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Mingyang ABA film blowing machine leverages ABA co-extrusion technology, endowing the film with more diverse performance attributes and application features. As a pivotal piece of production equipment in the modern packaging sector, it delivers dependable solutions for product packaging and protection, while driving the industry's development and innovation.
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The ABA configuration is the standard in packaging film production for one reason: it cuts raw material cost without the customer noticing. Two virgin PE skin layers (A) encapsulate a core layer (B) that can contain up to 30% recycled PE, off-spec resin, or lower-cost filler-grade material. The film looks, prints, seals, and performs like all-virgin — because the surfaces the customer touches are virgin. The recycled content stays buried in the middle.
Film Product | Skin Layers (A) | Core Layer (B) | Typical Recycled % |
|---|---|---|---|
Shopping bag film | LDPE/LLDPE virgin | Post-consumer recycled PE | 20-25% |
Garbage bag film | LDPE/LLDPE virgin | Post-industrial or post-consumer PE | 25-30% |
Garment bag film | Metallocene PE virgin | Off-spec LDPE | 15-20% |
Industrial liner film | LDPE/HDPE blend virgin | Post-industrial recycled PE | 20-30% |
Agricultural mulch film | LDPE/LLDPE + UV virgin | Recycled LDPE | 15-20% |
Packaging film producers whose raw material cost is the single largest expense. Resin typically accounts for 65-75% of film production cost. Running 25% recycled PE in the core layer cuts that line item by roughly $100,000-150,000 per year for a factory producing 500 tons of film annually. The ABA machine costs $25,000-40,000 more than a mono-layer line — that premium is recovered through material savings within 18-24 months.
Factories supplying supermarket chains and retailers with recycled content requirements. Many large buyers now mandate minimum recycled content percentages in packaging. An ABA machine documents exactly how much recycled material goes into each film batch — critical for sustainability reporting and tender qualification.
Producers expanding from mono-layer into multi-layer film. If your current mono-layer machine limits you to 100% virgin material, an ABA line opens a lower-cost product tier without changing your customer-facing film quality.
If your film product does not benefit from recycled content. High-clarity display packaging or medical-grade film should not contain recycled material in any layer. A mono-layer blown film line configured for your specific resin grade is the correct choice.
If you need barrier properties (oxygen, moisture, aroma). ABA gives you two materials — not three independent polymers. For PE/PA/PE or PE/EVOH/PE barrier structures, you need an ABC co-extrusion blown film machine.
If your recycled PE supply is inconsistent or unwashed. The core extruder can handle variability, but heavily contaminated post-consumer recyclate — with paper, metal fragments, or mixed polymers — will eventually block the screen changer or damage the die. Invest in a recycling pelletizing line first to upgrade your recycled feedstock quality.
Not sure if ABA is right for your production? Send us your current raw material cost per kg and target recycled percentage. We will calculate your estimated annual savings with an ABA line.
The two virgin skin layers (A) encapsulate the recycled core (B), so the film surfaces that matter — print surface, seal surface, customer-facing side — are 100% virgin PE. The core can run up to 30% post-consumer recycled PE, off-spec resin, or lower-cost filler-grade material. The film's tensile strength, elongation, dart impact, and seal performance are determined primarily by the skin layers. In a 25-micron film with a 20% recycled core, the virgin skins account for roughly 80% of the film's mechanical properties. Unlike blending recycled PE into a mono-layer machine — where every surface shows the recycled content — ABA isolates it where it does not matter.
The spiral mandrel die is designed to handle melt streams with different viscosities without layer instability. Recycled PE typically has a wider MFI range than virgin resin — a batch might be 0.8 MFI, the next might be 1.5 MFI. When two melts of different viscosity meet in the die, the lower-viscosity material tends to encapsulate the higher-viscosity material — a phenomenon called viscous encapsulation that causes visible layer distortion. The ABA die geometry compensates for this by matching the flow channel dimensions to the expected viscosity ratio between skin and core melts. If your recycled PE supplier changes, the extruder temperature profile can be adjusted to bring the viscosities back into balance.
Three smaller extruders running in parallel consume less total energy than one large extruder producing the same output. A single 150 kg/h extruder running LDPE draws roughly 90-110 kW. Three 50-60 kg/h extruders in an ABA configuration draw roughly 65-80 kW combined — approximately 20-25% less energy per kilogram. The reason: smaller screw diameters have lower frictional heat generation and require less motor torque. Over 6,000 operating hours at $0.10/kWh, the energy difference alone saves $15,000-18,000 per year compared to an equivalent-output mono-layer line.
