CPE Embossed Breathable Film Extrusion Line

Our JCFPE series (screw diameter 120–135 mm, die width 1900–2800 mm) produces high-output breathable film at a line speed of 180 m/min, with product thickness ranging from 0.02 mm to 0.15 mm and a net width up to 2500 mm. Below you will see the actual application areas of these machines, why they outperform competitors, how we ensure quality, and answers to the most common technical questions.

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Application

These lines are designed for embossed CPE breathable film – widely used in hygiene, medical, and packaging industries.

Baby diapers and adult incontinence products
Example: A Turkish hygiene product manufacturer uses the JCFPE-135-2800 to produce breathable backsheet film 2500 mm wide and 0.025 mm thick at 180 m/min. The 2800 mm wide die reduces edge trim to less than 5%, directly improving material utilization.

Sanitary napkin release film and breathable backsheet
Example: A Polish converter uses the JCFPE-125-2300 to produce 2000 mm net width embossed film for pantyliner products. The 0.02–0.05 mm thickness range perfectly matches low basis weight requirements.

Medical protective clothing and surgical drapes
Example: During the pandemic, a Chinese medical supplier adopted the JCFPE-120-1900 to produce 1600 mm wide breathable barrier film. The ±0.003 mm thickness tolerance ensures stable water vapor transmission rate (WVTR > 5000 g/m²/24h).

Breathable packaging (fresh produce and baked goods)
The 0.15 mm upper limit enables production of strong yet breathable bags that prevent condensation.

Advantages

Feature	Value Proposition
Φ120–135 mm screw	High plasticizing capacity – the 135 mm screw reaches 350 kg/h, supporting 180 m/min line speed without melt fracture.
2800 mm die	2500 mm net width = only 300 mm edge trim (10.7% waste), well below industry average (15–18%).
0.02–0.15 mm thickness	One machine covers both ultra – thin hygiene film and thicker agricultural/industrial breathable film.
180 m/min line speed	Actual output: 2500 mm × 0.03 mm × 180 m/min ≈ 810 kg/h of breathable film – comparable to European lines.
Integrated embossing unit	Forms uniform micro – patterns (e.g., diamond, dot, or custom patterns), improving breathability and reducing gloss.

Real case: A Vietnamese diaper manufacturer replaced two old 1500 mm lines with one JCFPE-135-2800, saving 40% of factory floor space and reducing energy consumption per ton of product by 22%.

Process

We implement a 5 – step online and final quality control process to ensure every roll of film meets hygiene and machinery standards.
Online monitoring
Online thickness gauge (beta ray or X – ray) – scans full 2500 mm width, reports deviations within ±0.002 mm. Alarms and automatically adjusts die bolts when out of range.
Line speed synchronization – PLC ensures speed deviation between unwinding → embossing → winding is <0.5%, preventing stretching marks.
Edge trim control – Ultrasonic sensors automatically control trim width; waste is ground in – line and recycled to the extruder (allows up to 30% reprocessed material).

Laboratory tests (every 8 hours)

Test Item	Standard	Acceptance Criteria
Thickness profile	ASTM D374	50 points across full width – max/min ratio ≤1.05
Tensile strength (MD/TD)	ASTM D882	MD ≥25 N/50mm, TD ≥15 N/50mm (for 0.03 mm film)
Elongation at break	ASTM D882	MD ≥200%, TD ≥400%
Air permeability	ASTM D737 (or Gurley)	300–1500 mm/s (adjustable via embossing pattern)
Hydrostatic head	AATCC 127	>300 mm H₂O (for medical grade)
Embossing depth uniformity	Optical microscope	±5% across full width

Finished roll inspection
Roll end quality – no telescoping, soft edges, or wrinkles.
Roll hardness – Shore A 65–75, ensuring stable unwinding tension.
Real case: During a factory acceptance test for a German customer, the JCFPE-125-2300 ran continuously for 12 hours at 180 m/min producing 0.02 mm film. The online thickness gauge recorded 99.7% of data points within ±0.0015 mm – exceeding customer requirements.

Parameters

Model	Screw diameter (mm)	T-die (mm)	Products width (mm)	Product thickness (mm)	Line speed (m/min)
JCFPE-120-1900	Φ120	1900	1600	0.02–0.15	180
JCFPE-125-2300	Φ125	2300	2000	0.02–0.15	180
JCFPE-135-2800	Φ135	2800	2500	0.02–0.15	180

Q1: Can you produce thickness below 0.02 mm, e.g., 0.015 mm?
A: Not recommended with the standard screw. The 0.02 mm lower limit is based on melt strength and bubble stability. At 180 m/min, thinner film would cause frequent web breaks. For 0.015 mm, we can upgrade to a high L/D ratio screw (custom).

Q2: How do you change the embossing pattern? Does it affect line speed?
A: The embossing roll uses a quick – change design (with roll change trolley, ≤45 minutes). Different patterns (dot, zig – zag, satin) do not reduce line speed – the line remains at 180 m/min. However, deeper patterns (>0.2 mm depth) may require slower cooling, so we recommend testing first.

Q3: What is the typical energy consumption per ton of product?
A: Measured on JCFPE-135-2800:
Extruder + heating: 220 kW
Chiller + air knife: 35 kW
Winder + drives: 25 kW
Total power ~280 kW, corresponding to 800 kg/h output → 350 kWh/ton. This is 15% lower than singlescrew lines without an integrated embossing unit.

Q4: How do you solve edge thickness non – uniformity?
A: Our die has adjustable flexible lip bolts spaced 40 mm apart. Combined with the online thickness scanner, the PLC automatically adjusts each bolt every 2 seconds. Edge bolts within the first 150 mm on each side are independently controlled to eliminate “dog – bone” thickness profiles.

Q5: Can you use calcium carbonate masterbatch to produce breathable film?
A: Yes. The screw is tungsten carbide coated for hardness and features a specially designed mixing section for 40–50% CaCO₃ filler. We recommend starting at 40% and then gradually increasing. The vented barrel removes moisture from the filler – critical for bubble stability.

Q6: What is the recommended floor space for the JCFPE-135-2800?
A: Extruder + die + embosser + winder = 18 m (length) × 6 m (width) × 4.5 m (height). Add an extra 3 m on each side for roll storage and maintenance access.