Scenario

Maguire + Syncro worked together to support a Food packaging producer improve the efficiency and correct critical issues on their blown film line. 

• Food packaging producer in the USA.
• Blown film process. 
• Kiefel Co-Extrusion Line - 3 layer Blown film plant (2000 model).
• Critical lay flat variations.
• Critical bubble non uniformity and lack of stability.
• 2 sigma deviation between 10 and 13%. 
• Increase throughput.

Technical Specifications of Blown Film Line

• Line output: 220 Kg/h (500 pph)
• Die size: 350mm 
• Material: LL / LLDPE blend 
• Lay flat: 550mm to 1990mm
• Film thickness: 60 to 155 micron
• Screw sizes: 60 / 60 / 80mm
• Haul off type: Oscillating 

Maguire + Syncro Products Installed

• WXB Gravimetric Blender with M+S Extrusion Control with PLC I/O. Control interfaces to #1 Extruder + #1 Haul Off.
• Conveying management by blender. 
• Air ring - Typhoon with one lipset engineered with 2 air streams to optimize stability and cooling, enabling increases in output. 
• Air ring provided with stabilizer with manual adjustment. 
• New calibration basket with the addition of OBC control and lay flat control. 
• New gauging system - SkYmex capacitive gauging system
• New supervisory system - Syntrol Extrusion Control. The line has been configured so an upgrade to Maguire + Syncro's supervisory system can be easily setup in the future. 

Benefits

• Lay flat variations reduced to ±3mm.
• Achieved bubble stability and uniformity
• Lowered 2 sigma deviation from 13% down to 4%. 
• On average, throughput increased by by 25% across the full product range and all film types. 

Installation 

The dismantle of old equipment, mechanical and electrical installation took 2 weeks.

Start up and commissioning took 3 days.