Group 7: Jacildo, Benjamin Luke Cabilar, Venus

Fang-asan, Adrian Liis, Nemuel Cyzar Dolit, Shaira

FILM SHEETS
I. Definition:
 A heat-extruded thermoplastic polymers
 Films: Continuous layer of polymers up to 0.2–0.3 mm thick
 Thicker layers of polymeric materials are called sheets
 Made from different resins thus containing different kinds of properties
 Examples: Polypropylene and polyethylene terephthalate or cast molded (e.g., acrylic).
 Film is usually oriented in two directions (biaxially), which means that is pulled or stretched in one
direction.

Groups of Polymer Films

A. Natural polymers
⦁ Proteins, natural rubber and cellulose
⦁ Eg. Cellophane
B. Artificial / Synthetic polymers
⦁ Products of the chemical treatment of natural polymers
⦁ Includes films produced from cellulose esters, as well as from natural rubber that has undergon
e prior hydrochorination.
⦁ Largest group
⦁ Films based on polyolefins, polyvinyl chloride, polyamides, polyvinylidene chloride, polystyrene, 
polyethylene terephthalate, and polyimides.

II. Raw Materials

⦁ LDPE/LLDPE – wraps, bags, packaging
⦁ HDPE – packaging, bags, liners
⦁ PP – shrink wrap, tape, sterile wrap
⦁ PVC – red meat package
⦁ PET – nonfood packaging (xray film, photographic film)
⦁ Other Resins

III. EXTRUSION PROCESSES

1. FILM AND SHEET CASTING
Sheet / Film Extrusion is the process which is used for the products like plastic sheets or films.
A. EXTRUSION- During extrusion of these plastic materials, Plastic resins need to be melted first
in the extruder by mechanical energy.
 B. DIE- The molten polymer is to be introduced in the die which is a rectangular and wide cross
section having a small gap. It shapes the polymer into another form that harden during cooling.
C. CHILL ROLL- The rollers should be about 3 or 4 in number. Molten extrudate is cooled on the
chilled rollers then solidifies. The rate of cooling determine some of important properties of the
finished product. Longer cooling means there is more available for crystal growth therefore the
crystallinity will be larger. Cystallinity affects some of the properties of the film coefficient of
friction, impact and barrier.
D. CORONA TREATMENT- increases the surface energy of plastic films, foils and paper to be
more receptive to inks, adhesives or other coatings.
E. BETA GAUGE- for measuring the thickness and trim reclaim
F. STACK-Consists of 3 rolls for sheet lines. To produce films with thickness exceeding 0.25 mm.

2. FILM BLOWING PROCESS

Typically, blown film extrusion is carried out vertically upwards, however horizontal and downward
extrusion processes are now becoming more common.

A. PELLET MELTING: The polymer material starts in a pellet form, which are successively compacted
and melted to form a continuous, viscous liquid. This molten plastic is then forced, or extruded,
through an annular die.
B. EXTRUSION OR EXPANSION: Air is injected through a hole in the center of the die, and the
pressure causes the extruded melt to expand into a bubble. The air entering the bubble replaces air
leaving it, so that even and constant pressure is maintained to ensure uniform thickness of the film.
C. COOLING: The bubble is pulled continually upwards from the die and a cooling ring blows air onto
the film. The film can also be cooled from the inside using internal bubble cooling. This reduces the
temperature inside the bubble, while maintaining the bubble diameter.
D. WINDING: After solidification at the frost line, the film moves into a set of nip rollers which collapse
the bubble and flatten it into two flat film layers. The puller rolls pull the film onto windup rollers.
 The film passes through idler rolls during this process to ensure that there is uniform tension in the
film. Between the nip rollers and the windup rollers, the film may pass through a treatment centre,
depending on the application. During this stage, the film may be slit to form one or two films, or
surface treated

ADVANTAGES:

1. Blown film generally has a better balance of mechanical properties than cast or extruded films
because it is drawn in both the transverse and machine directions. Mechanical properties of the
thin film include tensile and flexural strength, and toughness. The nearly uniform properties in
both directions allow for maximum toughness in the film
2. Blown film extrusion can be used to make one large film, two smaller ones, or tubes that can be
made into bags.
3. Also, one die can make many different widths and sizes without significant trimming

DISADVANTAGES

1. Blown film has a less effective cooling process than flat film.
2. The resins used for casting typically have a lower melt flow index, which is the amount of
polymer that can be forced through a standard die in 10 minutes according to a standard
procedure. The melt flow index for cast film is about 5.0 g/10 min whereas for blown film it is
about 1.0 g/10 min
3. The production rates for cast film are higher
4. Cast film has better optical properties, including transparency, haze, and gloss

IV. TYPES AND USES OF FILM SHEETS

Classification of film sheets are based on the materials used to manufacture it.
 1. LDPE - high-density version of polyethylene (HDPE), which is heavier, less flexible, and less elastic
—and therefore, not as useful for making protective film. LDPE film comes in a variety of types,
which allows it to be used for many different applications.
2. Co-Ex LDPE - is short for co-extruded low-density polyethylene. Co-extrusion means that two or
more layers of plastic are created simultaneously and formed together into a single sheet of film.
For example, one common co-ex combines a layer of black plastic with a top layer of white plastic.
This allows the advantage of the different characteristics of each layer, such as combining UV
reflection (white) with UV absorption (black) to provide better overall UV protection.
3. PVC - is very elastic and has a slick surface, which makes it ideal for many metal forming
applications.
4. PP - useful for high-heat applications.
5. PO - is a plastic film used on some painted metal surfaces and acrylic glass applications.
6. Semiembossed film – Semiembossed film can be used as a liner to the calendered rubber to
retain the properties of rubber and also to prevent dust and other foreign matters from sticking to
the rubber while calendering and during storage.

V. Benefits of Polymer Films

 Source Reduction: Plastic Film has a high strength to weight ratio, which means that
manufacturer can use less material when making a product or package.
 Cost: Because very little plastic film is needed to produce a highly functioning flexible package
(thicknesses generally range between .0005 and .003 inches), the manufacturer has to purchase
less material for the package, which translates into lower costs.
 Functionality: Used for
a. Containment: A package must be able to hold a product and give the consumer a
convenient way to transport it.
b. Protection: package made with plastic film is protecting the product from exterior influences
that could harm and/or devalue the product.
c. Convenience: Film in packaging and no packaging applications also provides convenience
to consumers. For example, film can be clear, which allows consumers to see a product
before they buy it or colored to protect the product from too much exposure to light.
d. Information:
 Versatility: Another benefit of plastic film is that it is versatile; it can be used alone, used in
conjunction with other plastic resins or even used in conjunction with other materials, such as paper
and aluminum.

References:

(2019). Film Sheets. Retrieved from https://encyclopedia2.thefreedictionary.com/Polymer+Films

(November 29, 2019)
V., John and Muller J & P (2012). Flat Film and Sheet Dies.
Understanding Plastic Films: It’s Uses, Benefits and Waste Management Options, 1997. A report prepared
by Headly Prat Consulting for American Plastic Council.