sizing and specisizing and speciifying a coifying a co-ex ... · sizing and specisizing and speci...

Sizing and SpeciSizing and SpeciFil

VijayVice

Mamata BramptoAhmedabaAhmedaba

ifying a Co ex Blownifying a Co-ex Blown m Line

By y Shankar e Presidenton Engineering Pvt.Ltd.ad Gujarat Indiaad,Gujarat, India.

FILM

Cast Blo

HM HDPE High Neck PPTQ D dHM-HDPE High Neck Bubble

(Mono / Multi Layer)

PPTQ Downward(Mono / Multi

Layer)

B i FilBarrier Film usPA, EVOH, PV

5-11 Layer

WHAT WE ARE GOING TO TALK ABOUT

own

PE / PP / Barrier Upward

i

PE/PP/ Barrier Downward

sing DC s

Non Barrier Film 2/3 Layer and above Mono Layer

3 layer and

above

Basic Blown FilmBasic Blown Film

Fi 1

Line Line

Elements of Blownn Film

Melt Orientation Th

Fi 3

heory

Blow Up Ratio (BUR) = B

BUR = 0.637 x La Die Dia

Drawdown Ratio (DDR) = Wid Film

Bubble Diameter Die Diametere a ete

ayflat Widthameter

dth of Die GapThickness x BUR

Theory Geometry oCollapsing BubbleCollapsing Bubble

of the

Rotation

Roll Defects

Gauge BandsNon-Uniform Surface HardnessConvex FaceConvex FaceConcave FaceTapered Through LengthWrinklesCorrugated EndsFuzzy EndsFuzzy EndsTelescopingBlocking, wound with too much tensiCrushed CoresRoll End ColorDamaged Edgesg gScuff MarksCore Ends

ProtrudingBuried

SplicesWeightDiameterRoll-to Roll-UniformityIdentification—missing roll labelsTreated SurfaceW d W Sid O tWound Wrong Side OutIncorrectly IdentifiedNot IdentifiedIncorrect Additive Levels

Film Defects

Low YieldGauge Bands, TDVariable MD GaugeVariable MD GaugeFlatnessCamberWrinklesVariable WidthUneven GussetsUneven GussetsFuzzy Ends

ion BlockingTreatment LevelSplittiness

MD Film StrengthgEdge CreasesDie & Weld LinesScratches

AppearanceGlossClarityColor

ImperfectionsApplesauceGelsA h dArrowheadsAir Ring Chatter

BlockingVery High GlossIncorrect Additive Levels

How To Configure A BlowWhat You W

The OnlC tCusto

Selection

wn Film Line To Produce Want To Sell?

ly Way Is iz domized

n Criteria…

A. Macro Level Config

Width Of TWidth Of T

guration (Customer’s requirement)

The LineThe Line

Co-ex blown film having capabiith li ibl h f iwith negligible chances of pin

the film wider in multiples of any mono layer film line.

More the width more the More the Die size more t

surfacMore the output Lowe

LoweLowescopLow

filmfilm LoweUltim

lity to offer better melt strength h l i h i t bl holes gives us a choice to blow

minimum size required against

Die Size for a given BURthe output due to higher cooling ce in and around the bubbleer the cost of manufacturinger the over all space required

h d der the man power required due to pe of viable automationswer the energy consumed per kg of

er the over all Wastagemate economy of SCALE

A. Macro Level Config

How Many

guration (Customer’s requirement)

Layers

Case StudyCase Study

L t U T k ALet Us Take A Films Required Fq

Edibl

C St d OCase Study On For Packaging Of g ge Oil

Th i i1. They are sensitive to c2. They pick up Moisture

spoiledspoiled.3. There are two type of

1. Hydraulic Rancidity: Faty yto growth of bacteria wthe product

2 Oxidative Rancidity: Fat2. Oxidative Rancidity: Fatform peroxides which g

4. Fats also absorb odor dgoods

liclimate / Oxygen and get

rancidity:-ts absorbs moisture and leads hich splits the fats and spoils

ts absorbs oxygen from Airts absorbs oxygen from Air gives rise to rancidity/ flavors from other

16

Mustard /Rapeseed

SaturatedProducts

Soybeans

Sunflower

Mustard /Rapeseed

5Palm

2Groundnut

y

6Butter

6Vanaspati

6Ghee

9Coconut

Higher the unsaturation percentage

946

Unsaturated fatty acidsd fatty acids

8416

8812

946

5050

8020

3763

3961

3664

1090

e, fast will be the spoilage

17

MATERIALS. N.

