ABC 3-Layer Co-Extrusion Film Blowing Machine

Applications

The ABC 3-layer co-extrusion film blowing machine produces multi-layer blown film from PE, PP, and functional polymer combinations. Three independent extruders feed a single die, allowing each layer to use a different material or additive formulation. This machine is built for packaging film manufacturers, industrial film producers, and converters who need to combine barrier performance, mechanical strength, and material cost optimization in a single film structure.

Film products this machine produces:

• Heavy-duty shipping sack film: A-layer (virgin LDPE/LLDPE for heat sealing) + B-layer (HDPE for stiffness and tensile strength) + C-layer (CaCO₃-filled compound for cost reduction). Typical structure: 15/70/15% layer ratio at 80-150μm total thickness.

• High-clarity packaging film: A-layer (metallocene LLDPE for clarity and hot-tack) + B-layer (LLDPE/LDPE blend for body) + C-layer (LLDPE for seal integrity). Three independently controlled extruders prevent the clarity-degrading over-shear that occurs in mono-layer machines running metallocene resins.

• Barrier stretch film: A-layer (tackified LLDPE for cling) + B-layer (high-MW LLDPE for puncture resistance) + C-layer (slip-modified LLDPE for unwind). Independent layer control allows cling and slip additives to be confined to their functional layers — no additive migration across the film cross-section during storage.

• Agricultural greenhouse film: A-layer (UV-stabilized LDPE + anti-drip) + B-layer (EVA for IR retention and light diffusion) + C-layer (UV-stabilized LDPE + anti-fog). Each additive package stays in its designated layer, preventing antagonistic interactions between anti-drip and anti-fog chemistries that occur when all additives are melt-blended in a mono-layer process.

• Lamination film for flexible packaging: A-layer (primed surface for lamination bond) + B-layer (HDPE for stiffness and temperature resistance) + C-layer (heat-seal layer with low SIT). The ABC structure allows the seal layer to initiate at 105°C while the A-layer withstands 140°C lamination tunnel temperatures without blocking.

• Collation shrink film: A/B/C layers with differentiated shrink ratios in MD vs TD. Independent extruder control enables asymmetric layer shrinkage — the core layer (B) can be formulated for high TD shrink while skin layers manage MD orientation balance.

Who This Machine Is For

• Packaging film manufacturers producing 500–3000 tons/year who need to upgrade from mono-layer to multi-layer film capability. The ABC platform lets you offer customers differentiated film structures — barrier, strength, seal performance — without buying a separate machine for each film type.

• Converters integrating backward into film production who currently buy multi-layer film from third parties. Running your own ABC line lets you control layer recipes, reduce film cost per kg by 15–30% through CaCO₃-filled core layers, and eliminate the supplier's margin.

• Industrial film producers competing on cost in commoditized segments (garbage bags, construction film, agricultural mulch). The graded-material capability means you can load 40–60% CaCO₃ in the core layer while maintaining surface quality through virgin skin layers — achieving cost reduction that a mono-layer machine cannot match at equivalent film quality.

• Film plants requiring formulation flexibility across multiple product categories. Three independent extruders with their own temperature controllers mean you switch from a heavy-duty sack recipe (HDPE core at 190°C) to a clarity film recipe (mLLDPE skin at 160°C) by changing the recipe, not the machine configuration. One ABC line replaces 2–3 dedicated mono-layer lines for plants with diverse product portfolios.

• Export-oriented manufacturers supplying markets with strict packaging regulations (EU food-contact, REACH compliance). Layer isolation lets you confine food-contact-approved resins to the product-contact layer while using cost-optimized materials in core and outer layers — full compliance without full-cost penalty.

Who Should NOT Buy This Machine

• Startup film producers with monthly output under 50 tons. An ABC line requires 3× the raw material inventory (3 extruders, 3 hoppers, 3 material types), 3× the purging time during material transitions, and more sophisticated operator skill than a mono-layer line. If your volume doesn't justify the layer capability, a PE Film Blowing Machine or High-Speed Film Blowing Machine will deliver better ROI at lower operating complexity.

