BLOWN FILMBlown Film

2

High clarity paper overwrap and embossedfilms for diaper applications

Shrink films for security bundling

High clarity and excellent sealing propertiesfor automatic packaging

Converter grade film for stand-up pouches

Three-, five-, and seven-layer structures for meatand cheese packaging

3

Systems Designed for ProfitableBlown Film Production

Battenfeld Gloucester is the worldwide leader in

blown film production lines. Built into every

Gloucester system, is the versatility, productivity

and control you need to be profitable. Each product,

from single-layer commodity film to advanced multi-

layer high-barrier structure, has its own set of unique

requirements. Using industry-leading technology,

Gloucester’s experienced blown film specialists will

help you implement the right system for virtually any

blown film application.

Converter grade films for printing, laminatingand coating

High clarity films for pouches and automaticpackaging

High-barrier film for food packaging

Paper towel and tissue overwrap

Heavy-duty shipping sacks

Smooth or textured geomembrane sheet

Construction and agricultural films

Specialized medical packaging

Shrink films

Stretch film

Synthetic paper

Monolayer and coextruded retail T-shirt bags

Tough films for demanding packaging

Blown stretch film offering well-balanced properties

4

Expert Guidance at Every Step

The technologies neededto create a cost-effectiveproduction system mustbe carefully balanced.In all cases, BattenfeldGloucester’s blown filmprofessionals have theexperience to guide youto the right choices for:

Systems that Growwith You

Material feeding andblendingExtruder size andscrew design Single or multilayer,low profile, stationaryor oscillating dies Air rings and internalbubble cooling (IBC)

New markets andapplications for plasticfilms are developing allthe time. As a result,innovative materialsand film structures arecontinually introducedto keep pace withmarket demand.

Taking advantage ofpotential growthdemands an integrated

Collapsing frames andoscillating hauloffsAutomatic winders foryour unique productsFully integratedprocess controlsystemsSystems design andproject management

Gloucester’s blown filmexperts work with youduring equipment spec-ification, installation,startup, and ongoingoperation, providingconsultation and assis-tance long after theinstallation is complete.

production systemflexible enough toadapt to thesechanges. Access to the newestand most specificproduction technology,and reliable technicalexpertise and support,is why leading filmproducers continuegrowing with blown filmsystems fromBattenfeld GloucesterEngineering.

Broad range of extrudersizes for a variety ofapplications

… to production

Technical expertise from planning …

Advanced screwdesign for high- quality melt

5

Superior Film for Demanding Applications Begins with Superior Extrusion

Longevity andReliability

The heavy-duty gearboxis designed for yearsof reliable operation.Hardened gears andhigh-capacity thrustbearings meet high torque requirementsand reduce operatingnoise, making allBattenfeld Gloucesterextruders a safe anddurable investment.

the film. The innovativedesign of ourContracool® Extruderscontrols this problemby directing heated airaway from the bubble.

High-performance films for challenging processes

Consistency in theProduction of FlatFilms

Production of high-qualityfilm requires that everycomponent in the systemworks together. One ofthe most important stepsin this process requiresthe extruder to feed ahigh-quality melt at highvolume. To assure this,our exclusive Variable

Lead Barrier Screw wasdeveloped for both oursmooth bore and grooved feed extruders.The VLB design provideshigh output and a consistently uniform meltacross a wide range ofpolymers.

Rugged construction guarantees high-quality rolls

Superior quality filmssuch as those used inlamination, metallizing,printing and otherconverting operationsare produced understrict specifications,and demand a highly

controlled process. Forinstance, heated aircarelessly vented froman extruder can causefluctuations in thetemperature aroundthe bubble, which cancause gauge bands in

Versatile die designsoffer innovative solutions

6

Precision Dies Deliver Uniform Layers and Flat Film

Targeting from Automatic Packaging to High Barrier Applications

This maximizesuniform flowdistribution for tightgauge control. Anoptimized shear rate is

generated along thechannels to preventcarbon buildup or gelformation, speeding upproduct changeovers.

All die components aremachined from highestaircraft grade drop-forged, through-hardened, and uniformlystress-relieved alloy steelto prevent distortionduring heat and coolcycles. The mass ofeach component isoptimized to providethermal homogeneityand maximum deflectionresistance throughout

the die. The result isdimensional stabilityyielding exceptionallyuniform flow rate andsuperb gauge control.For maximum uptime,Gloucester’s innovativetaper-lock, self-aligningdie parts can beassembled anddisassembled quicklyand easily at thecustomer’s plant; andthe die diameter and

die gap can bechanged withoutchanging the entiredie. All flow surfacesare electroless nickel-plated as standard toresist abrasion andcorrosion; alternativecoatings are also available.