EVOH F at 0% RH2

PVDC1

HDPE5

PA 64

EVOH at 100% RH3

PP7

OPP6

LDPE (LLDPE)8

Ionomer10

EVA (>12% VA)9

LDPE (LLDPE)8

Oa2: permeability measured as cc.mil/100 in2 day.atm

H2Ob:g.mil/100 in2.day. @ 38 degree C, 90% RH

H2ObOa2

3.80.01

0.05-0.50.08

0.3-0.6530-250

24-262.6

1.15

0.25-0.7150

0.3-0.4110

1 0 1 5250 840

1.3-2.1226-484

3.9515-645

1.0-1.5250-840

m @ 23 degree C.

18

S N DescriptionsS N Descriptions

1 LL (C4)2 LD 3 m-LL4 HDPE5 Tie Layer Resin 6 Polyamide7 EVOH7 EVOH8 Master Batch

PricePrice

68.0084.0081.0068.00

140.00192.00360 00360.00135.00

Mono layer Structure:

No. of Layers

Polymer 45%

% Thickness

Total Thickness

Price

1

%LLDPE +10% HDPE+ 10% LDPE +30% m-LLDPE + 5% MB

100%

120 Microns

R 76 85Rs. 76.85

3 layer Structure:y

No. of Layers 1 (OUTER)

Polymer 70%LLDPE + 10% LDPE+ 20%m-LLDPE

% Thickness 20%% Thickness 20%

Total Thickness

Benefits

Price

•Distinct skin layers – slip on sealant for opestacking•Low COF on inner layers for faster speeds •Chances of least pin holes & hence down gChances of least pin holes & hence down g•Coloured master batch only in middle and/ •Possibilities of using PP, HDPE & PE in desbest of both world benefits against limitationSAVING OF RS 3 82 PER KG AS COMPA•SAVING OF RS.3.82 PER KG AS COMPA

2 3 (INNER)

75%LLDPE75%LLDPE + 10%HDPE+10%

LDPE+5MB

60%LLDPE +10% LDPE + 30%m-LLDPE

60% 20%60% 20%

100 Microns

Rs 73 03Rs. 73.03

en-ability & non slip on surface for printing &

on FFS machinesgauging to save on resin costsgauging to save on resin costsor outer layer to avoid contact with oilsirable blends in different layers available for

ns of mono layers to do soARED TO MONO LAYERARED TO MONO LAYER

5 layer Structure:

No. of Layers 1o o aye s

Polymer

65%LLDPE(C4) +10%LDPE+

20% TPolymer 20%m-LLDPE +

5%MB

T

% Thickness 35% 7% Thickness 35% 7

Total Thickness

Benefits

Price

e e tsExcellent Gas Barrier Properties in 5 Lain cool dry place)

2 3 4 53 5

Tie Poly Amide Tie60LLDPE(C4)

+ 10% LDPE +Tie Poly Amide Tie + 10% LDPE +30% m-LLDPE

5% 15% 7 5% 35%.5% 15% 7.5% 35%

100 Microns

Rs. 104.67

ayer (Shelf Life up to 6 months if stored

7 l St t

No. of Layers 1 (O) 2

7 layer Structure:

y ( )

l

70%LLDPE(C4) +10%LDPE+ 20%

85%LLDPEPolymer +10%LDPE+ 20%

m-LLDPE LLDPE0%LDP5%MB

% Thickness 17.5% 17.5%

Total Thickness

Price

BenefitsLower resin cost of the skin layers withSAVING OF RS. 1.11 PER KG IN 7 LA

3 4 5 6 7 (I)( )

+1 Poly

85%LLDPE+10%L

60LLDPE(C4) + 10% +1

PE+ Tie PolyAmide Tie +10%L

DPE+5%MB

LDPE +30% m-LLDPE

7.5% 15% 7.5% 17.5% 17.5%

100 Microns

Rs. 103.56

the same barrier propertiesAYER AS COMPARED TO 5 LAYER

7 layer Structure (Thicker Nylon L

No. of Layers 1

70%LLDPE(C4)8

Polymer

70%LLDPE(C4) +10%LDPE+ 20%

m-LLDPE

L1+

% Thickness 10% 1

Total ThicknessTotal Thickness

Price

Limitation:To improve on shelf life from 6 months toincreased to 30%.increased to 30%.

