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The advanced blown film extrusion line can process various raw materials, such as polyolefin, barrier layer and tackifying resin, as well as various additives, such as masterbatch and biopolymer. Generally speaking, these resins can be used as feed particles. They can be generated in the reactor or mixed with additives through two processes before being sent to the converter. Film manufacturers mix these resins, additives and masterbatch to produce a wide range of blow molded films up to 11 layers. Mineral modifiers provide opportunities for the economic production of films. At the same time, the mechanical properties of polyolefin films have been improved, and the thickness has been greatly reduced. Among them, calcium carbonate (CaCO3) is one of the most commonly used mineral modifiers.
1、 Calcium carbonate (CaCO3) is the most commonly used mineral
Rocks are taken from quarries, then milled to powder, and then beaten and surface treated. They can be used for various purposes in the field of plastics. Due to the large amount of CaCO3 deposition, this mineral is considered to be an almost impossible source of raw materials.
2、 CaCO3 powder can be directly added to the blown film processing line
CaCO3 is usually added to polyolefin in the form of filler. However, some special production lines can directly add CaCO3 powder into the production process of pipes and polypropylene sheets. The manufacturer has been able to add CaCO3 powder directly to the blown film processing line.
3、 Advantages of CaCO3 in blown film
It is worth noting that the selection of the right type of CaCO3 powder is the prerequisite for excellent performance in plastic applications, such as the correct specific particle size distribution, high purity and optimized surface treatment.
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Why CaCO3 is suitable for blown film
In addition to adhesion resistance, calcium carbonate has a variety of properties, such as higher mechanical and optical properties and other specific functions related to cost savings.
In addition, it can also change the physical properties of polymer melts. Compared with unfilled polyolefin, CaCO3 has higher density, lower thermal conductivity and thermal capacity, and can maintain solid state in extrusion process. Therefore, the main characteristics are as follows:
● increase the output of extruder
● reduce melt pressure and extruder torque
● increased efficiency and faster bubble cooling
● melt homogenization
In a word, adding CaCO3 into blown film production line is a simple and effective way to improve production efficiency and output.
The advantages of adding CaCO3 in blowing film
One
Improve film properties
Adding fine surface treated CaCO3 into the semi crystalline polymer matrix improves the properties of blown film, such as:
● increased stiffness
● improve impact resistance of drop hammer
● anti adhesion effect
● improved tearing resistance (Elmendorf)
● improved barrier performance
● slightly increase surface tension
● not stretched: increase film density
● stretching: reduces density and, if necessary, permeability
The change range of the above polymer properties depends on the film composition, film thickness, mineral content and CaCO3 type to a great extent.
Examples of successful application of CaCO3 in blown film include shopping bag, vest bag, garbage bag, paper film, agricultural film, heavy packing bag and back plate film.
Two
Reduce recipe cost
The addition of CaCO3 increases the film density, so it is necessary to reduce the film thickness to maintain a constant film weight, so-called downward metering. It is worth noting that there is no linear relationship between this increase and mineral content. For example: the content of CaCO3 is 30%, and the film thickness needs to be reduced by only 20% to keep the weight of the film constant.
Three
Improve sustainability
The whole process chain also saves energy. By mixing the CaCO3 powder, the hyperfusion technology also provides higher sustainability. The process saves heat energy in the extrusion process because these minerals have significantly lower specific heat than polymers. From this result, the technology can significantly reduce the carbon emissions of products and their impact on the environment.
Four
Advantages of direct feeding
The direct feeding of CaCO3 can save a lot of raw material cost. The potential of cost saving is shown in Figure 3, which is based on the polymer price of about 1100 euro / ton.
It can be seen that the material cost saving potential brought by the direct addition of CaCO3 powder in the direct extrusion process. This technology is very profitable, especially when the packing level is very high and the output of the extrusion line is very important. Another advantage of the direct extrusion solution is the opportunity to add other minerals directly, making the cost savings more significant. In addition, in some cases, the direct extrusion of CaCO3 still has the potential of cost saving and the effect of improving mechanical properties through the reinforcement of minerals.
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