Recycled PE causing melt pressure fluctuation. Variable-viscosity recycled feedstock — where one pellet melts at 120°C and the next at 130°C — creates pressure spikes at the die. The barrier mixing section on the core extruder screw homogenizes the melt before it enters the die, smoothing pressure variation from ±8-12% down to ±3-5%. Without this, the bubble pulses visibly — the frost line moves up and down, and gauge variation doubles.
Moisture in recycled feedstock causing bubble holes. Post-consumer recycled PE often contains residual moisture from washing. When wet pellets enter the extruder, the water flashes to steam at melt temperature, creating pinholes in the bubble — operators call them "fish eyes." The core extruder's vented barrel design allows moisture to escape before the melt reaches the die. If your recycled PE supplier does not pre-dry material, specify the vented barrel option.
Skin-to-core layer ratio drifting during long runs. Over an 8-hour shift, screw wear, ambient temperature rise, and raw material batch changes cause the actual layer ratio to drift from the setpoint. A 20% core becomes 25% — film properties shift. Gravimetric dosing on each extruder maintains the target mass ratio regardless of these variables. For producers supplying customers who test recycled content claims, dosing is not optional.
Scenario | Skin Material | Core Material | Output | Annual Material Saving |
|---|---|---|---|---|
Shopping bag film, 25 microns, 25% recycled core | LDPE/LLDPE virgin | Post-consumer PE | 120-140 kg/h | $90,000-120,000 |
Garbage bag film, 20 microns, 30% recycled core | LDPE/LLDPE virgin | Post-industrial PE | 100-130 kg/h | $110,000-150,000 |
Garment bag film, 18 microns, 15% recycled core | Metallocene PE virgin | Off-spec LDPE | 90-110 kg/h | $50,000-70,000 |
Industrial liner, 60 microns, 30% recycled core | LDPE/HDPE blend virgin | Post-industrial PE | 140-170 kg/h | $130,000-170,000 |
Material Feeding: Two skin extruders (A) feed virgin PE from a shared hopper or individual gravimetric dosing units. One core extruder (B) feeds recycled PE, off-spec resin, or filler-grade material. Automatic vacuum loaders reduce manual handling and contamination risk.
Melting: Each extruder runs its own temperature profile. Skin extruders: 180-210°C for LDPE/LLDPE — standard PE processing window. Core extruder: 190-220°C with barrier mixing section — slightly higher temperature to homogenize variable-viscosity recycled feedstock. The vented barrel option allows moisture to escape before the melt reaches the die.
3-Layer Co-Extrusion: Three melt streams converge in the spiral mandrel die. The ABA mandrel geometry positions the core melt between two skin melts, with flow channels sized to compensate for the expected viscosity difference between virgin and recycled material. The three-layer bubble exits the die gap as a single film.
Bubble Cooling: Dual-lip air ring provides external cooling. Optional IBC cools from inside for higher output. The frost line height is visually monitored — if it drops (closer to the die), recycled feedstock viscosity has decreased and the core extruder temperature needs adjustment.
Winding: Oscillating haul-off distributes gauge bands. Surface or center winder produces finished rolls. For lines above 100 kg/h, dual-turret winding enables continuous operation.
Option | What It Does | Why It Matters for ABA |
|---|---|---|
Gravimetric Dosing (per extruder) | Controls mass flow to ±0.5% accuracy | Maintains exact recycled content claims. Without it, core ratio drifts 3-5% over a shift. |
Vented Barrel (core extruder) | Allows moisture to escape from melt | Essential if recycled PE is not pre-dried. Prevents pinholes from steam. |
Hydraulic Screen Changer (core) | Continuous filtration without stopping | Recycled PE carries contaminants. Manual screen changers require operator intervention — most operators delay changing until film quality degrades. |
IBC | Internal bubble cooling | Adds 15-25% output. Compensates for slower cooling from recycled-content films. |
Auto Air Ring | Gauge-feedback lip adjustment | Maintains ±5% gauge uniformity across shifts. Reduces scrap from ambient drift. |
Corona Treater | Surface treatment for ink adhesion | For producers printing on ABA film. Virgin skin accepts corona treatment uniformly. |
Lagos, Nigeria — 2024. A packaging factory producing garbage bag film for municipal contracts replaced a mono-layer line with this ABA machine.
Metric | Before (Mono-Layer) | After (ABA) |
|---|---|---|
Material cost per kg of film | $1.15 (100% virgin LDPE) | $0.89 (25% recycled PE core) |
Scrap rate | 6.5% | 3.2% |
Annual material cost (500 tons) | $575,000 | $445,000 |
Machine payback | — | 14 months |
The 23% reduction in material cost per kilogram — achieved entirely through the recycled core layer — recovered the full machine investment in 14 months. Scrap reduction came from better gauge control via the spiral mandrel die and auto air ring. The factory also qualified for a municipal tender requiring minimum 20% recycled content — the mono-layer line could not meet this specification.