Layer):

2 3 4 5 6 7

85% 85%LLDPE+

60LLDPE(C4) + 10%LLDPE+

10%LDPE+5%MB

Tie PolyAmide Tie

LLDPE+10%LDPE+5%

MB

4) + 10% LDPE +30% m-LLDPE

10% 15% 30% 15% 10% 10%

100 Microns100 Microns

Rs. 132.50

o 12 months, PA layer thickness to be

9 layer Structure with split PA Laye

No of Layers 1 2 3No. of Layers 1 2 3

70%LLDPE(C4) +10%LDPE+ 20%

85%LLDPE

Polymer+10%LDPE+ 20%

m-LLDPE +10%LDPE+5%MB

Tie A

% Thickness 10% 15.5% 7%

Total Thicknessota c ess

Price

As PA has less flex crack resistance - 30% PHence, need to go for 9 layer line by splitting SAVING OF RS.8.27 PER KG COMPARED

ers:

4 5 6 7 8 94 5 6 7 8 9

85%LLDPE+10%LDP

60LLDPE(C4) + 10% LDPE

+PolyAmide Tie Poly

Amide Tie10%LDPE+5%M

B

+30% m-LLDPE

14% 7% 14% 7% 15.5% 10%

100 Microns00 c o s

Rs. 124.23

PA will crack and loose the barrier in long run. PA.7 LAYER FILM WITH 30% NYLON

9 layer Structure with EVOH:No. of Layers 1 2 3

Polymer

70%LLDPE(C4) +10%LDPE+ 20%

m-LLDPE

87%LLDPE+10%LDPE+3 Tie%MB

% Thickness 10% 31% 3%

Total Thickness

Benefits

Price

e e tsEVOH is introduced as a sandwich layer bproperty at same cost / same barrier propePRICE SAVING DUE TO USE OF EVOH A

4 5 6 7 8 9

60LLDPE(C

PolyAmide EVOH Poly

Amide Tie

87%LLDPE+10%LDPE+3%MB

60LLDPE(C4) + 10% LDPE +30% m-LLDPE %MB

4% 4% 4% 3% 31% 10%

100 Microns

Rs. 101.84

between two PA Layers to increase barrier erty at lower cost.AS SANDWICH LAYER RS. 22.39/KG

11 layer Structure

No. of Layers 1(I) 2 3 4

70%LLD

Polymer

70%LLDPE(C4)

+10%LDPE+ 20%

m-

88%LLDPE+10%LDPE+2%MB

88%LLDPE+10%LDPE+2%MB

Tie PA

LLDPE %MB B

% Thickness 10% 15.5% 15.5% 3%

Total Thickness

Benefits

Price

BenefitsEngineered the film to see that almost all more than 15.5% of total thickness to havSAVING W.R.T. 9 LAYER FILM RS.0.85 WITH MUCH BETTER FILM IN EVERY A

5 6 7 8 9 10 11(O)

88% 88% 60LLDPE(C4)

Polymide EVOH Poly

Amide Tie

88%LLDPE+10%LDPE

88%LLDPE+10%LDP

E(C4) + 10%

LDPE +30% m-LLDPE+2%

MBE+2%MB

LLDPE

15 5 15 54% 4% 4% 3% 15.5%

15.5% 10%

100 Microns

Rs. 100.99

layers are of similar thickness i.e. No layer ve inbuilt flexibility.

AND W.R.T. ORIGINAL 5 LAYER RS 3.68 ASPECT

A. Macro Level Config

Automation LeveAutomation Levebe produced

Auto Gauge Control System-Thickness measurement CapacThickness measurement – Capacbased, contact/ non contact Thickness Control – By segmentLip OR By Deflected Die Lip Gap

Auto GSM Control (Gravimetric Simple Hopper Loader with Off LGravimetric Feeding with Off LinM l i C Bl di (CMulti Component Blending (Con

Auto Width Control – For Non IBOthers – ITALYCS (Integrated TeSystem) Easy Change SCADA (System), Easy Change, SCADA (Acquisition) etc. for ease of ope

guration (Customer’s requirement)

el - Based on tolerances of film toel Based on tolerances of film to

citance based/ Nuclear based/ Infra redcitance based/ Nuclear based/ Infra red

ted Air flow/ temperature OR By Heated Die

Feeding) –Line Blending/ Single Component ne Blending

i / B h)ntinuous/ Batch)BC Lines/ IBC Lineemperature & layer Yield Control (Supervisory Control And Data(Supervisory Control And Data eration

