This is where we show them to you.

Imported automatic air ring — a gauge that holds

At the customer’s plant the gauge never held, so every roll was blown heavy just to bring the thinnest point into spec — a good share of every tonne of resin wasted. We supplied them a blown film line with the imported fully automatic air ring. The ring is imported: the supplier has been with us for more than ten years, a long-term partner, so the part can be relied on. Fitted on the machine, it controls the air pressure and the temperature, and the film gauge stays constant. Once the gauge holds, what you save per tonne is profit.

IBC cooling, changeovers in minutes

This customer’s orders come in small lots, with several size changes a day. A change used to mean someone standing at the bubble working the lay-flat width out by trial, and the trial film never reached the warehouse — it was scrap. Push the line speed and the bubble would not hold, so the line ran slow. The machine carries our own IBC internal cooling control: it governs the cooling inside the bubble and corrects in milliseconds, and it keeps up however awkward the schedule. Gauge tolerance is now very small and every roll matches; a size change takes minutes, changeover scrap is largely gone, and the minutes saved turn straight into output.

Fully automatic twin winder — no downtime

At the customer’s plant winding was manual: a roll change stopped the line, the film was cut and spliced by hand and a bad splice wrote off the roll; a full 200 kg roll was lifted by hand; and one winder could not take both thin and thick film. We supplied our own fully automatic centre-surface twin winder. Three winding modes switch with the film; automatic tension control tracks and adjusts tension for different film processes and gives a flat roll; cutting, roll change and unloading are automated, with hydraulic unloading. Roll changes no longer stop the line, scrap is down, and one operator does the work of two.

One integrated solution for a modern plant

Blown film equipment is moving to the high end: smarter, more automated, more efficient. Machine stability and energy use are where the competition sits, and service response and build-to-spec decide who wins the order. Demand grows fastest in multilayer co-extrusion and degradable material, with PBAT and PLA capacity expanding; downstream, beyond packaging and agricultural film, battery separator and PV backsheet film pull high-end demand. The plastics machinery market is about 85 billion yuan, hollow forming around 18 per cent, growing 6–8 per cent a year. We build one integrated scheme: work out what film and how much a year, then configure the equipment. The whole line comes from one maker, so the machines need not accommodate each other; installation, commissioning, trial production and spares are followed through.

Central computer control, quicker setup

The line runs from one touchscreen computer control, software written in house, Schneider automation throughout; a Schneider CANopen bus links the inverters and servo drives, so control is reliable and response immediate. Haul-off and winders run on servo motors for precise control. Melt temperature, screw speed, melt pressure, IBC internal cooling, the external air ring, bubble stabilising, rotating haul-off, line speed, tension and winding are all set and watched on the one screen, with alarms and self-diagnosis. Process settings are stored per film, so the next run starts from the conditions you had. Three PLCs — extruder and haul-off, plus one per winder — mean a winder fault does not stop the line. Interfaces are open: air rings and hoppers from Plast-Control or Syncro connect straight in.

Wicket bag side seal machine

A side seal machine with hot cut: shopping bags, bin liners, food bags, courier bags, plain top or vest handle. The film roll goes straight onto the unwind, and unwinding, feeding, sealing and cutting run through in one pass; on printed film a photocell tracks the register mark, so bag length is accurate and the print does not drift. Sealing and cutting knives are synchronised, the seal is flat and does not open. Bags drop into the wicket collector: the blades turn, catch each bag, stack it square and divide the stack at the count you set, so the operator only takes it away to pack — nobody stands at the tail end squaring bags by hand. Changing size is a matter of setting bag length and count on the touchscreen.

High-speed centre seal bag machine

The machine is in steady production at a customer’s plant. Everything is built around the centre seal: a standard unwind; film folded and joined on the centre line; longitudinal sealing with standard cooling, a firm flat seal; cross sealing on a widened beam with rows of springs — high pressure at low temperature, and a flat bag mouth.

Cutting and collection are automated: twin knives, a CCD knife or die cutting, with stacking and inspection that rejects bad bags — no one at the tail end.

Built to order: machine width, servo unwind, 50 m continuous roll change; twin cut, CCD trimming and die cutting optional, CCD positioning holds the cut exact.

Central computer control, the line’s brain

One touchscreen computer control runs the whole line — software written in house, Schneider automation throughout. A CANopen bus links the inverters and servo drives: reliable control, immediate response. Haul-off and winders run on servo motors.

Temperature, melt pressure, IBC cooling, air ring, bubble stabilising, rotating haul-off, tension and winding all sit on one screen, with alarms, self-diagnosis and remote parameter setting.

A 15-inch touchscreen runs the extruder, each winder its own 10-inch screen; three PLCs mean a winder fault leaves extruder and haul-off running. The main screen sits on a new swing arm; air rings and hoppers from Plast-Control or Syncro connect straight in.

IBC bubble cooling control, our own

Film quality is decided inside the bubble. The IBC internal cooling control is our own development, and it governs that whole cooling cycle — which is what gives the line its output.

Gauge is held to within a millimetre, so sizes stay stable and one batch matches the next; feedback is read and corrected in milliseconds, so the line holds its setting when conditions shift. Size changes are automatic and quick, which cuts changeover time and scrap.

Better film, lower cost, quicker to switch.

