PP/PS Sheet Extrusion Lines

The JW series PP/PS sheet extrusion lines (models: JW5120/65-1000, JW5130/75-1000, JW5150/90-1000, JW985/65-1000, JW590-H, JW5100-H) are designed to produce high-quality rigid sheets with a thickness of 0.2–2.0 mm and a standard width of 800 mm. These lines are widely used in the thermoformed packaging industry and can process polypropylene (PP) and polystyrene (PS) materials.

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Application

Thanks to a wide output range (350–850 kg/h) and thickness flexibility, these lines serve various packaging sectors:

Food Packaging Containers
Case study: A Thai food packaging manufacturer uses the JW5130/75-1000 (output 500–650 kg/h) to produce 0.4 mm PP sheets for microwave lunch boxes. The line runs 22 hours per day, maintaining thickness tolerance consistently within ±0.01 mm.

Disposable Cups & Lids
Case study: A Mexican cup producer selected the JW5150/90-1000 (700–850 kg/h) for high-output PS sheet production. The 800 mm width perfectly matches the layout of its cup thermoforming machines, reducing edge trim scrap by 12%.

Electronic Trays (Anti-Static)
Case study: A Chinese electronic component supplier uses the JW590-H (400–500 kg/h) to produce 0.8 mm anti-static PS trays for IC shipping. The line’s precise melt temperature control prevents degradation of the conductive additives.

General Thermoforming Sheets
The JW5100-H (600–700 kg/h) is a popular choice for dairy cup and yogurt cup production, while the JW985/65-1000 (550–700 kg/h) offers a balance between the smaller JW5120 and larger JW5130, suitable for mid-sized factories.

Advantages

Advantage	Technical Support	Real Benefit
Wide output range	350–850 kg/h across models	One line handles both small and large orders without equipment changeover
Precise thickness control	0.2–2.0 mm adjustable; automatic thickness control system	Material savings – e.g., reducing over-thickness by 0.01 mm on 1.0 mm sheet saves ~8 tons of raw material per 8000 operating hours per year
Dedicated extruder combinations	JW5120+JW565, JW5130+JW575, etc.	Screw designs optimized for PP or PS, ensuring higher plasticizing capacity and lower specific energy consumption
800 mm standard width	Compatible with most global thermoforming machines	No slitting or custom mold adjustments needed – reduces secondary operations
High-output H-series models	JW590-H / JW5100-H	Up to 700 kg/h with lower back pressure; suitable for 24/7 continuous operation

Real Customer Feedback
A Turkish packaging company replaced two old lines with one JW5150/90-1000, increasing daily PS sheet output from 12 tons to 16.5 tons while reducing energy consumption by 18% – thanks to the efficient screw and barrel design.

Process

Each JW extrusion line undergoes rigorous in-line and post-production testing to ensure consistent sheet quality and machine reliability.
A. Incoming Material & Melt Quality
Each batch of PP/PS resin is tested for MFI (Melt Flow Index) before feeding.
Screen pack condition is monitored via melt pressure sensor – alarms operator when back pressure rises >10%.
B. During Extrusion (Real-Time)

Parameter	Target	Monitoring Method
Thickness profile	±3% of setpoint	Online beta gauge (cross-web scanning)
Width shrinkage	≤1.5%	Laser edge sensors
Surface defects (gels, black specks)	<0.5 per m²	Automatic visual inspection system
Mechanical properties (tensile, elongation)	Batch sampling every 4 hours	Universal testing machine (ASTM D882)

C. Post-Production Testing (Finished Rolls)
Dimensional stability test: Samples placed in 50°C oven for 24 hours – acceptable shrinkage <2%.
Heat sealability test (for PS trays): Seal strength ≥25 N/15mm at 130°C.
Case – Quality Verification
A Polish rigid film processor requested a complete FAT (Factory Acceptance Test) for its JW5100-H line. A trial run produced 5 tons of 0.5 mm PS sheet. Third-party lab results showed:
Thickness tolerance: +0.008 / -0.006 mm
Haze (PS): 2.1% (standard <3%)
Output stability: 645–658 kg/h over 8 hours
All passed the customer’s strict requirements for medical blister packaging.

Parameters

Model	JWS120/65-1000	JWS130/75-1000	JWS150/90-1000	JWP85/65-1000	JwS90-H(High-yield)	JwS100-H(High-yield)
Material	PP、PS
Extruder Specification	JWS120+JWS65	JWS130+JWS75	JWS150+JWS75	JWP85+JWS65	JWS90	JWS100
Products Width(mm)	800	800	800	800	800	800
Products Thickness(mm)	0.2-2.0	0.2-2.0	0.2-2.0	0.2-2.0	0.2-2.0	0.2-2.0
Capacity(Max.)(kg/h)	350-450	500-650	700-850	550-700	400-500	600-700

Q1: Can the same line process both PP and PS?
A: Yes. All JW models can run both PP and PS. However, switching materials requires a screw purge and temperature profile adjustment (PP: 190–230°C; PS: 170–210°C). The JW590-H and JW5100-H are equipped with a quick-change screen pack system, reducing changeover time to less than 30 minutes.

Q2: What is the actual output for 0.3 mm PP sheet on the JW5130/75-1000?
A: Based on customer data: approximately 480–520 kg/h. The nominal range of 500–650 kg/h is for 0.5–1.0 mm sheets. Thinner sheets yield slightly lower output due to line speed limitations (max 35 m/min at 800 mm width). Our engineering team can provide specific output curves for your target thickness.

Q3: How can I avoid thickness stripes (cross-web thickness variation)?
A: Thickness stripes typically come from die lip contamination or non-uniform temperature distribution. We recommend:

Cleaning the die lips daily with a copper scraper.

Using an automatic die bolt heating system (optional on JW5150 and JW985 models) to fine-tune local thickness.

Ensuring the melt pump (integrated on JW5130 and above) runs at a constant speed – any speed fluctuation indicates a feeding issue.

Q4: What is the difference between standard models and “-H” high-output models?
A: The JW590-H and JW5100-H feature:

Larger L/D ratio (36:1 vs. standard 33:1)

Grooved feed section for higher conveying efficiency

Intensified cooling barrel – allows 20–30% higher screw speeds without overheating.
Result: up to 700 kg/h vs. ~450 kg/h for a similarly sized standard line.

Q5: My factory has limited floor space. Which model is most compact?
A: The JW5120/65-1000 has the smallest footprint (approx. 18 m × 2.5 m including winder). It still delivers 350–450 kg/h – sufficient for small to medium packaging producers. The JW985/65-1000 is also relatively compact but offers higher output (550–700 kg/h) with a slightly longer cooling section.

Q6: What is the typical energy consumption per ton of sheet?
A: On-site data from a Vietnamese customer running the JW5150/90-1000 on 0.6 mm PS:

Total installed power: 280 kW

Actual consumption: 0.28–0.32 kWh per kg of sheet (including extruder, pull rolls, winder, and heating/cooling).
For PP, energy consumption is about 5% higher due to higher melt temperatures.