What Is the Typical Output Capacity of a Modern Co Extrusion Casting Film Machine?
Typical output capacity for a modern co extrusion casting film machine is not a single fixed number, because capacity changes with film thickness, line speed, effective width, resin density, trim loss, and real uptime. In practical production, most factories define capacity in two ways: linear output per minute at stable speed, and finished kilograms per hour after trimming, slitting, and winding stability are considered. If you want a reliable estimate for purchasing or planning, the correct method is to calculate theoretical output first, then apply realistic efficiency factors that match your product mix.
SAIBANG designs industrial Casting Machine solutions for breathable film, lithium battery film, printing film, packaging composite film, high temperature cooking film and more, with flexible width and online slitting and winding options depending on configuration.
What capacity means in real casting film production
Capacity is often misunderstood as only line speed. In casting film, output depends on how much material passes through the die per minute and becomes sellable finished film. Two production lines can share the same speed rating but deliver very different hourly output if one runs thicker film, wider usable width, or higher uptime.
A modern co extrusion casting line is typically evaluated by:
Stable running speed range for your film type
Maximum effective product width after edge trim
Film thickness range and thickness stability
Slitting layout and number of finished reels
Winding diameter limit and changeover frequency
Production stability, scrap rate, and quality yield
The main variables that control output capacity
Line speed is only the starting point
Many modern co extrusion casting film lines are designed for high mechanical speed. In real production, the stable operating speed may vary based on resin, cooling capacity, and thickness control. When comparing machines, ask what speed can be maintained with your thickness and width, not only the headline speed.
Product width determines how many kilograms you make per minute
Casting film output increases linearly with width. A wide line running at moderate speed can outproduce a narrower line running faster. Modern configurations often support wide ranges because buyers produce multiple SKUs and want width flexibility.
Thickness drives output more than most buyers expect
Thickness is the biggest lever in capacity calculations. Doubling thickness doubles output at the same width and speed. This is why capacity claims must always be linked to a defined thickness range.
Density and formulation matter
Film density varies by polymer type and additives. Breathable film, composite structures, and specialty formulations can shift density and cooling behavior, which affects both theoretical output and stable line speed.
Real uptime is the difference between brochure capacity and factory capacity
Even if the line is capable of high speed, output is limited by changeovers, cleaning, roll handling, quality inspections, and downstream packaging. This is why experienced buyers use an efficiency factor rather than treating maximum speed as full-time speed.
How to calculate casting film output capacity
The most practical way to estimate output is to compute theoretical mass flow, then adjust for trim and uptime.
Step 1: Calculate theoretical output
Use the relationship between speed, width, thickness, and density.
Film thickness in microns must be converted to meters
1 μm = 0.000001 mApproximate formula for mass output in kg/h: Output (kg/h) = Speed (m/min) × Effective width (m) × Thickness (m) × Density (kg/m³) × 60
This gives a theoretical maximum assuming continuous stable operation and no scrap.
Step 2: Apply real production factors
Practical output often uses:
Trim and edge loss factor
Start-up scrap and steady scrap factor
Uptime factor based on changeovers and planned stops
Quality yield factor for customer acceptance
Typical factors that reduce theoretical capacity
| Factor | What It Represents | Typical Impact on Output |
|---|---|---|
| Edge trim and slitting loss | Edge waste and knife layout losses | Reduces effective width |
| Start-up and transition scrap | Thickness stabilization, die cleaning effects | Reduces sellable output |
| Changeover time | Resin changes, die gap changes, roll changes | Reduces uptime |
| Winding stability limit | Speed reduction near full roll or during defect control | Reduces stable speed |
| Quality yield | Rejected rolls due to defects or off-spec | Reduces final accepted output |
Example capacity calculation with realistic assumptions
Assume a line runs:
Stable speed: 200 m/min
Effective width after trim: 2.0 m
Thickness: 50 μm = 0.00005 m
Density: 920 kg/m³
Uptime: 85 percent
Theoretical output:
Output = 200 × 2.0 × 0.00005 × 920 × 60
Output = 1,104 kg/h
Practical output with uptime:
Practical output ≈ 1,104 × 0.85 = 938 kg/h
This is a more realistic planning figure for continuous production. If thickness changes to 25 μm under the same conditions, practical output drops by roughly half. If thickness increases to 100 μm, output roughly doubles, but speed stability and cooling capacity may become the limiting factor instead.