• Producers making only mono-layer film with no plan to add multi-layer products. Three extruders consume more electricity per kg of output than one — the ABC configuration burns approximately 2.2× the kWh/kg of an equivalent-output mono-layer line due to three drive motors, three heating systems, and three cooling circuits. If your customer base doesn't pay for multi-layer performance, don't pay for the capability.

• Operations running 100% recycled content film. While an ABC machine can process recycled material in the core layer, heavily contaminated post-consumer reclaim requires frequent screen-pack changes across all three extruders, multiplying maintenance downtime. A PE Film Blowing Machine with a single robust filtration system may be more practical for 100% recycled applications.

• Laboratories or R&D centers doing small-batch formulation work. Each formulation trial on an ABC line consumes 3× the material of a mono-layer trial, and purging three extruders between incompatible polymer families can waste 25–40 kg per transition. For R&D-scale work, see our Lab Film Blowing Machine which performs film-formulation screening with 500g minimum material.

Technical Advantages

Three Independent Extruders with Isolated Temperature Control

Each A/B/C extruder runs its own temperature profile, screw RPM, and material formulation — no compromises between layers. In a mono-layer machine, you pick one barrel temperature that works for the entire blend. On an ABC line, the skin layer extruder (A) can run at 155°C for heat-sensitive metallocene resin while the core extruder (B) runs at 195°C for HDPE with 40% CaCO₃ filler. The C-layer extruder runs independently with its own additive package. This means you can process polymer combinations that would degrade, burn, or fail to melt uniformly in a single-screw machine. Each extruder uses a 38CrMoAlA nitrided screw with 30:1 (MYB-1000/MYB-1400) to 32:1 (MYB-1800) L/D ratio, driven by independent inverter-controlled motors from 15 kW to 30 kW per extruder depending on model.

Graded Material Strategy — Virgin Skin, Low-Cost Core

Unlike a mono-layer machine where 100% of the film cross-section uses the same material cost structure, ABC co-extrusion lets you concentrate cost where it matters. A typical heavy-duty sack film structure: A-layer (15% of thickness, virgin LDPE for sealing and print surface), B-layer (70%, HDPE + 30% CaCO₃ for stiffness at reduced cost), C-layer (15%, virgin LLDPE for inner seal integrity). The 70% core layer carries the filler load, but the film's surface properties — gloss, COF, seal strength — are determined entirely by the 30% that is virgin resin. Result: film cost reduced by 18–25% versus 100% virgin mono-layer, with identical surface quality to the customer. This is the core economic advantage of ABC over mono-layer: you pay for performance where it's needed, not everywhere.

40Cr Mirror-Surface Spiral Mandrel Die — Layer Uniformity Within ±3%

The spiral mandrel die design with 40Cr hardened steel and mirror-surface flow channels delivers layer thickness uniformity that non-coex machines cannot approach. Each of the three melt streams enters the die through its own spiral channel, and the mandrel geometry ensures that each layer wraps the circumference of the bubble with even distribution before the three streams merge at the die lip. The mirror-polished flow surfaces (Ra ≤ 0.1μm) prevent material hang-up at layer interfaces — a common source of gel formation and optical defects in lower-grade coex dies. Die head diameters from 70mm (MYB-1000) to 200mm (MYB-1800) match the output range, keeping melt residence time consistent across model sizes.

Servo-Driven Haul-Off with Automatic Tension Control

The servo motor take-up system, paired with a torque-motor friction winder, maintains consistent film tension from startup through full roll diameter. Production ABC lines running thin film (12–25μm stretch film, for example) are sensitive to tension variation — a 5% tension spike during winding creates a stretched band that fails at the customer's unwinding station. The servo drive responds to diameter build-up on the winder within milliseconds, adjusting haul-off speed to maintain programmed tension. An automatic discharge roll mechanism drops full rolls without operator intervention, keeping the line running during shift changes. Roller widths of 1000mm (MYB-1000), 1400mm (MYB-1400), and 1800mm (MYB-1800) accommodate the full film width range.

