Coextrusion system for the production of 3 layer blown film

FLEXIBILE – MODULAR – EFFICIENT

Film coextrusion is becoming more and
more widespread in the packaging
industry and is quickly replacing
monolayer film production.
Today, companies that invest in a new
film extrusion system typically choose a
3-layer co-extrusion line with the highest
output engineered into the center layer
which optimizes productivity and line
flexibility.

Always in tune with the industry needs,

Macchi introduced at the Plast 2000
exhibition in Milan, the innovative series
of COEX flex® extrusion systems, which
immediately met with huge success.

Macchi’s COEX flex® compact extrusion

systems are equipped with three
extruders, a side-fed co-ex die, tubing
and all required connectors. All
components are assembled on a
custom platform and offer a compact
group that is in tune, user friendly, easy
to install and economical to transport.
One of the great advantages of the
COEX flex® system is its ability to
replace a traditional monolayer
extrusion system and still occupy the
A

same floor space. This up-grade has

been successfully applied in dozens of
applications worldwide.

By virtue of our current level of design

technology in dies, air rings and B
extrusion feed screws, it has allowed the
Macchi COEX flex® line to achieve a
standard manufacturing series COEX flex® Configurations
production level.
Die Range Kg/h max Dimension Weight Kg
Size Extruders mm mm
The criteria followed for the construction 2 x 45 Min 150 A 2100
Size 1 1 x 55 Max 300 200 / 230 B 4950 7200
of the platform have always been: 2 x 55 Min 180 A 2100
Size 2 1 x 65 Max 300 300 / 350 B 4950 8500
devoted attention to detail, choice of
2 x 65 Min 220 A 2100
first quality materials and the desire to Size 3 1 x 80 Max 400 450 / 500 B 5800 10500

offer the industry a ready-to-use, 2 x 65 Min 300 A 2100

Size 4 1 x 80 Max 500 350 / 600 B 5800 11200
reliable product incorporating world- 2 x 80 Min 300 A 2100
Size 5 1 x 100 Max 500 400 / 600 B 6800 12000
wide available quality components.
2 x 80 Min 400 A 2100
Size 6 1 x 100 Max 600 500 / 800 B 6800 14000
Primary Standard Components

• A/C Motors
exhibiting low energy consumption,
minimum maintenance and a greater
quality control

• Bi-metallic Extrusion Barrels

an inherent high resistance to wear
and corrosion

• Infrared Barrel Heating

power saving up to 20%, long heater
element life and quicker cooling
response times

• Air Ring and IBC Blowers

filtered and insulated for noise and
dust control. All motors are inverter
controlled

• Technologically Advanced
Electrical Components
focusing on the main drive speed
control, the advantages represent a
cleaner and more efficient electrical
consumption, keeping in mind a
respect for international safety
regulations for both personnel and the
additional electrical components

• Control Panel Conditioning

Systems
designed to maintain an ideal
temperature inside the electrical
cabinets allowing optimum
component performance under the
most demanding conditions.
Feedscrew, Screenchanger and
Die Technology

The feedscrews are a barrier type,

designed for optimum performance in
processing a wide variety of materials
including LDPE, LLDPE, EVA,
Metallocenes, PP, PS, PA resins and the
major HDPE resins available on the
market today.
Particular attention has been paid to the
consistency of our manufacturing
processes and the quality of materials in
order to guarantee a long and productive
life span.
Custom coated bimetallic screws
perfected by Macchi after many years of
experience are available as an option.

The screenchangers are a prime

consideration when processing materials
that are temperature sensitive.
These hydraulic Macchi screenchangers
are manufactured to tight tolerances,
designed with minimal allowable
polymer volume and streamlined flow
paths in order to avoid hang-up points
and to facilitate material change over
operations.

The extrusion dies are the heart of the

system. Macchi COEX flex® dies have
proven their flexibility and quality since
1997 with the beginning of their series
production.
The operating principles and material
distribution are distinct and superior to
the more traditional bottom fed or
multi-level side fed die technologies
available on the market today.
This is due mainly to:

• approximately 30% less material

contained inside the die than with
standard designs. This leads to
quicker and more efficient material
changes.

• lower operating pressures while

maintaining maximum output rates.
This allows greater flexibility in
processing a wider variety of
materials even with high viscosity.

• the integrated IBC system is

completely independent from the
heated components of the line,
allowing for the least amount of heat
exchange to take place and reducing
any chance of gauge variation due to
temperature variables.

• all layer flow paths are kept

independent until combined in the
top die zone just below the die lips.
This allows for near perfect
distribution of the thickness of each
layer, regardless of differing material
viscosities.

• Macchi’s exclusive die design

maintains equal material residence
times on each layer, whereby stack
die designs engineer a variety of flow
paths and time relative to the number
of layers.
Application of the Macchi
COEX flex® Group

At present, there exist three different

sizes of the Macchi COEX flex® unit:
small, medium and large. They have
been designed also to easily substitute
a typical monolayer extruder and
transforming the line into a co-extrusion
system while limiting the cost of the
investment.
With this up-grade, improved gauge
uniformity due to the new die
technology and increased production
due to the IBC system present on the
medium and large models are
guaranteed.
The complete line is available in different
versions by using various components
and configurations due to the
remarkable modularity of the elements.

Oscillating take-off units

Built exclusively in the horizontal
version, they are available in 1200 mm,
1600 mm, 1800 mm, 2400 mm.
The COEX flex® groups have also been
fitted on large lines with take-off units up
to 2800 mm and 3200 mm widths.

Winders
Manufactured in various models and
dimensions, the most popular types are
the Macchi BSA basic automatic winder
and Macchi BO Plus® . These are part of
a line of winders that are considered one
of the top performing winders available
on the market worldwide.
The BO Plus® winder can now be
equipped with various features such as:
winding with gap, pure axial winding
and reverse wind capabilities.
The top of the line BO Plus® winder is
protected by 3 different patents.
Its final configuration is dependent on
the type of film production required.
Modular roboticized systems have been
designed in order to entirely automate
the production process and to
guarantee a safe work place.

Gravimetric systems
Macchi gravimetric systems have been
designed to be compact, practical and
easy to integrate with the extruders.

Control systems
Macchi COEX flex® group is complete
with world-wide available quality
electrical components and operator
control console. Many of the operating
systems available today can be
integrated into these production
controls.
Modular and expandable, Macchi’s
EASY CONTROL® is one of the most
complete production managing
systems available today.
Film thickness profile control is one of
the many systems available as an
option.
 www.bonobodesign.it
14500 mm

Rev.004-11/05
The content of this catalogue is for informative purposes only. All data concerning technical specifications and production rates granted depend exclusively on contractual agreements.
16000 mm

Typical layout where the COEX flex® group can be fitted on high-tech coextrusion lines up to 3200 mm, or simple lines with
BSA automatic winders.

9350 mm

13400 mm

Macchi S.p.A. - 21040 Venegono Inferiore (VA) Italy - via Papa Paolo VI, 5 - Tel. +39 0331 827.717 - Fax. +39 0331 827.750
email: macchi@macchi.it - www.macchi.it