Protective film for milk packaging

Reliable films for consistent sealability

Thermoformable high barrier films for food packaging

Self-aligning features guaranteeuniform layer thicknesses

Battenfeld Gloucester’sdies are designed toeffectively process awide range ofmaterials. Computer-

analyzed spiral flowchannels minimizeresidence time and lowflow areas to preventpolymer degradation.

7

Exceptional Cooling and Bubble Stabilization are Key Factors for High-Clarity Films

Battenfeld Gloucesterhas system engineereda series of interrelatedtechnologies thatvirtually eliminatebubble instability atconsistently high

outputs. The uniqueflow design of ouradjustable dual-lipUltraCool Air Ringprovides the widestrange of blow-upratios, the highest

Internal Bubble Cooling(IBC) is a very dynamicprocess that exchangeslarge volumes of hotand cold air inside theblown film bubble foradditional film cooling.It is a proven way to

Excellent optical properties areeasier to achieve using ourDigisonic IBC technology

High transparency is essentialto enhance product appeal

UltraCool advanced design offersup to 35% more throughput

New or existing lines areenhanced with our UltraCool Air Ring

Digisonic™ controlauto-balances blowerspeeds, trims airflow,and maintains superblayflat width accuracy.By using BattenfeldGloucester’s patentedfixed-position sonicsensors, the systemcompensates for swayand offset bubbleposition, while providinga direct digital readoutof layflat width.

Our patentedAutoprofile™ Air RingControl System workswith any Gloucester AirRing, adjusting airtemperature at preciseareas around the

bubble circumferencein response to onlinegauging data.Battenfeld Gloucester’sclosed loop controlsystem assures theflattest film in the

industry. The Autopro-file control system canalso be applied toBattenfeld Gloucesterdies, thermally adjust-ing die lip temperaturesinstead of air ring temperatures.

add up to 35% morethroughput to a blownfilm line. IBC supplieschilled air to the insideof the bubble throughan internal air ring whilehot air is removedthrough an exhaust

stack. IBC systems arecomprised of twovariable-speedblowers, an optionalchiller coil, an airflowcontrol valve, and ourDigisonic™ IBC layflatcontrol system.

cooling efficiency andthe tightest filmthickness control in theindustry. Thistranslates into faster,flatter and more cost-effective filmproduction.

8

Film is Flat and Smooth Before it Leaves the Tower

film needed for high-speed converting. AnOscillating Hauloff letsyou avoid the expense,floor space, andmaintenance neededby rotating dies orplatforms.

The Gloucester Air BoardCollapsing Frame uniformly“floats” the film’s entiresurface with regulatedairflow, virtually eliminatingfilm drag. Our compositeidler collapsers and slatcollapsers with low-frictioncovers are lower costalterna-tives that greatlyreduce bagginess in theweb caused by surfacedrag.

Both the Vertical andHorizontal orTraversanip® OscillatingHauloffs provide 100%randomization of thebubble usingcontinuous, smooth,nip roll oscillation. Itprovides the kind ofultra-flat randomized

… or horizontal Traversanip hauloffsdepending on film characteristics

Low-friction components contribute to smooth flat film

Select vertical …

As with extrusion andcooling, BattenfeldGloucester systemtechnologies bringunprecedentedprecision to collapsing,gauge randomization,

and physical hauloff ofthe blown film web; allcontributing to flat filmthat converts at consis-tently high rates day inand day out.

9

Winding Smooth Rolls for High-Speed Conversion

Battenfeld GloucesterSeries 1000 Winderscombine advancedengineering, heavy-dutyconstruction, andcentralized automatedcontrols. The diverseselection ofconfigurations andmodels assures

optimum roll quality foryour uniqueapplication. Rigid physical structuring,such as massive sideframes and cross girts,eliminates vibration, soyou can increase speedwithout compromisingroll edge quality.

Programmable logiccontrol (PLC), built intoSeries 1000 winders,provides more thanjust an excellent controlsystem. Software-based,your winder’s controlscan be readily custom-programmed to yourspecific production

needs, then easily reprogrammed to matchfuture requirements. ACflux vector drives provideextended range winding control whether theproduct is a thin mulchfilm or a thick heavy-dutysack.

