A two-layer blown film plant (often configured as AB or ABA) is an extrusion system that melts and combines two distinct polymer streams into a single, multi-layer plastic film. It is widely used to manufacture cost-effective, moderate-barrier films for shopping bags, courier bags, agricultural mulch films, and food packaging.

Core Plant Components

The blown film process combines precision hardware with automated controls to guarantee even layers and consistent film thickness.

Twin Extruders: The plant features two separate extruders. Each melts a specific polymer (such as LDPE, LLDPE, or HDPE) using heated barrels and rotating screws, allowing manufacturers to blend different materials or additives for customized film characteristics.

Co-Extrusion Die: A specialized die-head merges the two melted polymer streams into a dual-layer tubular structure. This die ensures uniform layer distribution and strong layer-to-layer bonding.

Air Cooling Ring: Positioned right above the die, this component blows a controlled stream of air to cool and solidify the upward-moving molten plastic tube (or bubble).

Collapsing Frame & Haul-Off: The solidifying film bubble is guided upward into a collapsing frame and pulled by nip rollers. These rollers control the film tension and speed, directly influencing the final thickness (micron) of the film.

Winding Unit: Finally, the flattened multi-layer film is rolled onto cores via a single or double-station winder, ready for storage or further processing (like printing or bag-making).