Real Production Issues It Solves

Problem 1 — "Our mono-layer film is priced out of the market because we compete on 100% virgin resin with factories that cut cost with filler." When you add CaCO₃ to a mono-layer film, surface roughness increases, COF rises above spec, and print quality degrades because the filler particles protrude through both film surfaces. The ABC solution: confine filler to the B (core) layer at 40–60% loading, keep A and C layers at 100% virgin. The filler never reaches the surface. Film cost drops 20% while surface properties remain within customer specification. This moves your product from a commodity-price competition (lose) to a cost-structure competition (win).

Problem 2 — "We run different film products on different days, and each changeover wastes 2–3 hours of production." Switching a mono-layer extruder from a HDPE heavy-duty sack recipe (190°C, 120 rpm) to an LDPE clarity film recipe (155°C, 80 rpm) requires a full temperature ramp-down, purging, stabilization, and process tuning — typically 2+ hours of non-productive time. On an ABC line, multiple film types can often be produced by changing only layer recipes while keeping the machine at operating temperature. A factory producing both industrial sacks and high-clarity packaging can schedule them on the same ABC line with a 30-minute transition versus the 2-hour mono-layer switch, recovering 6–8 production hours per week.

Problem 3 — "Our barrier film requires EVOH or PA, but our mono-layer extruder can't process these resins — the temperature windows are incompatible with PE." EVOH processes at 190–230°C. PA6 processes at 230–260°C. LLDPE degrades above 200°C. Putting all three in one extruder is impossible — you either burn the PE or fail to melt the barrier resin. ABC co-extrusion solves this by dedicating one extruder to the barrier layer at its required temperature, while skin extruders run at PE-compatible temperatures. The three melt streams only combine at the die, where contact time is measured in seconds and interface temperature equilibrates without degrading either component. This opens up film structures — PE/EVOH/PE, PE/PA/PE, PP/tie/EVOH/tie/PE with adhesive layers — that are physically impossible on mono-layer equipment.

Problem 4 — "Humidity in our tropical factory location causes moisture-related defects when processing hygroscopic materials in the core layer." In coastal or high-humidity regions (SE Asia, West Africa, Central America), CaCO₃-filled compounds absorb ambient moisture during storage. Processing damp compound in a mono-layer extruder produces steam bubbles that rupture through both film surfaces — visible pinholes, scrap, and customer rejection. On an ABC line, moisture in the core layer may produce micro-voids, but the virgin skin layers seal them from reaching the film surface. The film still meets visual and mechanical specs even when core material moisture content exceeds 0.1%. This is especially critical during rainy season production when material drying infrastructure is limited.

Production Scenarios

How It Works

1. Material Feeding (3 Streams): Each extruder hopper is loaded with its designated layer material — A-layer formulation, B-layer compound (often CaCO₃-filled), and C-layer formulation. Automatic loaders with vacuum conveying are available as an option to maintain consistent hopper levels during continuous operation.

2. Independent Plasticizing: Each extruder melts and homogenizes its material stream at its own temperature profile. The A extruder may run at 150–170°C for a seal-layer resin while the B extruder operates at 180–200°C for a filled HDPE core. Inverter drives allow each extruder RPM to be set independently, controlling the mass flow contribution of each layer to the final film thickness ratio.

3. Layer Distribution in Spiral Mandrel Die: The three separate melt streams enter the 40Cr mirror-surface spiral mandrel die through dedicated feed ports. Each melt stream is distributed evenly around the die circumference through spiral channels. The mandrel geometry ensures each layer wraps 360° before the three streams merge into a combined melt just before the die lip exit — the layer interfaces form cleanly without cross-contamination.

4. Multi-Layer Bubble Formation: The combined 3-layer melt tube exits the die and is inflated by low-pressure air into a bubble. The operator adjusts internal bubble pressure, frost line height, and blow-up ratio (typically 2:1 to 4:1). The bubble's multi-layer structure is set at this stage — layer thickness ratios established at the die are preserved as the bubble stretches biaxially.