Auto Gauge MeasurementAutomation:

g

Auto Gauge Cog

Di H t d Li TDie Heated Lip Type

Multi Component Gravimetric Dosing SystemGravimetric Dosing System

ontrol Systemy

A t G Ai RiAuto Gauge Air Ring

A. Macro Level Config

Output – kg/hr of the linOutput kg/hr of the linActual film requirement – 250 Thr/day & 26 days/month workiDie Diameter finally selectedDie Diameter finally selected –maximum film width of 2250 mExtruder Combination to match1:4:1…) – extruder size of 75-11:4:1…) extruder size of 75 1kg/hrCooling Capacity – In excess ofWinder Line Speed – Upto 150 mp pkg/hr for 20 micron film at 150Recipes to run – whether LL/mLmelt strength & less than 500 ksupported recipes (better melt more than 500 kg/hr)Issues of Blocking – Ambient teeffective height tacky materiaeffective height , tacky materialayer

guration (Customer’s requirement)

ne (Example – 500 kg/hr)ne (Example 500 kg/hr)T/ month (450 kg/hr based on 22 ng) 500 mm on 2375 mm Line to produce500 mm on 2375 mm Line to produce

mm (2.86 Blow Up Ratio)h with Layer ratio (1:1:1 or 1:2:1 or 120-75 to pump 180+450+180 = 810120 75 to pump 180+450+180 810

f 1 kg/hr/mm of die Diameterm/min to match the output of 500 / p00 mmLL rich, PP based, Nylon based (lower kg/hr) OR conventional LD/ HD/ MD strength & hence possible to offer

emperatures mainly in summer, plant ls like Primacor Affinity etc in innerls like Primacor, Affinity etc. in inner

A. Macro Level Config

RETURN ON INVESTRETURN ON INVEST◦ Interest on Plant & machin◦ Manpower Costs◦ Electrical Power Costs◦ Wastages & other costs

B i C f i / K◦ Basic Cost of conversion/ K◦ Value additions by putting

Raw material savings if anyRaw material savings if anyDown gauging possibilitiesProperties enhancements if

l f◦ Real Cost of conversion/ ◦ Pay Back period for the en

guration (Customer’s requirement)

TMENT (ROI)TMENT (ROI)ery Cost

KKg“Right” Blown Film line –

yy if anyf anykkgntire Investment

OPTION 1 OPTION 2OPTION - 1 OPTION - 2

660 mm 990 mmLine Width 32” 44”

Level of Automation Manual Winders Semi Automatic Winders

Approx Line cost Rs. 3,000,000/- Rs. 8,100,000/-

Land & Building Rs. 5,000,000/- Rs. 7,500,000/-

Approx Project Rs. 8,000,000/- Rs.15,600,000/-pp j , , , ,

Approx Ag. O/p 75 Kg/hr 150 Kg/hr

Investment / Kg Rs.106,667/ KG Rs.104,000/ KG

Fixed Cost / KGFixed Cost / KG

Interest @ 13% Rs. 2.02 Rs. 1.96

Variable Cost / KG

Power cost Rs 3 00 Rs 2 70Power cost(6 Rs/Unit)

Rs. 3.00(0.5 Unit/Kg)

Rs. 2.70(0.45 Unit/Kg)

Manpower cost p. a. Rs. 1,000,000/- Rs. 1,500,000/-

Man Power Cost/kg Rs. 1.94 Rs. 1.45Man Power Cost/kg Rs. 1.94 Rs. 1.45

Total Cost / kg Rs. 6.96 Rs. 6.11

OPTION 3 OPTION 4 OPTION 5OPTION - 3 OPTION - 4 OPTION – 5

1320 mm 1980 mm 2640 mm64” 84” 104”

Fully Automatic Winders with Single Component Gravimetric

Fully Automatic Line with Auto Gauge, GSM & Width Control

Fully Automatic Line with Auto Gauge, GSM & Width Control

Rs. 27,000,000/- Rs. 54,000,000/- Rs. 72,000,000/-

Rs. 10,000,000/- Rs. 15,000,000/- Rs. 15,000,000/-

Rs. 37,000,000/- Rs. 69,000,000/- Rs. 87,000,000/-, , , , , ,

275 Kg/hr 450 kg/hr 575 kg/hr

Rs. 134,545/ KG Rs. 153,333/ KG Rs. 151,304/ KG

Rs. 2.54 Rs. 2.90 Rs. 2.86

Rs 2 52 Rs 2 40 Rs 2 10Rs. 2.52(0.42 Unit/Kg)

Rs. 2.40(0.40 Unit/Kg)

Rs. 2.10(0.35 Unit/Kg)

Rs. 1,800,000/- Rs. 2,000,000/- Rs. 2,000,000/-

Rs. 0.95 Rs. 0.65 Rs. 0.50Rs. 0.95 Rs. 0.65 Rs. 0.50

Rs. 6.01 Rs. 5.95 Rs. 5.46

A. Macro Level Config

SUCCESS OF THE PSUCCESS OF THE P◦ Supplier of Blown Film Line◦ Raw material suppliers – T◦ Operating Team – The skil

guration (Customer’s requirement)

