Film

Sheets
Group 7
WHAT IS
FILM SHEET ?
Is it a Plastic Wrapper?

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 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 s
heets
Made from different resins thus containing
different kinds of properties
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 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.
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 Groups of Polymer Films
Natural polymers Artificial / Synthetic  largest group
polymers
⦁ Proteins, natur   films based on polyolefin
⦁ Products of the chemical  s, polyvinyl chloride, poly
al rubber
treatment of natural poly amides, polyvinylidene chl
and cellulose
mers oride, polystyrene, polyet
⦁ Eg. Cellophane ⦁ hylene terephthalate, and
 Includes films produced 
from cellulose esters, as   polyimides.
well as from natural rubb
er that has undergone pri
or hydrochorination

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Benefits of
Polymer Films
 Source Reduction: Plastic 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 Containment, Protection, Convenience,

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. 8
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Use diagrams to explain your
ideas

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89,526,124
Whoa! That’s a big number, aren’t you proud?

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89,526,124$
That’s a lot of money
185,244
users
And a lot of users

100%
Total success!
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Film Sheet Extrusion

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Film Sheet Extrusion
Sheet / Film Extrusion is the process which is used for the products like plastic
sheets or films. During the extrusion of these plastic materials, the required
cooling is achieved by the action of pulling which is done through a specific set of
cooling rolls that are generally three or four in number. These cooling rolls are
also called calender or “chill” rolls. Extremely fast running speed develops
“nerve”, which is an undesirable condition. This condition occurs when insufficient
contact time is permitted to dissipate the heat, which is available in the extruded
plastic.

In the plastic sheet extrusion, the rolls deliver the required cooling in addition to
determining the sheet thickness along with surface texture. This is done specially
in the case of structured rolls; i.e. levant, smooth, haircell, etc). Commonly, co-
extrusion is used for applying one or more layers for acquiring various specific
properties like soft touch or "grip", UV-absorption, matte surface or energy
reflection.

The units for the solid sheet extrusion comprises minimum one Extruder along
with one sheet extrusion die. These are supported by polishing stack which
commonly includes 3 calenders that calibrate & cool the sheet with the use of
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their calender nips or surfaces. Behind this, the draw-off rolls to cool air and roller
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Materials And Applications

Polystyrene is the most general polymer used in sheet

extrusion. It is major plastic material for the thermoformed
packaging, and it gives competition to ABS & PP in the
technical markets.

The end use applications of the sheet / film extrusion include

margarine, tubs and pots for yogurt and desserts.
In the liquid packaging industry (wine boxes, juice cartons,
etc.), the base if the process of plastic extrusion onto paper. In
addition, there is also an aluminum layer present in this
process.
In the food packaging, the plastic film is occasionally metalized.

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Film Blowing Process

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2 3 4

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Pellet Melting
The polymer material starts in a pellet form, which
are successively compacted and melted to form a
continuous, viscous liquid

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Extrusion or Expansion
Air is injected through a hole in the centre of the annular die and
the pressure causes the extruded melt to expand into a bubble.

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Cooling
Air is injected through a hole in the centre of the annular die and the
pressure causes the extruded melt to expand into a bubble.

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Winding
The film moves into a set of nip rollers which collapse the bubble and flatten it into
two flat film layers

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Film Blowing Process

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 ADVANTAGES:
 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

 USAGE: Blown film extrusion can be used to make one large film, two
smaller ones, or tubes that can be made into bags.

 Also, one die can make many different widths and sizes without
significant trimming
 DISADVANTAGES:
 Blown film has a less effective cooling process than flat film.

 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 where as for blown film it is about 1.0 g/10 min

 The production rates for cast film are higher

 Cast film has better optical properties, including transparency, haze, and

gloss
Thanks!
Any questions?

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