5. Bubble Stabilization and Cooling: The external air ring (and optional internal bubble cooling system) cools the bubble. Because each layer may have a different crystallization temperature — HDPE core freezes at ~120°C while mLLDPE skin remains molten to ~105°C — the frost line height is set to ensure the highest-melting layer has fully solidified before the collapsing frame. Ceramic heater band temperature control on the die maintains melt temperature stability at ±2°C during continuous production.

6. Collapsing, Haul-Off, and Winding: The bubble passes through a collapsing frame that flattens it into a double-layer film. Servo-driven haul-off rollers pull the film at precisely controlled speed, maintaining tension within the programmed window. The torque-motor friction winder builds the finished roll with consistent winding hardness from core to full diameter. Automatic discharge drops the completed roll and starts a new core without line stoppage.

Optional Configurations

Customer Case

Location: Nairobi, Kenya — packaging film manufacturer serving the East African agricultural and industrial packaging market

Machine: MYB-1400 ABC 3-Layer Co-Extrusion Film Blowing Machine (Φ55mm × 3 screws, 1250mm max lay-flat, Φ110mm die)

Application: Heavy-duty fertilizer sack film (120μm, 1100mm lay-flat) for 50kg chemical fertilizer bags, and agricultural greenhouse film (150μm, 2000mm lay-flat on a second line)

Before: Customer operated two mono-layer PE film blowing machines producing heavy-duty sacks from 100% virgin LDPE/LLDPE blend. Film cost was approximately $1,380/ton based on East African resin import pricing. Competing imports from Egypt and India were entering the market at $1,180–1,220/ton due to CaCO₃-filled film structures. Customer was losing market share — volume dropped 22% over 18 months.

After: MYB-1400 ABC line commissioned. Fertilizer sack structure redesigned to A: LDPE virgin seal (15%) / B: HDPE + 35% local CaCO₃ (70%) / C: LLDPE virgin inner seal (15%). Film cost reduced to $1,125/ton — a $255/ton saving. Film tensile strength (MD: 28 MPa, TD: 24 MPa) matched the previous 100% virgin mono-layer film. Surface quality and heat-seal performance unchanged. Customer regained market share within 6 months and added a second ABC line (MYB-1800) for greenhouse film production. Combined annual production: 4,200 tons across both ABC lines. Payback on the first machine: 11 months from material cost savings alone.

Why Choose Mingyang Machinery

• 15+ years manufacturing film blowing extrusion lines — we design and build the screws, barrels, dies, and control systems in our own facility. The 38CrMoAlA nitrided screws and 40Cr mirror-surface dies are machined, heat-treated, and polished under our quality control, not sourced from third-party workshops.

• CE-certified electrical systems with Siemens PLC and Schneider electrical components. Every ABC machine undergoes a full 3-layer co-extrusion test run (A: LDPE + B: HDPE/CaCO₃ + C: LDPE) for a minimum of 6 continuous hours before crating. Layer ratio, thickness profile, and bubble stability are verified against the order specification.

• Exported to 50+ countries with installed ABC lines operating in tropical (35°C+, 85% RH), high-altitude (2,000m+), and voltage-unstable grid environments. Our electrical panels include phase-sequence protection, under-voltage trip, and surge suppression as standard — not as optional add-ons.

• 12-month comprehensive warranty covering all mechanical and electrical components. Dedicated spare parts inventory for ABC series: screws, barrels, ceramic heaters, gearbox seals, inverter drives, and PLC modules. Standard spare parts ship within 48 hours; emergency shipments within 24 hours for production-critical failures.

• On-site installation and operator training available. Our commissioning engineer stays for 5–7 days: mechanical installation verification, electrical commissioning, 3-layer startup procedure training, recipe development for your first film structure, and operator training on layer ratio adjustment and troubleshooting. Remote video support included for the life of the machine at no additional cost.

Frequently Asked Questions

Performance and Material Compatibility

What is the practical output range for each model?