PROJECTPROJECTe – The experiencehe Knowledgel

B. Micro Level ConfiguExtruder Design◦ Type of Gear Box, motors & Drives –

Loop/ SensorlessLoop/ Sensorless ◦ Gearless Motors (New Energy Saving ◦ Compression/ Barrier Screws

Smooth Bore/ Grooved Feed Barrels◦ Smooth Bore/ Grooved Feed Barrels◦ L/D ratio◦ Metallurgy of the screw & Barrel – Bim

N d f ddi i l D i S◦ Need of any additional Dosing System◦ Pressure Gauge/ Transducers◦ Melt Temperature Indicators

d f l◦ Need of Temperature Control Units i◦ Need of any additional mechanical sa

discs

uration (M/c supplier’s expertise)

A/c Vector Flux Close

motors)

metallic/ Nitro alloylik Li id PIB D ims like Liquid PIB Dosing

d hn Feed throatafety devices like rupture

B. Micro Level ConfiguDie Design◦ Spiral mandrel/ Stackable/ ◦ Conical◦ Die Metallurgy – EN8/ EN 24◦ Spiral geometry in line with recipe &◦ layer ratio◦ Machining Accuracy◦ Die Gap as per the recipe

uration (M/c supplier’s expertise)

Streamlined Co(Single half module SCD)(Single half module SCD)

o-extrusion Die

37

B. Micro Level Configu

Air Ring & IBC Desig◦ Mono Lip/ Dual Lip/ Duo Cool Air R◦ Screen Type/ pancake Type IBC◦ IBC Control MechanismIBC Control Mechanism◦ IBC Response/ Features to control th◦ IBC an instrument to increase produ

uration (M/c supplier’s expertise)

gning

he width/ change the sizeuctivity

B. Micro Level Configu

Oscillating Haul Off◦ Horizontal◦ Vertical

uration (M/c supplier’s expertise)

f options

B. Micro Level Configu

Winder Options ◦ Surface/ Centre /Combina/ /◦ Maximum Line speed◦ Maximum Roll Diameter◦ Maximum Roll Weight◦ Various Features on roll ch

l di / h dli iloading/ handling options

uration (M/c supplier’s experience)

ation

hange over options/ air shaft

AmbientAmbient◦ Height of the Plant◦ Temperature and humidityp y

Selection of Utilitie◦ Chiller (chilled or cold water)( )◦ Compressed and Dried Air◦ Uninterrupted & Stable Power

A ili iAuxiliaries◦ Dryer for resins◦ Material handling System / Ce◦ Material handling System / Ce◦ Corona Treater◦ Web guide◦ Testing Equipments

es

supply

ntralized loading systemntralized loading system

BackgroundBackground –A Customer from Western Africanmillion people whose capital DAKAk d DAKAR C ll (Fknown due to DAKAR Car rally (FrIn 2006-7, company was producincomponents and 100+Tonnes of At t t f I j tiAt present, apart from Injection a4 Monolayers, 1 Dolci make 3 layefully loaded line (350 kg/hr) and upgraded by MBE for high outputupgraded by MBE for high output retrofitting Extruders , Die and AiThey also do contract packing & sAfricaNow they they will reach to 1000 installing 300 T/month new fully

Country Senegal with just 12.50 AR is a famous tourist place & well

P i D k 4000 k )rom Paris to Dakar – 4000+ km)ng 200+ Tones of Injection molding Flexible Packaging d bl ldi hi th hnd blow moulding machines, they have

er line (350 kg/hr), 1 MBE make 3 Layer 1 Taiwan make non IBC 3 layer (from 90 kg/hr to 180 kg/hr) by(from 90 kg/hr to 180 kg/hr) by r Ring

selling packaging machines in Western

Tones+ of Flexible Packaging after loaded 3 Layer Line from MBE

43

Major Requirements of Flexible Pa

Sr. No. Description

1 Milk Powder

2 Detergent

3 Seasoning Powderg

4 Water Pouches

5 Shrink Wrap p

6 Stretch Wrap

7 Biscuit Packaging Bagsg g g

8 Agriculture films

9 Edible Oil Films

ackaging in Senegal

Type of films

Lamination films

Lamination

Lamination

Surface printed Films

Heat Shrinkable Films

Machine Wrap Films

Surface Printed outer bags to replace CartonsUV based Films

Surface Printed Films

Major Requirements of Flexible Pa

Sr. No. Description

10 Cereals

11 Sugar

12 Coffee

13 Tarpaulin

14 Bleach packagingp g g

15 Lidding Films

16 Cosmetics

17 Fish Packaging

18 General Purpose Films18 General Purpose Films

ackaging in Senegal

Type of films

Lamination films

Surface Printed Films

Lamination

Films

Surface Printed Films

Lamination Films

Lamination Films

Fish/ lamination Films

LaminationLamination

Aft h i 2 3 lAfter having 2 no. 3 layline from Taiwan, they wexpansion in 2007 Theexpansion in 2007. Themachine capable to runstructures as a supplierstructures as a supplierSTRUCTURS:◦ 100% MLLDPE (Outer) : 10100% MLLDPE (Outer) : 10

