Cast Film Extruder is a high-performance, multifunctional production equipment designed for the manufacture of a variety of film materials, including lithium battery separators, breathable films, stretch films, printed films, packaging composite films, and high-temperature cooking films. This equipment stands out for its low energy consumption design, which can significantly reduce production costs. At the same time, it is equipped with an advanced slitting system to achieve efficient online slitting and winding operations to meet diverse production needs. This Cast Film Extruder not only improves production efficiency, but also greatly improves product quality. It is an indispensable equipment in the modern film production industry.

1. High efficiency in production

The mechanical design speed of Cast Film Extruder is up to 250 meters per minute, which is the leading speed among similar equipment. For example, compared with the speed of 150 meters per minute of traditional equipment, its production efficiency has increased by about 66%. Therefore, in the same amount of time, the equipment can produce more products to meet the market's large demand for film materials. The fast and stable operation of the equipment is due to its advanced transmission system and optimized screw design, which ensures the uniform delivery of molten resin and the rapid molding of film. High efficiency in production not only increases the output of the enterprise, but also reduces the energy consumption and production cost per unit product, and enhances the competitiveness of the enterprise in the market.

2. Width adjustment capability

The product width of the equipment can be flexibly adjusted between 1200-3500 mm to meet the production needs of film materials of different specifications. Width adjustment is achieved through a high-precision hydraulic or electric drive system with an adjustment accuracy of ±1 mm, ensuring the uniformity and stability of the film material when the width changes. Taking the production of packaging composite film as an example, when the width needs to be adjusted from 2000 mm to 2500 mm, the equipment can complete the adjustment and put into production in just 30 minutes, which is significantly more efficient than the 1-2 hour adjustment time of traditional equipment. The flexible adjustment capability of wide width enables enterprises to respond quickly to market changes and produce products of various specifications, which improves the utilization rate of equipment and the market adaptability of enterprises.

3. Wide material applicability

Cast Film Extruder can process a variety of film materials, including lithium battery separators, breathable films, wrapping films, printed films, packaging composite films and high-temperature cooking films. The processing parameters of different materials can be quickly set and adjusted in the control system of the equipment. Taking lithium battery separators as an example, the equipment can accurately control the melting temperature between 220℃-280℃ and the screw speed between 30-120 rpm to ensure uniform molding and stable performance of the separator. For the production of breathable films, the equipment can adapt to lower processing temperatures (180℃ - 240℃) and higher screw speeds (80 - 150 rpm) to ensure uniform distribution of pores and strength of the film material. This wide range of material applicability enables the equipment to play a role in multiple industries and meet the diverse needs of different customers.

4. Precise thickness control

The product thickness range can be precisely controlled between 25-500 microns to meet the requirements of film material thickness in different application scenarios. The equipment adopts an advanced automatic thickness control system, which monitors the film material thickness in real time through a high-precision infrared or laser thickness gauge, and automatically adjusts the screw speed of the extruder and the haul-off traction speed. When producing a printed film with a thickness of 100 microns, the thickness deviation can be controlled within ±2 microns to ensure the clarity and adhesion of the printed pattern. This precise thickness control capability not only improves the quality of the product, but also reduces the waste of raw materials and reduces production costs.

5. High production qualification rate

The comprehensive performance of the equipment ensures a high production qualification rate, and the product qualification rate can reach more than 95%. Its advanced temperature control system can control the temperature fluctuation of molten resin within ±1℃, ensuring uniform molding of film. For example, when producing high-temperature cooking film, the precise temperature control enables the film to maintain good physical properties and barrier properties, without delamination or cracking, after a 30-minute cooking test at 121℃. The stability and accuracy of the equipment reduce the production of defective products caused by uneven thickness, temperature fluctuations and other factors, reduce production costs, and improve the economic benefits of the enterprise.

6. Fast slitting and winding

Equipped with an advanced slitting system, it can achieve efficient online slitting and winding operations. The slitting tool is made of high-hardness alloy material with sharp blades. Multiple slitting knives can be set at the same time to achieve slitting of multiple rolls at one time. Taking the production of winding film as an example, the equipment can slit 6-8 rolls of film with a width of 500 mm at the same time. The slitting speed is synchronized with the extrusion speed, and the slitting accuracy can reach ±0.5 mm. The winding system adopts variable frequency speed regulating motor, which can automatically adjust the winding speed according to the thickness and tension of the film material to ensure the flatness and tightness of the film roll. Compared with traditional slitting and winding equipment, its slitting and winding efficiency is increased by about 40%, which effectively shortens the production cycle and improves production efficiency.