MYB-1000: 80–180 kg/h depending on film thickness and material. MYB-1400: 150–300 kg/h. MYB-1800: 250–500 kg/h. These ranges assume standard HDPE/LLDPE/CaCO₃ formulations at 30–100μm thickness. Output decreases for thin-gauge film (≤20μm) where line speed becomes the bottleneck rather than extruder capacity, and for high-viscosity resins (HMW-HDPE, metallocene grades) that increase melt pressure. The 500 kg/h figure represents peak output on MYB-1800 running HDPE-heavy formulations at ≥60μm thickness. Contact our engineering team with your target film specs for a throughput estimate specific to your product.

Can the ABC machine process barrier resins like EVOH or PA (nylon)?

Yes, but it requires specifying the extruder configuration for the barrier layer at time of order. Standard ABC machines are configured for PE-family materials (LDPE, LLDPE, HDPE, mPE) with processing temperatures up to 220°C. For EVOH (190–230°C) or PA6 (230–260°C), the dedicated barrier-layer extruder requires: (a) a corrosion-resistant screw and barrel (EVOH generates acetic acid at processing temperature), (b) extended temperature range heater bands, and (c) a barrier screw design with the correct compression ratio for the specific resin grade. This is a standard customization — specify your barrier material when requesting a quotation and we include the correct extruder specification.

How precisely can I control the layer thickness ratio?

Layer ratio is controlled by the relative screw RPM of each extruder against a calibrated mass-throughput curve. In practice, ratio control accuracy is ±2% of target for each layer on the standard configuration, and ±0.5% with the optional Mick weight controller (gravimetric per-extruder dosing). For example, a 15/70/15% A/B/C target will deliver between 13–17% for the skin layers and 66–74% for the core under standard control, tightening to 14.5–15.5% / 69–71% / 14.5–15.5% with gravimetric control. Layer ratio stability during a production run is tighter than the absolute setpoint accuracy — typically ±1% drift over an 8-hour shift once the machine is thermally stable.

What is the maximum CaCO₃ loading the core layer extruder can handle?

Up to 60% by weight with a properly formulated CaCO₃ compound (coated particles, ≤10μm D50, compatible carrier resin). Beyond 60%, melt strength drops to the point where bubble stability becomes the limiting factor — not the extruder's ability to convey and melt the compound. Practical production loading is 30–50% for most sack and bag film applications. The extruder screw design (30:1 or 32:1 L/D with gradual compression) provides sufficient residence time for the compound to plasticize without pushing filler particles through the melt in unmelted clusters, which would appear as surface roughness or gel-like defects in the finished film.

Purchasing and Delivery

What is the typical delivery lead time for an ABC 3-layer machine?

Standard configuration: 45–55 working days from order confirmation to factory acceptance test. Machines with optional configurations (rotary die, IBC, gravimetric control, barrier-layer extruder upgrade) add 10–15 working days. The three-extruder configuration, spiral mandrel die machining, and multi-zone electrical panel assembly are more complex than a mono-layer machine — this lead time reflects the manufacturing and testing required for proper 3-layer integration. Sea freight to major ports: 15–35 days depending on destination. Air freight is available for urgent projects; the machine is shipped in sub-assemblies on flat-rack containers or break-bulk crating.

What is the minimum factory ceiling height required?

Machine heights: MYB-1000 = 7,000mm, MYB-1400 = 8,500mm, MYB-1800 = 10,500mm. Add 1,500mm clearance above the machine for bubble access, maintenance, and air circulation. The MYB-1800 requires an approximately 12m ceiling or an opening in the roof with a weather-protected tower extension. Existing factory buildings with 8–9m ceilings can accommodate the MYB-1000 and MYB-1400 without structural modification. Confirm available height before model selection — it is the most common installation constraint for ABC lines.

Do you offer a smaller ABC machine for lower output requirements?

The MYB-1000 with 50mm screws is our entry ABC model, with typical output of 80–180 kg/h and 850mm maximum lay-flat width. For output below 80 kg/h or narrower film, a 3-layer ABC configuration becomes economically less attractive because the fixed overhead of operating three extruders (energy, purging material, setup time) erodes the material savings advantage. For sub-80 kg/h multi-layer requirements, we recommend evaluating whether a ABA Film Blowing Machine (2-layer) satisfies the functional requirement with lower complexity. Contact our engineering team for an honest assessment — we will not recommend an ABC if a simpler configuration delivers equivalent value at your scale.