What modern co extrusion Casting Machines can typically support
Modern co extrusion casting film lines are designed to cover wide product ranges, and capacity is achieved by combining high mechanical design speed with wide width capability and stable winding.
In SAIBANG casting line configurations, common design characteristics may include:
Mechanical design speed up to 250 m/min on certain co extrusion casting film line configurations
Product width ranges that can extend from 1200 mm to 3500 mm depending on the line layout
Typical co extrusion casting film thickness ranges around 25 to 500 μm for applications such as breathable film, lithium battery film, printing film, packaging composite film, and cooking film
Winding diameter ranges that can support high-capacity rewinding such as 600 to 1000 mm depending on configuration
Mold width adjustment to adapt to different specifications
Multiple slitting knives to support online slitting and winding
These parameters help explain why capacity varies widely. A 1200 mm line running thinner film will have a very different output profile from a 3500 mm line running mid-thickness film, even if both share similar speed design targets.
SAIBANG’s Casting Machine platform is positioned to support this width and product flexibility so buyers can plan capacity around their actual SKUs rather than a single fixed claim.
Capacity planning for co extrusion lines versus single layer lines
Co extrusion machines are often selected for multilayer functional films because they support performance targets that single layer lines cannot meet. Output capacity depends on the total thickness and the stability of each layer’s flow balance.
From a planning perspective:
Co extrusion lines can maintain high output while producing functional films, but stability and layer uniformity may limit speed at extreme thin gauges
Single layer lines can be highly efficient for simpler products and broad thickness ranges, but they may not match multilayer performance requirements in breathable or specialty films
The correct selection depends on whether your market needs performance layering, barrier structure, breathability, or printing and lamination compatibility.
What buyers should ask when comparing capacity claims
To avoid comparing numbers that do not match your product, confirm these items in the quotation stage:
At what thickness is the stated capacity calculated
A capacity claim without thickness is not useful for procurement decisions.What width is considered effective width
Confirm how much trim loss is assumed and how slitting layout affects usable width.What speed is stable for your film type
Stable speed under your resin and thickness matters more than maximum speed.How many reels are produced online and how roll change is handled
Roll change frequency impacts uptime and labor cost.What winding diameter is supported and whether speed must drop at high diameter
Some lines reduce speed as rolls approach maximum diameter, which reduces average output.
Why SAIBANG is a practical partner for capacity driven projects
Capacity is achieved when mechanical design, process control, and downstream winding stability work together. SAIBANG focuses on complete line capability, including width adaptability, online slitting options, and winding design suited for continuous production. This approach helps buyers translate theoretical output into real factory output with fewer stability compromises.
If your purchasing goal is to scale output for breathable film, battery-related film, printing film, composite packaging film, or similar applications, SAIBANG’s Casting Machine solutions provide a practical foundation for planning capacity around your actual product specifications.
Conclusion
The typical output capacity of a modern co extrusion casting film machine depends primarily on speed, effective width, thickness, and real uptime. The correct way to evaluate capacity is to calculate theoretical kg/h from speed, width, thickness, and density, then apply realistic factors for trim loss, changeovers, and quality yield. With modern line designs that support high mechanical speed, wide product widths, and online slitting and winding, a properly configured system can deliver scalable capacity across different film types. For buyers who need configurable width, stable production performance, and practical manufacturing output planning, SAIBANG’s Casting Machine offers a strong solution path.