20+ years focused on blown film. Screw design, die optimization, and co-extrusion line integration is the entire business. Factory in Jiangyin, Jiangsu Province.
CE certified. Full documentation for EU and international customs clearance.
Engineer support: Pre-sales — we calculate your estimated material savings based on your actual resin pricing and target recycled percentage. Post-installation — video call, remote diagnostics, optional on-site dispatch.
Spare parts same-week dispatch: Heater bands, thermocouples, SSRs, seals, screen changer blades stocked. Long-lead parts pre-orderable.
60+ countries: Container loading, sea freight, destination port coordination.
Up to 30% in the core layer for standard packaging films — shopping bags, garbage bags, industrial liners. Above 30%, the core layer begins to affect film mechanical properties because the skin-to-core thickness ratio becomes too low for the virgin skins to dominate tensile and impact performance. For films requiring high clarity — like garment bags — we recommend capping recycled content at 15-20% to maintain optical quality in the skin layers.
Post-industrial recycled PE — factory scrap, edge trim, start-up waste from your own or a known source — can typically be fed directly if ground to consistent pellet or flake size. Post-consumer recycled PE should be washed and dried. If drying is not available, specify the vented barrel option on the core extruder. Heavily contaminated recyclate with paper, metal, or mixed polymers needs a dedicated recycling pelletizing line to produce usable feedstock.
No. The two virgin PE skin layers completely encapsulate the recycled core. The film surface — print side and seal side — is 100% virgin PE. The film looks, prints, seals, and handles identically to all-virgin film. The only difference is a lower raw material cost and a documented recycled content percentage you can report to customers for sustainability compliance.
Yes, but you will need to adjust the core extruder temperature profile. Different recycled PE batches have different melt flow indices. If the new batch has a lower MFI (thicker melt), increase core extruder temperature by 5-10°C to bring its viscosity closer to the skin layer viscosity. If viscosity mismatch is too large, you will see visible layer distortion — wavy patterns in the film when viewed under polarized light. The operator adjusts until the frost line stabilizes at a uniform height across the bubble circumference.
14-22 months based on material savings alone, assuming 20-30% recycled content in the core. The Lagos case study recovered the full machine cost in 14 months at 25% recycled content. Higher recycled percentages and higher virgin resin prices shorten the payback. If your local virgin PE price exceeds $1,000/ton, the economics are compelling.
Approximately 0.40-0.50 kWh per kg of film — 20-25% less than an equivalent-output mono-layer machine because three smaller extruders consume less total power than one large extruder. At $0.10/kWh and 6,000 hours/year producing 130 kg/h: roughly $31,000-39,000 annual electricity cost. Servo motor upgrade reduces this by a further 12-18%.
An ABA 3-layer line costs approximately $25,000-40,000 more than an equivalent-output mono-layer line. This premium is almost always recovered through material savings within 2 years. After that, the ABA machine generates $100,000+ in additional annual savings — every year — because the recycled core continues to reduce raw material cost for the life of the machine.
With a hydraulic continuous screen changer: the filter screen advances automatically as it clogs. The operator monitors the pressure differential across the screen — when it exceeds the setpoint, the hydraulic cylinder indexes fresh screen into the melt stream. Screen change frequency depends on recycled PE cleanliness: post-industrial feedstock may run 2-3 days between screen advances; post-consumer feedstock may need a screen advance every 8-12 hours. Keep 3-4 spare screen rolls in stock — running out means stopping the line.
You will see it in the frost line first — it becomes uneven, with the bubble diameter pulsing. This is a sign of melt pressure fluctuation from inconsistent feedstock. If you have a hydraulic screen changer, increase the advance frequency. If the problem persists, the recycled PE batch may be contaminated with a non-PE polymer (PP contamination is common). Reduce the core layer percentage to 10-15% temporarily, run the remaining recycled stock, and inspect the next batch before loading.
Send us your production parameters. We will calculate your estimated annual material savings with an ABA line and provide a detailed configuration proposal:
Current virgin PE price per kg (delivered to your factory)
Available recycled PE source and estimated cost per kg
Target recycled content percentage in the core layer
Film width (lay-flat, mm) and thickness range (microns)
Required output per day or month (kg)
Electrical supply (voltage, frequency, phases)
carrie@jymingyang.com | +86-189-6169-1127
