PS Sheet Extrusion Line

Food & Consumer Packaging (Blister / Thermoforming)
Case – Berry Containers (Europe)
A European fruit distributor uses our PS extrusion line to produce transparent hinged-lid berry trays. They run 0.35 mm thickness, 1200 mm width. With EVOH co-extrusion capability, the line provides an oxygen barrier that extends shelf life by 6 days.
Case – Disposable Cups & Lids (Turkey)
A Turkish manufacturer processes HIPS at 0.45 mm thickness and 380 kg/h output, supplying 500,000 cups per day to fast-food chains.

Stationery & Decorative Sheets
Case – PVC-Free Ruler (Japan)
A Japanese stationery brand switched from PVC to PS sheet (0.6 mm thick, 900 mm wide). Our line’s low-shrinkage die ensures edge flatness of ±0.03 mm – critical for high-precision printing.
Case – Folder Dividers & Name Card Holders (Vietnam)
A Vietnamese factory produces 0.18 mm PS sheets at 420 kg/h, delivering matte-finish dividers for office product exporters.

GPPS Thick Sheets (1.5–10 mm) – LED Light Diffusers
Case – Light Diffuser Panels (China)
A Chinese manufacturer runs GPPS at 2.5 mm thickness, 1400 mm width, achieving 92% light transmittance. The roll cooling system eliminates optical distortion.

Energy-efficient screw – Consumes 18% less energy per kg compared to conventional single-stage screws. Verified by a Malaysian customer running 24/7.
Fast thickness changeover – Automatic die gap adjustment cuts changeover time from 45 to just 12 minutes.
Vertical three-roll calendering – Eliminates fisheyes and surface flow marks, even at 0.15 mm ultra-thin sheets.
Online thickness gauge with closed-loop control – Holds thickness tolerance within ±3% of the target value.

Every batch is fully traceable.

Stage 1 – In-Process Monitoring
Thickness scanning: A traversing beta gauge scans 36 points across 1500 mm width every 2 seconds. Alarms trigger at ±0.01 mm deviation.
Melt pressure & temperature: Sensors at adapter and die. Target melt temps: 190–210°C (HIPS), 200–230°C (GPPS).
Chill roll surface temperature: Monitored by infrared thermal camera – max 2°C variation across the entire roll.

Stage 2 – Offline Lab Testing

Stage 3 – End-Use Simulation
Thermoforming test: Each batch of blister sheet is run on a former identical to one used by a Polish dairy customer – 200 trays checked for stringing and corner thinning.
Printability test: Stationery sheets screen-printed with UV ink, then cross-cut tape test per ASTM D3359 (must achieve 4B rating).

Stage 4 – Long-Term Reliability
Aging test (72h, 60°C / 90% RH): No yellowing or warping – essential for tropical markets (e.g., Philippine food exporters).
Dimensional stability: After 24h at 50°C, shrinkage ≤1.5% in both directions.

Q1: Can the same line run both 0.2 mm and 8 mm sheets without changing the screw?
A: Yes, with a small caveat. The standard screw is optimized for 0.3–3.0 mm. For 8–10 mm GPPS, we recommend swapping to a 34:1 L/D screw – a 2 – hour changeover. A Canadian customer runs 0.18 mm on weekdays and 6 mm diffuser panels on weekends using our dual-screw setup.

Q2: What’s the maximum line speed for 0.2 mm PS sheet?
A: At 0.2 mm thickness and 1400 mm width, you can reach 28 m/min (≈470 kg/h for GPPS). If your recipe includes 15% recycled PS, reduce to 22 m/min to maintain surface quality.

Q3: How do I eliminate die lines on transparent stationery sheets?
A: We include a 120 – mesh melt filter and edge dam devices to prevent carbonized material buildup at the die ends. A Brazilian notebook cover manufacturer eliminated 99% of die lines – verified over 500 m of continuous production.

Q4: What’s the actual energy consumption per ton?
A: Measured on a Turkish line running HIPS (0.5 mm, 1200 mm, 380 kg/h): total installed power 285 kW, real consumption 210 kWh per ton – including extrusion, winding, and edge trimming.

Q5: Can I co-extrude EVOH for barrier sheets?
A: Absolutely. The line supports 3-layer A/B/A or A/B/C configurations. A Spanish meat packager runs a 0.4 mm total thickness structure: HIPS (0.35 mm) + EVOH (0.05 mm). We supply a feedblock with feedback control to keep EVOH layer uniformity within ±5%.

Q6: How often should the chill rolls be polished?
A: For mirror – finish stationery grade – every 2000 operating hours. For matte or embossed blister rolls – every 4000 hours. We include a surface roughness tester (Ra ≤ 0.05 μm) for on – site verification.

Q7: What scrap rate can I expect?
A: Under normal conditions (stable raw materials, consistent ambient temperature), we guarantee scrap ≤3% (including edge trim and start – up waste). A Korean electronics tray manufacturer achieved 2.1% over three months – verified by their own records.