CPP Cast Film Extrusion Line

·Leveraging its wide-web capabilities and precise thickness control (0.02–0.12 mm), the JCF series serves a diverse range of end-use applications:
·Flexible Packaging – High-clarity CPP films for food packaging paper, snack bags, and candy twist wraps. The line speed of 250 m/min supports high-volume orders while maintaining stable optical properties.
·Textile Lamination – Soft, low-noise CPP films for diaper backsheets, sanitary napkin cover layers, and medical protective gowns. Finished widths of 4200 mm and 5200 mm reduce slitting losses and increase output per roll.
·Metallized Substrates – Low-gel, high-surface-energy films suitable for vacuum metallizing processes, used in decorative packaging and capacitor insulating materials.
·Composite Films – As a heat-seal layer in multi-layer structures (e.g., laminated with PET or BOPP), providing excellent heat-seal strength and puncture resistance.
·Real-world case: A leading flexible packaging producer in the Middle East installed a JCF4500PP to replace three narrow-width lines. They now produce 35-micron CPP film for snack bags at 1.4 t/h, with a 40% reduction in plant floor space and 18% lower energy consumption per kg. The wider web (4200 mm) enables slitting into 12 finished rolls simultaneously, raising daily output to over 33 tons.

·Ultra-wide width specifications – A 5500 mm die produces film with 5.2 m effective width, suitable for jumbo rolls, reducing roll-change frequency and joint waste.
Uniform 250 m/min constant speed across all lines – This consistency simplifies production planning, ensuring that the widest line runs at the same high speed as narrower lines, maximizing return on investment.
·Thickness tolerance of ±3% – Achieved through advanced automatic die lip gap control and chill roll temperature profiling, ensuring uniform optical and mechanical properties even at the edges.
·High output density – The JCF-5500PP can achieve 1600 kg/h, i.e., over 38 tons of 20-micron film in 24 hours – setting a benchmark for high-capacity CPP production lines.
·Energy-saving design – Insulated die heaters, all-motor variable-frequency drives, and heat-recovery air knives reduce unit energy consumption to below 0.32 kWh/kg.

We implement a four-stage quality assurance program to ensure every roll meets international standards (ASTM D882, ISO 527-3, and FDA/EU food contact compliance requirements).
Stage 1 – Online Thickness Monitoring
A beta-ray or X-ray gauge is installed after the chill roll, scanning the full web width. Data is fed back in real time to the automatic die bolt heating system, adjusting local die lip gaps to keep thickness fluctuations within ±0.001 mm.
An optical defect detector uses CCD cameras to capture pinholes, gels, and streaks at 250 m/min, triggering an alarm when defect density exceeds 5/m².
Stage 2 – Offline Laboratory Testing
Samples are taken every 2 hours for the following tests:
·Tensile strength (MD/TD) – ≥40 MPa in MD and ≥25 MPa in TD for 30-micron film.
·Elmendorf tear strength – Measured to ensure balanced tear performance for easy opening.
·Haze and gloss – Using a haze meter; typical haze <2% for transparent grades, and 45° gloss >85 GU.
·Coefficient of friction (COF) – Dynamic COF adjusted between 0.2–0.4 for smooth machinability.
Stage 3 – Roll Hardness and Winding Quality
A digital durometer checks roll density; uneven winding can cause roll telescoping and blocking. Our closed-loop tension control system maintains a precisely controlled taper tension profile, ensuring uniform mother-roll hardness with a hardness deviation ≤2 Shore A.
Stage 4 – Traceability and Documentation
Each batch is assigned a unique QR code linking all process parameters (melt temperature, chill roll temperature, line speed, thickness gauge readings). This enables full traceability from resin lot to finished roll, supporting ISO 9001 and IATF 16949 audits.
Case study: A Japanese hygiene film processor reported that after adopting our recommended quality control scheme, their customer complaint rate dropped from 2.1% to 0.3% within three months. The online thickness feedback system alone reduced scrap by 12%, saving over USD 45,000 in raw material costs annually.

Q1: Can the JCF line process materials other than PP?
A: Yes. The extruder screw and die are designed for PP homopolymers, copolymers, and terpolymers, but with barrel and screw modifications, it can also process PE and certain biodegradable resins (PLA/PBAT). We offer custom screw geometries for multi-resin flexibility.

Q2: What is the minimum thickness achievable at maximum width?
A: At 5200 mm finished width, the minimum thickness for stable production is 0.02 mm (20 microns). For thinner films (down to 12 microns), we recommend reducing the width to 4000 mm or lowering the line speed to 180 m/min to maintain thickness uniformity.

Q3: How long does it take to change die gaps for different thicknesses?
A: The motorized die lip adjustment system allows complete thickness changes (e.g., from 20 to 50 microns) within 10–15 minutes while the line is running, using preset recipe memory, without manual shim adjustments.

Q4: What are the recommended maintenance intervals for the chill roll and die?
A: The chrome-plated chill roll should be polished every 3000 operating hours; the die lip should be cleaned after every 500 tons of production (or weekly, whichever comes first). Our predictive maintenance software alerts operators when vibration or temperature trends deviate, preventing unplanned downtime.

Q5: How does the line handle edge trim reduction?
A: We integrate edge-trimming units with a pelletizing reclaim system. Trimmed edges (typically 50–80 mm per side) are automatically returned to the extruder hopper via a forced-feed crusher-reclaimer, keeping material waste below 1.5% of total output – well below the industry average of 3–4%.

Q6: Can the line be upgraded to higher speeds later?
A: Yes. The gearbox and motors are designed with reserve capacity for future upgrades to 300 m/min by replacing screw and barrel assemblies. Many customers choose this option after two years of operation to expand capacity without purchasing a completely new line.