Client Background
A materials engineering research center sought to develop innovative CPP/aluminum foil multi-layer composite packaging films. The key requirement was to use compact experimental equipment for process verification and small-batch pilot production, simulating industrial processes to minimize trial-and-error costs. Additionally, the equipment needed user-friendly operation, easy maintenance, and compatibility with laboratory and pilot workshop environments.
Core Pain Points
- Poor Compatibility: CPP and aluminum foil have poor compatibility, leading to delamination, wrinkling, and aluminum foil oxidation during lamination, which compromise barrier properties and appearance.
- Process Precision: Strict control of temperature, pressure, and speed is essential to ensure consistency between experimental and mass production data, while balancing CPP's heat resistance and aluminum foil stability.
- Production Stability: Reliable pilot production is critical to guarantee batch consistency of composite films, meeting sample testing and market validation requirements.
POTOP Solution
POTOP tailored a comprehensive solution with the Precision Single-Screw Extrusion Casting Compound Machine, integrating process precision and operational ease to resolve key pain points:
- Equipment Configuration
The custom system comprises a 30mm single-screw extruder, casting composite molding unit, coating unit, drying device, winding system, two unwinding units, thickness gauge, and defect detection system.Equipped with precision melt gear pumps, multi-layer composite dies, high-sensitivity tension detectors, automatic deviation correction systems, and static elimination devices.Features a cast roller with a diameter of Ф400mm and width of 350mm, with an output speed range of 0-10m/min.Enables stable production of CPP/aluminum foil double-layer composite films, supporting integrated stretching and winding operations to prevent aluminum foil damage. Real-time thickness monitoring via the thickness gauge and immediate defect detection via the defect inspection system ensure product quality.
- Process Optimization
Optimized die flow channel design to precisely control composite temperature and pressure, avoiding aluminum foil oxidation and CPP thermal degradation. This ensures tight bonding between layers, eliminating delamination and wrinkling.The cast roller adopts a high-low temperature dual-roll structure for rapid cooling and forming, enhancing film flatness and bonding strength.
- Operation & Maintenance Optimization
Tool-free disassembly design for easy cleaning and maintenance.Industrial-grade PLC + touchscreen human-machine interface for convenient parameter adjustment, with short training requirements for operators.48-hour after-sales response to ensure stable equipment operation.
Application Outcomes
After commissioning, the equipment fully met the client's R&D and pilot production needs for CPP/aluminum foil composite packaging films, delivering remarkable results:
- Quality Assurance: Real-time monitoring by the thickness gauge and defect detection system, combined with the coating unit and drying device, ensures reliable bonding and stability, with no delamination or oxidation defects.
- Data Accuracy: Deviation between experimental and mass production data is ≤5%, providing strong support for large-scale production and reducing trial-and-error costs by over 60%.
- Efficiency Improvement: Continuous stable operation supports a monthly pilot output of 500-1000kg, meeting sample testing and market validation needs and accelerating product innovation.
- Cost Reduction: Easy operation and maintenance reduce labor and operational costs, while minimizing aluminum foil processing losses.
Case Summary
POTOP Precision Single-Screw Extrusion Casting Compound Machine, with precise process control and flexible adaptability, is the preferred equipment for R&D and pilot production in the CPP/aluminum foil composite packaging field. It effectively addresses core challenges in composite processing, balancing process precision and operational ease to help enterprises shorten R&D cycles, reduce production costs, and drive product upgrading.