7. Low energy consumption design

Cast Film Extruder adopts low energy consumption design, which significantly reduces energy consumption in the production process through optimized screw structure and efficient heating and cooling system. The screw adopts a twin screw design with a length-to-diameter ratio of 40:1 and a compression ratio of 3:1, which ensures uniform plasticization and low shear mixing of the resin and reduces energy waste. The heating system adopts zoned temperature control technology to increase the heating efficiency by about 25%, while the cooling system adopts circulating water cooling technology to increase the cooling efficiency by about 30%. Compared with traditional equipment, the equipment reduces energy consumption by about 35% when producing the same weight of film material, which not only reduces production costs, but also meets the environmental protection and energy-saving requirements of modern industry.

8. Flexible adjustment of mold width

The mold width can be flexibly adjusted according to production needs to adapt to the production of film materials of different specifications. The mold adopts a unique hydraulic expansion or contraction structure, with an adjustment range of 1000-3000 mm and an adjustment accuracy of ±0.1 mm. When producing packaging composite film, if the width needs to be adjusted from 2000 mm to 2500 mm, it only takes 20 minutes to complete the adjustment of the mold width. This rapid adjustment capability improves the production flexibility of the equipment, reduces production downtime caused by mold changes, and improves the overall utilization of the equipment.

1. Lithium battery separator

In the field of lithium battery separator production, Cast Film Extruder is a key equipment for manufacturing high-performance lithium battery separators. Lithium battery separators are required to have high porosity, good chemical stability and mechanical strength to ensure the safety and life of the battery. The equipment can accurately control the temperature, pressure and flow rate during the melt extrusion process to produce a separator with uniform thickness and reasonable pore distribution. In actual production, the thickness deviation of the separator can be controlled within ±1 micron, the porosity is increased to 45% - 50%, and the battery's charge and discharge cycle life is extended by about 20%. The high precision and stability of the equipment meet the stringent requirements of lithium battery separator production and promote technological progress in the lithium battery industry.

2. Breathable membrane

In the breathable membrane manufacturing industry, Cast Film Extruder is used to produce breathable membranes required for medical protective clothing, sanitary products, etc. Breathable membranes need to allow water vapor to pass while blocking liquids to maintain the comfort and dryness of the product. The equipment can accurately control the size and distribution of vents during the production process through optimized screw design and extrusion process. Taking the breathable film of medical protective clothing as an example, the breathable film can reach 3000-5000 g/m2/24 hours, the water pressure resistance exceeds 5000 Pa, and the product performance meets the requirements of EN14126 standard. The efficient production and precise control capabilities of the equipment help enterprises gain an advantage in the fierce market competition and meet the high-quality demand for breathable films in the medical and health industries.

3. Stretch film

In the production of stretch film, Cast Film Extruder can efficiently produce stretch films of various specifications, which are widely used in logistics packaging, agricultural covering and other fields. Stretch film requires good tensile strength, resilience and good self-adhesion. The advanced slitting system equipped with the equipment can realize online slitting and produce stretch film products of different widths and thicknesses. When producing stretch film, the tensile strength of the product can reach 25-35 MPa, the resilience is maintained at 30%-40%, the self-adhesion reaches 100-200 g/25 mm, and the product performance is stable and reliable. The high-speed and stable operation and precise slitting capabilities of the equipment enable enterprises to efficiently produce high-quality wrapping films to meet the market's large demand for packaging materials.

4. Printing film

In the field of printing film manufacturing, Cast Film Extruder is used to produce various printed films for packaging. Printing films are required to have good flatness, glossiness and printing adaptability. The equipment provides excellent printing performance for printed films through precise thickness control and uniform surface treatment. When using this equipment, the thickness deviation of the printed film can be controlled within ±1.5 microns, the glossiness reaches 80% - 90%, and the clarity and color vividness of the printed pattern are significantly improved. The high production efficiency and stability of the equipment enable enterprises to quickly respond to market demand, produce high-quality printed film products, and enhance the market competitiveness of enterprises.

5. Packaging composite film

For the production of packaging composite film, Cast Film Extruder can produce multi-layer composite films through co-extrusion process to meet the high barrier requirements of food, medicine and other packaging. The equipment can extrude up to 7 layers of resins of different materials at the same time, and achieve perfect fusion of each layer of materials through precise temperature and pressure control. In actual application, the oxygen permeability of the composite film produced by the equipment is less than 10 cm³/m²·24h·0.1MPa, and the water vapor permeability is less than 5 g/m²·24h, which effectively extends the shelf life of food. The versatility and precise control capability of the equipment provide high-quality composite film solutions for the packaging industry and meet the market's requirements for high performance packaging materials.

6. High-temperature cooking film

In the field of high-temperature cooking film manufacturing, Cast Film Extruder can produce high-temperature and cooking-resistant film materials, which are suitable for high-temperature sterilization packaging of food, medicine, etc. The equipment ensures that the film material maintains good physical properties and barrier properties during high-temperature cooking through optimized formulas and processes. Actual tests have shown that after a 45-minute cooking test at 121°C, the film has no delamination or cracking, the oxygen permeability remains below 20 cm³/m²·24h·0.1MPa, and the water vapor permeability remains below 3 g/m²·24h. The product performance meets the requirements of GB/T 10004. The reliability and stability of the equipment provide a strong guarantee for the production of high-temperature cooking films, ensuring the safety and reliability of food packaging.