Gloucester Series1000 Winders offer:

Single or dual turretdesignsShafted or shaftlesswindingForward and reversewinding and cutoverLoad cell tensionmonitoring and controlClosed loop layon rollcontrol and optionalgap winding mode

AC Flux Vector driveswith closed loop controldependent upon theapplicationSpeed matchedautomatic adhesivelesstransferCenter, surface, orcenter/surface windingWound roll diameters to60” (1520 mm)

Surface winder Model 1021Dual turret winder Model 1008D Single turret winder Model 1031S

To maximize profitabilityand flexibility,Gloucester offerstouchscreen controlson most Series 1000Winders allowing youeasy access to thePLC. Your operatorscan perform controlfunctions by just touch-ing the screen. Storedrecipes make customwinding setups easilyrepeatable.

10

Advanced, Easy to Use Process Control Systems

Easy to learn and operate,Extrol is a powerful tool thatcontinually monitors andmanages all setpoints andparameters including:

Vacuum loading, gravimetric blending, andlayer thickness controlAutoprofile film thicknesscontrolDrive speed andtemperature controlzonesAuto-trending of all datainputs, including process

Best of all, you canaccess your Extrolsystem from just aboutanywhere, thanks toExtrol Anywhere™ andExLink™ technology.The Extrol Anywheresystem provides se-curedial-in access fromvirtually any PC,enabling Gloucesterpersonnel or your staffto quickly andconveniently access

off-line or auxiliaryfunctions. Stored prod-uct recipes allow quickline startup and change-over with completerepeatability. And wedesigned our exclusiveExtrol technology with

investment protectionin mind. Softwareenhancements andupgrades integrateseamlessly with yourinstalled system – so itnever becomes obso-lete. That means you

can maintain the latestcontrol functionalitywithout incurring thecosts or disruption ofa major overhaul.

The BattenfeldGloucester Extrol™system gives yousingle-point control ofevery component andprocess on your line,from material feedingto film winding – even

tempera-tures, meltpressure, drive RPM andcurrentFull data logging ofalarms and eventsData links with othercomputers, networksFully automated orderlystartup and shutdownAutomatic ramping of alldrivesOn-demand SPC/SQCdata and reportsSophisticated safetylogic

Single-point line control

system control andstatus information atany time. ExLinktechnology enablesyou to downloadproduction informationto any networked PC,for user-customizeddata analysis andarchiving. Of courseall remote access ispassword-protected.

Compact AcuraBlendgravimetric system

Outstanding Service and Support

Extensive Blown Film Technical Center

Battenfeld GloucesterEngineering’s worldclass Technical Centeroffers the mostextensive blown filmlaboratory in NorthAmerica. The facilitiesprovide a state-of-the-art platform for a widevariety of tasksincluding industrial and

Battenfeld GloucesterEngineering

For over 40 years,Battenfeld GloucesterEngineering has beenthe world’s leadingmanufacturer ofextrusion systems forblown and cast film,sheet, foam, and bagmaking. The companyhas productionfacilities in the United

Gloucester is your singlesource for technical,turnkey installation,maintenance, processand market trendsexpertise, freeing you tofocus on your corebusiness.

States, Europe and thePeople’s Republic ofChina. BattenfeldGloucester is part ofthe SMS group, theleading global supplierof machinery, systems,and automation for themanufacture of plasticproducts.

Support includes:Complete processconsultationAccess to ourtechnical center formaterial andequipment evaluationon production-sizedequipment

customer R&D,process training, prod-uct development, andtechnologypresentation.

Gloucester’s world-wide network of skilled,knowledgeableservice engineersComprehensive engineering servicesConsultation onmaterials

Our extensiveinventory of partsand supplies Market trends

State-of-the-art technicalcenter

Outstanding installation expertise Extensive spare parts inventory andknowledgeable customer support

11

Battenfeld Gloucester Engineering Co., Inc.Blackburn Industrial Park · P.O. Box 900

Gloucester, MA 01931-0900 · U.S.A.Tel. +1 +978 281-1800Fax +1 +978 282-9111

welcome@bge.battenfeld.comwww.battenfeld.com BG

E 06

/03

(TS

06/0

3), G

L, 2

,500

, USA

, FSW

, 383

8 In

form

atio

n su

bjec

t to

chan

ge