High Barrier Cast Film Extrusion Line

Food Packaging: High-barrier films for meat, cheese, coffee, and snacks (using EVOH, PVDC, or AlOx layers).
Medical & Pharmaceutical: Sterile barrier bags and lidding films.
Industrial Laminates: Protective films for electronics or chemical-resistant liners.
Agricultural Films: Mulch films or silage stretch films requiring controlled water vapor transmission.

Real-World Case:
A European flexible packaging converter replaced a narrower line with the JCF-3000ZG. With a 2700 mm finished width and 150 m/min line speed, they increased output by 40% while maintaining a thickness tolerance of ±0.005 mm. The line produces a 5-layer EVOH-based barrier film for modified atmosphere packaging (MAP) of fresh pasta, achieving <2 cc/m²/day oxygen transmission rate.

Wide Width & High Output
2200–2700 mm finished width reduces slitting waste and increases throughput per batch.
Maximum output of 700 kg/h (JCF-3000ZG) supports high-volume continuous production.

Ultra-thin to Medium Thickness Flexibility
Thickness range 0.03–0.25 mm allows production of both ultra-thin high-barrier films and sturdy industrial-grade films. 

High-Speed Stability
Runs at 150 m/min with automatic die lip adjustment and air knife system to prevent web flutter.

Multilayer Co-extrusion Capability
Supports 5–7 layers (optional up to 9 layers) for tailored barrier performance (e.g., symmetrical ABA or asymmetrical structures).

Energy-Saving Design
Servo-driven winders and variable frequency drives reduce energy consumption by approx 15–20% compared to conventional lines.

Fast Material & Color Change
Compact screw and barrel design with rapid purging system minimizes downtime between batches.

To ensure every roll of film meets international standards (ASTM, ISO, JIS), we implement a 4–stage QC protocol:
Stage 1 – Raw Material Validation
Melt flow index and moisture content testing for each resin layer.
 
Stage 2 – In–line Real–time Monitoring
Thickness gauge (X–ray or β–ray): ±1% accuracy across 2700 mm width.
Ultrasonic flaw detector: Identifies gels, fish eyes, or contaminants.
Optical surface scanner: Detects die lines, scratches, or carbon deposits.

Stage 3 – Laboratory Testing (per shift)

Stage 4 – Finished Roll Inspection
Core inner diameter, roll hardness, telescoping, and static decay testing.

Real-World Case:
A customer in Southeast Asia using the JCF-2500ZG reported a scrap rate below 0.5% within six months of implementing our QC matrix, compared to 3–4% on their previous line.

Q1: Can this line produce biodegradable high – barrier films?
A: Yes. With suitable screw design, it can process PLA, PBAT, or PBS – based materials. However, barrier performance (especially OTR) will be lower than EVOH – typically 50–100 cc/m²/day. It works well for short – shelf – life products (e.g., fresh produce).

Q2: How long does it take to clean the die once?
A: Complete disassembly, cleaning, and reassembly takes about 2–3 hours. We recommend cleaning every 800–1000 operating hours or when the optical scanner shows persistent die lines.

Q3: What is the typical energy consumption?
A: For a JCF-3000ZG running at full capacity (700 kg/h), average power consumption is around 280–320 kW, including extruders, heaters, chillers, and winders. That equals 0.4–0.46 kWh per kg of film.

Q4: Can the line run with post – consumer recycled (PCR) material?
A: Yes, up to 30% internal/post – industrial recyclate in the core layer, provided melt flow index variation is within ±15%. For post – consumer recyclate, a melt filtration system (≥80 µm) is recommended.

Q5: What is the lead time for spare parts?
A: Standard wear parts (screws, barrels, dies, chill rolls) are stocked in our warehouses in Europe and the US – 5–7 working days. Custom parts require 3–4 weeks.

Q6: How do you ensure thickness uniformity across the 2700 mm width?
A: Our automatic die with 55 thermal adjustment bolts (for JCF-3000ZG) and profile control software adjust each zone every 0.5 seconds. Typical tolerance is ±0.003 mm across the full width.