Forged die head, mirror-polished channels

The die head is forged from alloy steel and machined on a five-axis centre in one setup, every main part finished there. The spiral channels of each layer divide the melt evenly, so the film comes out without weld lines or dead corners and the melt runs clean.

Heating is by plug-in ceramic heaters — steady temperature, even warm-up. Channels and die lips are ground to a mirror finish and then hard chrome plated, which stands up to wear and corrosion, holds the film quality and makes the tooling last.

Precision screw, permanent-magnet drive

Barrel and screw are 38CrMoAlA nitriding steel, the screw in twin alloy, with a high-mixing double-thread barrier profile that separates, barriers and mixes at once — specially hardened, so it resists wear and corrosion, plasticises well and gives high output on low power. The route is forged and tempered, machined, ground round to true, nitrided for 100 hours, stress-relieved at low temperature, hard chrome plated, then polished. The barrel carries zoned ceramic heaters and cooling fans, and the feed throat runs forced water cooling on a closed loop. The main motor is a Grade 1 efficiency permanent-magnet synchronous motor, about 15% less energy.

Imported air ring, ten years together

Every line we build carries an imported fully automatic air ring: the part that decides cooling is the one the international builders use. We have worked with that overseas supplier for more than ten years and are now long-term partners — we take part in the technical fit-up, in each revision of the part and in the quality control behind it. With a proven imported ring the cooling holds its setting and the bubble forms steadily, so gauge and uptime both rest on something dependable. We keep building in imported parts of this grade, so the machine stands up to long continuous runs.

Dual-station screen changer, no stops

The dual-station screen changer rests on five things. A self-expanding seal keeps the melt from leaking. The body is good alloy steel machined on a CNC centre, so the fit holds. Heating is ceramic, in two zones, for an even warm-up. Melt pressure and temperature sensors sit ahead of the changer: the operator watches the pressure move and corrects the process there and then. The change itself runs on air — switch stations and the line keeps running, which is safer, easier and quicker, with less scrap and less downtime.

Bubble cage with carbon fibre rollers

The bubble cage and the back-up cage are framed in aluminium profile: sound structure, and it looks the part. At the centre is a motorised squirrel-cage stabiliser — opening and height are both set by remote control, accurately and without effort, and the bubble forms more steadily for it. The rollers are carbon fibre: light, strong, and low in both friction and heat conduction, so neither heat nor drag works against the film. Film quality and surface hold up, which is what high-speed continuous running asks for.

Rotating haul-off, ±352° swing

The horizontal rotating haul-off swings ±352°, with line speed held steady and adjustable by servo. It replaces a rotating die and with it the long flow paths, the sealing trouble, the leaks and the awkward maintenance — and it puts an end to taper and wavy edges. The first haul-off cools over several rollers on a 2 kW servo motor, up to 128 m/min; the rollers are mirror polished and hard chrome plated, opened and closed by air cylinder. The 352° swing unit is one set: two low-friction air-cushion turning bars, two special rubber spreader rollers, 0.75 kW inverter drive. Start, stop and reset buttons sit on the main console and on the platform.

Stack die with flexible auto lips

The multilayer stack die is side fed, its streamlined channels suited to an inner PA barrier layer. Forged from good alloy steel, main parts machined on a precision five-axis centre, the spiral channels of each layer divide the melt evenly: no weld lines, no dead corners, melt running clean. The flexible lips are Syncro — one Ø450 set at 1.5 mm, with a 2.0 mm lip in reserve; plug-in ceramic heating, 12 zones on automatic control, about 200 kW; four adjustable levelling screws. Channels and lips are polished to a mirror finish and nickel-phosphorus plated against wear and corrosion. From the screen changer to the die the channel is flange connected and easy to fit, the bore hard chromed and specially hardened.

X-ray gauging, closed-loop control

The multilayer line carries X-ray beam gauging: a capacitive or non-radioactive X-ray sensor reads film thickness, with beam energy below 5 keV — nothing to worry about on radiation. The sensor feeds the reading to the PLC in real time and the system opens or closes the air ring to match, so measuring, feedback and adjustment close the loop and gauge deviation is corrected on line. Thickness stays even across the web and along it, which is what a high-grade barrier film and continuous running need.

EPC servo web guide, ±0.004 mm

Winder and unwind run an EPC full-touchscreen servo web guide that tracks the material edge, a line or contrast, and drops straight into an automated process. At its core are a 32-bit dual-core CPU, a 1000-line encoder and a closed-loop servo motor, working with several kinds of sensor for ±0.004 mm accuracy and 0.02 ms response. The sensor catches the drift as it happens, the CPU drives the motor, the encoder closes the loop; single-edge tracking and sparkless reversing are both there. The metal housing shrugs off interference and 30 kV of static, the maintenance-free build stays steady over the years, and the motor trims its own speed to save power.

Automatic winder, tension or taper

The automatic winder cuts the film, changes the roll, unloads it, counts the length and holds tension on its own, with hydraulic unloading. Three dual-station types are available — surface friction, gap, and driven plus friction — to suit different films. Maximum roll diameter is Ø1000 mm, for film from 0.02 to 0.2 mm. Tension comes from low-friction cylinders and an electro-pneumatic proportional valve: constant tension or a tension taper, tracked automatically against the surface tension feedback, so the roll builds flatter. Air shafts load and unload at one touch and a length counter is included — less hand work, less scrap, more output and a safer job.