"Smarter computer software for blown film is allowing less experienced workers to run complex processes. Macro Engineering & Technology has created what it calls the first fully automatic machine start-up software for blown film. Its new FAE (Fully Automated Extrusion) software is designed to speed start-up, especially of coex lines with many layers, which are notoriously operator dependent and may require hours to reach optimal operation. This software will be installed for the first time this month on a three-layer blown film line in Montreal. The second will go on a seven-layer line overseas at the end of September.

With the new program in place, an operator pushes only four buttons: Set-Up Recipe, Start Line, Thread Line, and Shut Off. After pushing Set-Up Recipe, the operator enters film gauge, film width, and resin blend. Then the operator manually threads up the line, and pushes “Start Line.” Everything else happens on its own, Macro says. The computer calculates the complete start-up sequence, including ramping up bubble width and IBC settings. When the processor changes product, the program adjusts automatically to the new set-up, as long as the line remains threaded...."

"Several machine makers showed new high-speed winders that are both more compact and able to wind bigger rolls of up to 60-in. diam. For example, Macro's new 6430 Stackable Turret Winder has a linear lay-on roll instead of a pivoting one, thus requiring less floor space. It can wind up to 60-in. rolls at up to 500 ft/min to keep pace with new high-speed printers...."

"Barrier cast film and sheet extrusion is getting a lot higher tech. In June, Macro shipped its most complex seven-layer cast film line ever. The line went to China to make meat packaging film. It has nine extruders—seven of 2 to 3.5 in., plus two of 1.75 in. for edge encapsulation. A feedblock and die from Cloren make a structure of PP-PE-tie-EVA-PVDC-EVA-tie-PE-PE. The structure could be said to have 11 layers, since some of the flow from one tie layer is diverted to encapsulate the PVDC and protect the die from corrosion..."

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