HOW PLASTIC FILM IS MADE
Our plastic film is made using a process called Blown Film Extrusion.
Raw material resin pellets are mixed and fed into the hopper of an extruder/ inflation machine. Just the right ratio and mix of materials is measured for the material batch.
The hopper feeds the material into the extruder – a heated barrel that reaches temperatures of around 190°C.
A large screw inside the barrel carries the resin forward while rotating, turning, and mixing the materials as they become a molten flow.
The molten material is forced under high pressure to pass through extremely fine mesh screens and up through a rotating die.
Air is injected into the material, blowing it up just like an air-filled bubble or balloon.
An air-ring blows cool air to stabilize the bubble as it is blown up a tower
The operator adjusts the die settings, air flow and machine speeds to determine the width and gauge (thickness) of the film
The film travels over rollers guiding it onto a cardboard core where it winds into a roll of film.
HOW WE MAKE COLORED and TINTED FILM
Colored opaque or transparent tinted film is made using the same process as natural (clear) film.
However, at the mixing stage a special masterbatch color is added in the correct quantity for the required finished product.
Masterbatch material batches are mixed constantly to ensure even distribution of the color or the tint throughout the film.
Uses for colored or tinted film include the food industry and color code identification in a variety of industries. We can also match PMS colors.
Tinted or colored film is used in the food industry due to its high visibility for rapid identification should it fall into ingredients or products.
An example of colored film we make is the blue sheets you may find between your frozen pastry sheets.
SPECIAL APPLICATION FILMS
Ice bag film and bags require a special resin that is not only food safe, but it provides the necessary film properties for this intended use.
This special resin incorporates technology to ensure frozen ice bags have the required impact strength to hold a bulky heavy load, under freezer conditions, and not split or shatter when handled or dropped.
Other specialty films we make include:
- Ice bag film
- MDPE & HDPE – high strength, frosty look film and bags.
- UV stabilized
- Corrosion Inhibited
- All our films can be printed and colored and made to your custom requirements.
HDPE, a higher density resin is used extensively in food packaging – such as freezer bags and produce bags as seen in the vegetable section of the supermarket and carton liners.
HDPE’s inherent frosted look and material stiffness is ideal for heavier gauge carry bags and retail display where an upmarket, classy look is desirable.