3 layers extrusion line

Macchi 3100 mm

The Macchi 3-Layers is a high-capacity blown film co-extrusion line intended for production of general-purpose films with high width and output demands.It processes LLDPE, LDPE, mLLDPE, MDPE, HDPE, and in upgrade configuration also PP.The system uses a 700 mm 3-layer die head and reaches an output capacity of up to 900 kg/hour, depending on formulation.
EXTRUSION GROUP:
• Extruders: 80 mm + 100 mm + 80 mm
• Infrared heating
• Hydraulic screen changers
Detailed upgrade specification:
• One extruder Plastex 100/30D (middle layer B)
• Two extruders Plastex 80/30D (layers A and C)
• Bimetallic barrels
• Nitrided screws
• Water-cooled grooved feeding sections
• 5 heating zones with IR heaters and blowers
• Motors:
- 150 kW DC motor (100 mm extruder)
- 100 kW DC motors (80 mm extruders)
• AC motor application with digital control (IP55) for reduced energy consumption and harmonic distortion
DIE HEAD:
• Model TE505
• 700 mm die diameter, die gap 1.8 mm
• 4+4 heating zones with ceramic heater bands (19 + 35 kW total)
• Mounted on a die cart with integrated air distribution manifold
• Insert range 600–800 mm
• Equipped with IBC system
COOLING SYSTEM:
• Dual-lip carbon fibre Karat air ring (K-Design)
• ASR4 Double Flux Cooling Ring, blower 15 kW
• Jet-7 IBC cooling control system
- 15 kW introduction blower
- 18 kW extraction blower
- Bubble diameter sensor
- Air balancing valves
- Variable-speed inverters

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TAKE-OFF UNIT:
• Take-off width: 3200 mm
• Oscillating nips
• Optional tower-mounted secondary nip with load-cell control


WINDING SECTION:
• Double automatic back-to-back winder
• Automatic roll change
• Maximum winding width: 3150 mm

FILM SPECIFICATIONS:
Film width range with 700 mm die: 2000–3100 mm
Thickness: 15–200 μm
Output example: 3000 mm width, 100 μm LDPE → 800 kg/h ±10%
LINE SPECIFICATIONS:
Installed power: 550 kW, 415 V, 3-phase + neutral
Screw speeds: 80/30D extruders: 0–130 RPM
100/30D extruder: 0–120 RPM
Cooling water consumption: 6 L/min
Compressed air requirement: 6 bar
ADVANCED CONTROL & MEASURING SYSTEMS:
• Doteco gravimetric dosing system Grado
• Thickness profile systems (EC Plus modules):
- S2 Automatic Die Control
- S3 Rotating Capacitive Thickness Scanner
- S4 Track Scanner
- Q1 Serial communication (extruder/gravimetric values)
- Q11 Printer module
- Q12 Online modem diagnostics
- Q7 Power consumption monitoring
• K-Design VARIOcool automatic thickness control
• Kundig reversing ring and thickness measurement
AUXILIARY EQUIPMENT
• Tower
• E+L web guiding system
• Corona treater AFS or 2800 station
• Calibrating basket with optional supporting basket
• Bubble guide GSRC 3200 (6 levels, motorized, IBC-linked)
• Micro-perforation system (FBF cold needle)
• Air shafts (8 pcs)