Primacore (Inner)◦ 100% MLLDPE (Outer) : 10

Affi i (I )Affinity (Inner)These structures were tnon refined African Oilnon refined African Oil seal through contamina

li f D l i d 1yer lines from Dolci and 1 were looking for ey were looking forey were looking for following specific

r selection criterion.r selection criterion.

00% PP (Middle) : 100%00% PP (Middle) : 100%

00% HDPE (Middle) : 100%

to be used to mainly pack packing to have betterpacking to have better

ation.

For first time they werIndian supplier to run raw material structureh hthese structures in the

To build their confideconsultant visited Indimachine running in InThey were very impresVariation performanceGauge Control Systemthe performance of md id d f MBdecided to go for a MB

re interacting with any such stringent specific

es (they could not run l )eir existing lines)

nce, their technical ia to see one of our dia. ssed with the Gauge e even without Auto

m and convinced with achine and hence BE 3 L liBE 3 Layer line

BUR 1.5Good

LFW 20002.52 52.5

Better3.18Out of Range

Sr. No. Application tubeFilm Width(mm)

Thickne(mic )pp

1 Surface Print 680 sheet 702 Surface Print 680 sheet 803 Surface Print 680 sheet 904 Lamination 760 sheet 40

(mm) (mic.)

5 Lamination 760 sheet 356 Lamination 880 sheet 1007 Lamination 910 sheet 408 Lamination 940 tube 409 Lamination 1000 tube 809 Lamination 1000 tube 80

10 Lamination 1000 tube 2511 Lamination 1000 tube 3012 Lamination 1040 sheet 4013 Lamination 1040 sheet 3014 L i ti 1040 h t 2514 Lamination 1040 sheet 2515 Lamination 1060 sheet 5016 Lamination 1060 sheet 3517 Lamination 1140 sheet 60

2000 2000 2000 2000 2000Max. width BUR BUR BUR BUR BUR

2000 375 400 425 450 475ess

1360 2.31 2.17 2.04 1.92 1.821360 2.31 2.17 2.04 1.92 1.821360 2.31 2.17 2.04 1.92 1.821520 2.58 2.42 2.28 2.15 2.041520 2.58 2.42 2.28 2.15 2.041760 2.99 2.8 2.64 2.49 2.361820 3.09 2.9 2.73 2.58 2.44940 1.6 1.5 1.41 1.33 1.26

1000 1 7 1 59 1 5 1 42 1 341000 1.7 1.59 1.5 1.42 1.341000 1.7 1.59 1.5 1.42 1.341000 1.7 1.59 1.5 1.42 1.341040 1.77 1.66 1.56 1.47 1.391040 1.77 1.66 1.56 1.47 1.391040 1 77 1 66 1 56 1 47 1 391040 1.77 1.66 1.56 1.47 1.391060 1.8 1.69 1.59 1.5 1.421060 1.8 1.69 1.59 1.5 1.421140 1.94 1.82 1.71 1.61 1.53

After successful instalcustomer requested tomake 3 Layer Line in o

d f l land film quality.After having detailed slayer Taiwanese line, tnos. 50 mm extruderslEliminator Air Ring wa

in 2008. The line is ped bl h idouble the output wit

lation of first machine o upgrade their Taiwan order to improve output

study of their existing 3 to increase the output 3 s with 225 mm Die &

f d h las retrofitted to the line erforming with almost h b lh better gauge controls.

During the meeting atDusseldorf GermanyDusseldorf, Germany, desire to go for 4th linserve specific marketserve specific market Processed Meat and FiAs the market potentiAs the market potentilimited to 100 TPM onapplications as mentioapplications as mentiogot major market sharHence they ultimatelyHence, they ultimatelylayer blown film line won the cost of converson the cost of convers

t K-2010 show in the customer put histhe customer put his e as a 5 layer Line to like Edible Oillike Edible Oil, ish packing Industry.al for barrier film wasal for barrier film was

nly and three layer oned above had alreadyoned above had already re out of this 100 TPM. y decided to go for 3y decided to go for 3 with focus on reduction sion.sion.

