Product Introduction

Also known as a split-type laboratory continuous film forming equipment. The complete line consists of two independent units: the twin-screw extruder host unit on the right and the separate casting, cooling, traction and winding unit on the left, connected via melt pipeline and coat-hanger casting die.

Adopting co-rotating twin-screw high-intensity mixing structure with modular screw elements, this line integrates polymer blending modification and cast film forming into a continuous pilot production line. Pellets, powders and composite fillers can be fed directly into the machine to complete melting, blending, dispersion and cast film formation in one step without pre-pelletizing. It fully reproduces the working principle of industrial cast film production. Experimental data can provide references for process scaling-up, predict mass production processing problems and reduce the cost of new material pilot tests.The whole machine occupies a moderate floor area and fits laboratory floor environment. It runs with low noise and features convenient material change and cleaning, which greatly cuts the loss of expensive raw materials such as PEEK, lithium battery separator powder and high-end additives. It is widely used in material colleges of universities, scientific research institutes, new energy material enterprises, biodegradable material manufacturers and functional film R&D laboratories.

Product Configuration

Loss-in-weight / volumetric metering feeding system, 25 co-rotating twin-screw extruder host, vacuum degassing port, melt filter, coat-hanger casting die, mirror cooling casting roll assembly, traction unit, edge trimming mechanism, constant tension winding unit, PLC touchscreen electrical control system.

●25mm Co-Rotating Twin-Screw Extruder Host System

Screw diameter: 25mm; L/D ratio: 28. Modular threaded elements; kneading blocks and conveying blocks can be freely disassembled and reconfigured to adjust shear strength for filling modification, toughening blending and reactive extrusion. Barrel is assembled in segments; split barrel is optional for easy disassembly and cleaning to avoid cross-contamination between formulations. The barrel is lined with alloy, wear-resistant and corrosion-resistant, suitable for high-filled powders such as calcium carbonate, glass fiber and carbon black. Multi-zone independent PID electric heating + water cooling circulation, temperature control accuracy ±1℃, processing temperature range from room temperature to 350℃. It meets the processing requirements of high & low temperature materials including PLA, PEEK, PPS and UHMWPE, inhibits thermal degradation of polymers and ensures repeatability of experiments. Vacuum vent port is reserved on barrel to remove low-molecular volatiles.

Main motor adopts servo drive; screw speed is continuously adjustable from 0 -120rpm for stable extrusion. Max. throughput: approx. 3kg/h for small-batch scientific research tests.

●Metering Feeding System

Volumetric feeder is standard; loss-in-weight metering feeder is optional. Special screws for powder and pellet feeding, servo drive to precisely control feeding rate and stabilize formulation ratio. It supports multi-component simultaneous feeding and can be equipped with liquid forced feeding system for liquid additives.

●Melt Pump System

Melt pump system is available. Optional hydraulic double-station rapid screen changer filters gel and impurities in melt to protect casting die and improve film surface quality. Optional melt metering pump stabilizes melt pressure and flow and reduces extrusion fluctuation.

●Coat-Hanger Casting Die

Coat-hanger casting die with effective die width of 200mm. Maximum effective film forming width: 150mm. Die lip gap can be manually fine-tuned with independent temperature control for the die.

●Mirror Cooling Casting Roll Assembly

Roll face width: 220mm, chrome-plated mirror roll with surface roughness Ra0.01μm. Constant-temperature circulating cooling water runs inside the roll to rapidly quench and shape the molten film, delivering flat and smooth film surface with few crystal points. Air knife is optional to assist film attachment and reduce film flutter.

●Traction & Edge Trimming Mechanism

Traction rolls are driven by independent servo motors with full-line speed linkage and synchronization. Line speed: continuously adjustable from 0 to 10 m/min to accurately control film draw ratio. Pneumatic edge trimming mechanism is equipped to cut off thick edges on both sides and obtain regular film samples.

●Constant Tension Winding Mechanism

The winding unit adopts servo-controlled constant tension system with real-time adjustable tension. Films are wound uniformly without tensile deformation to keep the original state of samples. Multiple groups of polished transition guide rollers are configured to prevent scratches on film surface.

Processable Material List

● General plastics: PP, PE, EVA, PVC

● Engineering plastics: PET, PC, PA6, PA66

● Biodegradable materials: PLA, PBAT, PHA, PCL

● Specialty polymers: PEEK, PPS, PI, UHMWPE (ultra-high molecular weight polyethylene for lithium battery separator powder)

● Modified composite materials: glass fiber/mineral filled systems, carbon black/color masterbatch systems, flame retardant modification, toughening blends, conductive composite materials

Application Fields

✅ Universities & research institutes: teaching for polymer majors, project research, sample preparation for graduation thesis, research on polymer rheology and forming mechanism

✅ Biodegradable material manufacturers: formulation development and process optimization of biodegradable packaging films and degradable mulch films

✅ New energy material enterprises: formulation and forming process research for lithium battery separators, EVA photovoltaic encapsulant films and energy storage functional films

✅ Functional film manufacturers: R&D and sample making of optical films, barrier films, conductive films, waterproof and breathable films

✅ Color masterbatch, additives and modified material suppliers: evaluation of filler dispersion, additive screening and formulation comparison tests

✅ Third-party testing institutions: preparation of standard film samples for material performance testing and standard method verification