickly according to different orders, realizing small batch, multi-category, and personalized product customization capabilities.

5. Expandable system: intelligent upgrade

Cast Film Integrated Production Line supports optional digital MES management system to achieve real-time tracking of multi-dimensional data such as raw materials, temperature control, output, yield, and energy consumption. Other optional devices include: black metal tape online pasting system, winding auxiliary pull-out system, automatic feeding system, etc., to build a smart factory ecosystem.

1. Baby diaper manufacturing factory: Huggies

Huggies baby diaper factory has long used Cast Film Integrated Production Line for the synchronous molding and printing of base film and outer film to ensure clear patterns, uniform film materials, and printing synchronization error control better than ±0.1mm. The JW-LY3000-Y model is used to meet the monthly production demand of millions of pieces.

2. Adult care product manufacturer: TENA

At TENA's adult incontinence product factory, Cast Film Integrated Production Line is used for the production of medium-thick PE base films, supporting precise adjustment of thickness in the range of 40~60g/㎡. At the same time, integrated winding improves packaging efficiency, avoids film roll damage, and ensures long-term stability of product quality.

3. Pet product manufacturing base: Simple Solution

The Simple Solution urine pad production base uses Cast Film Integrated Production Line for film base material processing, quickly delivers short-cycle orders, and realizes personalized LOGO synchronous printing. Flexible process switching is an ideal equipment to meet high-frequency order changes.

4. Food packaging company: Sealed Air

Cast Film Integrated Production Line is used in the Sealed Air food-grade composite film production project for the molding, printing of the surface PE cast film, ensuring the stability of the film surface tension, adapting to heat sealing and composite requirements, and ensuring that the product passes European and American food contact safety certification.

5. Sanitary napkin factory: Whisper

Whisper uses Cast Film Integrated Production Line in its Southeast Asian factory to manufacture base film for sanitary napkins. The equipment supports continuous operation for 120 hours without interruption. The finished product has high flatness and consistent roll diameter, which greatly improves the connection efficiency and stability of the automatic packaging line.

1. Screw and die maintenance: regular cleaning to prevent carbon deposition

The screw and die should be fully cleaned every 400-500 hours of operation to prevent uneven plasticization caused by residual carbonization of polymers. It is recommended to use special cleaning materials and slowly remove them after heating to 180-200℃.

2. Cooling system maintenance: ensure stable temperature control

The circulating water status inside the cooling roller group needs to be checked once a month to ensure that the water temperature is controlled within the range of ±1℃. Regularly replace the water tank filter to prevent uneven surface cooling due to scale crystallization.

3. Online detection system calibration: accurate control of product quality

Online thickness detection and printing registration systems need to be calibrated once a quarter, and standard film samples are used to detect errors to ensure that ±1μm (thickness) and ±0.1mm (registration) are controlled within the tolerance range.

4. Winding system tension detection: prevent film surface wrinkles

The winding tension system needs to adjust parameters according to different film thicknesses, and check the lubricity of the winding auxiliary pull-out device every month to keep smooth operation and prevent wrinkled film, loose roll and other problems.

5. Maintenance of electronic control and servo system: ensure intelligent operation

The electric control box should be checked every two weeks to see if the cable connector is loose, whether the servo system operation data is abnormal, and keep the control system stable. It is recommended to use dry air or nitrogen to clean the inside of the control room to prevent dust accumulation from affecting the signal.