BUR 1.5Good

LFW 272.52.52.5

Better3.18Out of Range

Sr No Application tubeFilm Width ThickSr. No. Application tube

1 Surface Print 680 sheet 72 Surface Print 680 sheet 83 Surface Print 680 sheet 94 Lamination 760 sheet 4

(mm) (mi

4 Lamination 760 sheet 45 Lamination 760 sheet 36 Lamination 880 sheet 107 Lamination 910 sheet 48 Lamination 940 sheet 49 Lamination 1000 sheet 89 Lamination 1000 sheet 8

10 Lamination 1000 sheet 211 Lamination 1000 sheet 312 Lamination 1040 sheet 413 Lamination 1040 sheet 314 Lamination 1040 sheet 215 Lamination 1060 sheet 516 Lamination 1060 sheet 317 Lamination 1140 sheet 6

750

2750 2750 2750 2750Max. width BUR BUR BUR BUR

2750 525 550 575 600kness 2750 525 550 575 600

70 2720 3.3 3.15 3.01 2.8980 2720 3.3 3.15 3.01 2.8990 2720 3.3 3.15 3.01 2.8940 2280 2.77 2.64 2.53 2.42

ic.)

40 2280 2.77 2.64 2.53 2.4235 2280 2.77 2.64 2.53 2.4200 2640 3.2 3.06 2.92 2.840 2730 3.31 3.16 3.02 2.940 1880 2.28 2.18 2.08 280 2000 2 43 2 32 2 22 2 1280 2000 2.43 2.32 2.22 2.1225 2000 2.43 2.32 2.22 2.1230 2000 2.43 2.32 2.22 2.1240 2080 2.52 2.41 2.3 2.2130 2080 2.52 2.41 2.3 2.2125 2080 2.52 2.41 2.3 2.2150 2120 2.57 2.46 2.35 2.2535 2120 2.57 2.46 2.35 2.2560 2280 2.77 2.64 2.53 2.42

Extruder 75 m

M Th h (K /h ) 225Max. Throughput (Kg/hr) 22533.3 : 33.3 : 33.3 % 18030 : 40 : 30% 18025 : 50 : 25% 15020 : 60 : 20% 10030 : 30 : 40% 13530 : 30 : 40% 13570 : 20 : 10% (PE : Tie : Surlyn) 210

mm 90 mm 75 mm Throughput(Kg/Hr.)

5 360 225 8105 360 225 8100 180 180 5400 240 180 6000 300 150 6000 300 100 5005 135 180 4505 135 180 4500 60 30 300

The plant is equipped Gravimetric Dozing SyGravimetric Dozing Sysingle component supAuto Gauge Control SyAuto Gauge Control Syair ring as against disklineline.Auto Width control syssecond linesecond line.SCADA system upgradoperate the machine toperate the machine tmodem.

with 1+3 Components ystem compared toystem compared to pplied in first line.ystem is with completeystem is with complete k type supplied in first

stem added in the

ded with navigator to thru’ internet againstthru internet against

A Lebanese owner with French a very small country dared to wM i l li lik D DMaterial suppliers like Dow, Duand hiring technical experts frofrom India to expand their busi1000 TPM (2011) within 4 yearsright Blown Film Lines to produWith a mix business of InjectionWith a mix business of Injectionflexible packaging customer coto expand in flexible packagingbusiness of Injection Mouldingbusiness of Injection Moulding flexible packaging mainly due treducing cost of Raw Material MB d bBased on above success customin other west African countries

citizenship with a small unit in work with best available Raw

E M bil S bipont, Exxon Mobile, Sabic etc. om France / UK and expatriates ness from 100 TPM (2007) to s by selecting / configuring

uce what he wanted to sell. n Moulding and blown filmn Moulding and blown film

ould derive that it is far better g rather than his earlier core due to better profit margins indue to better profit margins in

to value additions and scope of Man Power and Power cost.

i i i il imer is going to put similar units s like Ivory coast / Angola.

Brampton EngineeringWorld Leader In Blown Film

20082005BE2000

BE Milestones

History of blown film

1995of blown film

innovation

1990

1985197519751970

m TechnologyTenth AquaFrost® lineFirst 11-layer SCD lineI-Flex Family of Gauge ControlsFirst AquaFrost® lineFirst AquaFrost® line4+1 IBCEliminator Air RingFirst 10-layer SCD lineISOth SCDISOtherm SCD AntiBlock IBCBlown Film Technology CenterFirst 9-layer SCD lineyAutogauge Air RingFirst 8-layer SCD lineFirst 7-layer SCD lineFirst 5 layer SCD lineFirst 5-layer SCD line First 7-layer pilot lineFirst linear lay-on winderFirst ITALYCS control systemFirst Airfoil IBCFirst computerized controlsFirst computerized rheology modelFirst spiral dieFirst spiral dieFirst dual lip air ring

MBE Milestones 2010 ● 1st MBE w

Installed Installed.