Installation and Maintenance

How does installation differ from a mono-layer film blowing machine?

ABC installation is more involved due to three extruders, a larger die assembly, and more complex electrical integration. Key differences: (1) three extruders must be positioned at the correct angles to the die feed ports, with alignment verified before bolting down, (2) the spiral mandrel die is heavier and requires a lifting frame or hoist for assembly, (3) electrical commissioning checks three independent drive/heating/cooling circuits plus the integrated PLC layer-ratio control. Typical installation: 5–7 working days with our commissioning engineer on-site plus 2 local mechanical/electrical helpers. We provide a detailed pre-installation guide covering floor layout, power supply requirements (380V 3-phase, minimum 150A for MYB-1400, 200A for MYB-1800), and compressed air specifications before the machine ships.

What is the daily maintenance routine for an ABC line?

Daily: wipe die lips with a brass scraper (never steel) after shutdown to prevent polymer carbonization; check and clean screen packs on all three extruders; verify cooling air blower operation and filter cleanliness; inspect bubble stabilization cage alignment. Weekly: check screw thrust bearing temperature on all three extruders (abnormal temperature rise indicates excessive back-pressure or bearing wear); calibrate temperature controllers against an independent thermocouple; inspect haul-off roller surface for wear or deposit build-up. Monthly: verify gearbox oil level and condition on all three ZLYL gearboxes; check drive belt tension; clean electrical panel air filters (especially critical in dusty or high-humidity environments). The main consumables are screen packs, ceramic heater bands (2–3 year life per heating zone, 12–18 zones per machine), and haul-off roller rubber coating (annual re-grinding or replacement).

Can I run only one or two layers if I don't need all three for a particular product?

You can run two extruders and leave one idle, but with important caveats. The idle extruder's die feed port must either be purged with a thermally stable material (LDPE) that sits at temperature without degrading, or the idle extruder must be completely shut down and the die port blocked — which requires a machine stop and die disassembly. Running two layers on an ABC machine is operationally feasible for short runs but inefficient as a regular production mode because you consume electricity heating the idle extruder. If your production mix is predominantly 2-layer films with occasional 3-layer requirements, an ABA Film Blowing Machine may be the more appropriate platform. If you need both 2-layer and 3-layer capability regularly, the ABC provides the flexibility — budget approximately 30–45 minutes to bring the idle extruder online when switching from 2-layer to 3-layer operation.

Get Your ABC 3-Layer Film Blowing Machine Quote

Tell us about your film product and production requirements. Our application engineers will recommend the correct model, extruder configuration, and optional equipment — with pricing — within 24 hours.

Please include the following in your inquiry:

1. Target film product and application (e.g., heavy-duty sack, stretch film, greenhouse film, barrier packaging)

2. Desired layer structure: A-layer function / B-layer function / C-layer function, with target thickness per layer or total thickness

3. Target monthly output in tons and maximum required lay-flat width

4. Primary materials per layer — specify if barrier resins (EVOH, PA) are required

5. Available power supply: voltage, phase, frequency, and available amperage

6. Factory ceiling height (critical for model selection between MYB-1000, MYB-1400, MYB-1800)

7. Optional equipment interest: corona treatment, IBC, gravimetric dosing, rotary die, auto winder

Email: carrie@jymingyang.com

Phone / WhatsApp: +86-139-6163-3728

For ABC machine inquiries, including your target film structure and material cost data helps us provide a specific recommendation with payback analysis. Typical response time: within 4 business hours (GMT+8). WhatsApp for urgent requests.

Related Products

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• ABA Film Blowing Machine — Two-layer co-extrusion with a single material split into skin and core layers via one extruder and a material splitter. Ideal for CaCO₃-filled core cost reduction without the full complexity of three independent extruders.

• High-Speed Film Blowing Machine — High-output mono-layer or ABA machines optimized for thin-gauge film (10–30μm) at line speeds above 80 m/min. For HDPE carrier bag film, grocery sack, and thin packaging where output-per-kWh drives profitability.

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