1. Daily cleaning and inspection

After the production is finished every day, the Cast Film Extruder should be cleaned thoroughly immediately. Use compressed air to blow away dust, plastic debris and other debris on the surface and various parts of the equipment, especially key parts such as screws, barrels and molds. Use a soft cloth to dip in an appropriate amount of special cleaning agent and gently wipe the surface of the equipment to remove oil and residue. Check whether there are scratches, collision marks or abnormal wear on the appearance of the equipment, and deal with the problems found in time. Focus on checking whether there is plastic residue or damage on the surface of the screw. If plastic residue is found, it should be cleaned immediately with special tools; if the screw is damaged, it needs to be replaced in time. Check the fasteners of the equipment regularly to ensure that all fasteners such as screws and nuts are not loose. If there is any looseness, tighten it in time to prevent equipment failure and production accidents caused by looseness.

2. Regular lubrication and maintenance

According to the requirements of the equipment lubrication chart, lubricate each lubrication point of the Cast Film Extruder every shift, including gears, bearings, screw bearings and other parts. Use the specified grease or lubricating oil to ensure sufficient lubrication. Regularly check whether the oil circuit of the lubrication system is unobstructed and whether the oil pump is working properly. If there is any blockage or fault, it should be eliminated in time. Check the oil level of the equipment's reducer and gearbox every month to ensure that the oil level is normal and the oil is clean. Replace the lubricating oil every 3-6 months to ensure the efficient operation of the lubrication system and extend the service life of the equipment. Regularly check the sealing device of the screw to ensure that the seal is good to prevent grease leakage or foreign impurities from entering.

3. Inspection and replacement of key components

Inspect the wear of the screw and barrel every quarter, and use high-precision measuring instruments to ensure that the diameter of the screw does not exceed 0.1 mm and the inner diameter of the barrel does not exceed 0.2 mm. If the wear exceeds the allowable range, the screw or barrel should be replaced in time. Regularly check the surface finish and dimensional accuracy of the mold, and use optical instruments for detection to ensure that the surface roughness Ra of the mold is less than 0.4 microns and the dimensional accuracy is within ±0.05 mm. Calibrate the key measuring components of the equipment such as temperature sensors and pressure sensors every year to ensure measurement accuracy. Calibration should be performed by professionals using standard instruments. After calibration, the calibration data should be recorded to ensure the normal operation of the equipment and the stability of product quality.

4. Idle operation test and debugging

Perform an idle operation test of the equipment once a week to simulate various operations in the production process, including starting, stopping, speed change, reversing, etc., and check the operating status of the equipment. The idle operation time should be no less than 30 minutes, and observe whether the equipment has abnormal noise, vibration or jamming. If there is any abnormality, the equipment should be stopped immediately for inspection and troubleshooting. After replacing key components or adjusting equipment parameters, multiple idle operation tests and debugging should be performed to ensure that the various performance indicators of the equipment are in the best state. Through the idle operation test, potential problems of the equipment can be discovered in time, failures in the production process can be avoided, and the reliability and production efficiency of the equipment can be improved.

5. Production environment control and management

Ensure that the equipment is installed in a clean, dry and temperature-appropriate environment. The temperature should be controlled at 20-30℃ and the humidity should be controlled at 40%-60%. Avoid direct sunlight, rain or exposure to corrosive gas environments. During the production process, the workshop should be kept clean and well ventilated to reduce the impact of dust and impurities on the equipment. Establish a strict equipment management system to record the use, maintenance and upkeep of the equipment, including information such as the product type, production time, equipment operating status, and maintenance content of each production. Through data analysis, the maintenance needs of the equipment can be predicted in advance, a reasonable maintenance plan can be formulated, the service life of the equipment can be extended, and the comprehensive utilization rate of the equipment can be improved.

6. Professional training and technical support

Regularly organize operators and maintenance personnel to participate in equipment operation and maintenance training courses, and invite technical experts from equipment manufacturers to give lectures. The training content includes the structural principles, operating procedures, maintenance knowledge, troubleshooting methods, etc. of the equipment. Operators and maintenance personnel should obtain the corresponding training certificates before they can operate and maintain the equipment. Establish a long-term cooperative relationship with equipment manufacturers to ensure that professional technical support and solutions can be obtained in time when the equipment has major failures or requires technical upgrades. Regularly invite the manufacturer's technical team to inspect and evaluate the equipment, make improvement suggestions based on the evaluation results, continuously optimize the performance and operation status of the equipment, ensure that the equipment is always in the best working condition, and provide solid guarantees for the company's production.