2008 ● 50th MBE● 1st MBE 3

2007 ● 1st MBE 3

2006 ● 1st MBE w Installed

History of Joint Venture

2005 ● 25th MBE

2004 ● 1st MBE 3

2003 ● 1st ever 72003 ● 1st ever 7● 1st MBE

2002 ● 10th MBE

2001 ● Introducti for Indust

2000 ● 1st ever 5 in India

1998 ● 1st Line o

1997 ● 50:50 Join1997 ● 50:50 Join Mamata M

wider width 2895 mm higher output 800 kg/hr 3 Layer Line

E Line Supplied3 Layer line supplied to Australia

3 Layer Line to Europe

wider width 2375 mm higher output 500 kg/hr 3 Layer Line

E Line Supplied

3 Layer line export to Far East & Middle East

7 Layer Line installed in India7 Layer Line installed in India3 Layer Line export to West Africa and Russia.

E Vegaflex concept line sold within one year of launch.

ion of Vegaflex concept line - A new standard of excellence try to follow

5 Layer SCD Line Manufactured & Installed successfully

of the Joint Venture

nt Venture between Brampton Engineering Canada &nt Venture between Brampton Engineering, Canada & Machinery Pvt. Ltd.

THE MAMATA GROUPTHE MAMATA GROUP

The Flagship comThe Flagship com

AA jointjoint ventureventureENGINEERINGENGINEERING IIfilmfilm lineslines andand systsyst

AA jointjoint VentuVentuFlexopackFlexopack toto mamaformedformed PouchesPouches fofoformedformed PouchesPouches fofo

AA GreenGreen fieldfield PPforfor PurposePurpose ofof CooCooforfor PurposePurpose ofof CooCoo

AA JointJoint ventventAA JointJoint ventventKLöCKNERKLöCKNER DESDESmouldingmoulding machinmachin

mpany of the groupmpany of the group

ee:: MAMATAMAMATA MACHINERYMACHINERY && BRAMPTONBRAMPTONINCINC.. CANADACANADA toto makemake MultiMulti layerlayer BlownBlowntemtem elementselements includingincluding fullfull CNCCNC controlscontrols..

rere b/wb/w MamataMamata MachineryMachinery && SpanSpanakeake SpoutSpout FixingFixing lineslines andand FillingFilling lineslines forfor PrePre--oror PackagingPackaging IndustryIndustryoror PackagingPackaging IndustryIndustry..

rojectroject toto propagatepropagate UsageUsage ofof SolarSolar EnergyEnergyolingoling && HeatingHeating applicationsapplicationsolingoling && HeatingHeating applicationsapplications..

tureture :: MAMATAMAMATA MACHINERYMACHINERY andandtureture :: MAMATAMAMATA MACHINERYMACHINERY andandSMA,SMA, Germany,Germany, toto makemake RubberRubber InjectionInjectionnesnes andand ShoeShoe SolingSoling machinesmachines inin IndiaIndia..

THE MAMATA GROUPTHE MAMATA GROUP

AA JointJoint ventureventureHOLSTEINHOLSTEIN SEITSEIThighhigh--techtech statestate--ooplantsplants comprisingcomprisingplantsplants comprisingcomprisingSealers,Sealers, LabellingLabelling

A subsidiary oA subsidiary oA subsidiary oA subsidiary oproviding Hiproviding Hi--tectechardware solutihardware solutiand Novell.and Novell.

InIn--house Travelhouse Travelthe group companthe group compan

ee :: MAMATAMAMATA MACHINERYMACHINERY && KLöCKNERKLöCKNERTZTZ MACHINEN,MACHINEN, GERMANYGERMANY.. ToTo manufacturemanufactureofof--artart highhigh speedspeed BottlingBottling lineline // packagingpackaginggg ofof BottleBottle WashersWashers FiltersFilters PrePre--mixersmixers CapCapgg ofof BottleBottle Washers,Washers, FiltersFilters PrePre mixers,mixers, CapCap

MachinesMachines etcetc......

of MAMATA MACHINERYof MAMATA MACHINERYof MAMATA MACHINERYof MAMATA MACHINERYch computer software and ch computer software and ions. Authorized suppliers of IBM ions. Authorized suppliers of IBM

l Agencyl Agency providing all travel related services to providing all travel related services to nies.nies.

Thankk You!