LDPE ABA Three Layer Co-Extrusion Film Blowing Machine for Recycled-Core Film Production

Applications

This ABA three-layer co-extrusion film blowing machine (Model MYB-600) produces LDPE film with a recycled or CaCO3-filled core layer sandwiched between two virgin LDPE skin layers — reducing raw material cost by 20-40% while maintaining the surface appearance and mechanical properties of virgin film. Two 50mm screw extruders feed a co-extrusion die: the A extruder supplies virgin LDPE to both outer skin layers; the B extruder supplies CaCO3-filled or recycled LDPE to the core layer. The machine produces film from 0.015 mm to 0.15 mm thickness at up to 500 mm lay-flat width. Converters producing garbage bags, grocery bags, construction film, and general-purpose packaging run this ABA configuration to reduce virgin polymer consumption without the customer seeing or feeling a difference from 100% virgin film.

• Garbage bags / refuse sacks: LDPE garbage bags with 20-30% CaCO3 in the core layer — the virgin LDPE skins provide surface smoothness and tear resistance; the filled core reduces material cost while maintaining bag handle and drop-test performance.

• Grocery / shopping bags: Retail carry bags where surface printability and clarity matter — virgin LDPE skins accept printing ink and provide clear gloss; the recycled-content core is hidden inside the film structure.

• Construction film / vapor barrier: Heavy-gauge LDPE film at 0.08-0.15 mm for under-slab moisture barrier — the ABA structure allows higher recycled content in the core without the surface pinholes and rough texture that plague monolayer recycled film.

• General-purpose packaging film: Standard LDPE packaging film where cost reduction is the primary purchasing driver — the ABA structure delivers virgin-film appearance and strength at a filled-material price point.

Application vs. Recommended Layer Structure

Who This Machine Is For

• Film converters facing margin pressure from rising virgin LDPE prices who need to reduce raw material cost per kilogram without sacrificing film appearance or mechanical properties. The ABA structure puts virgin LDPE only where the customer sees and feels it — the skins — while the core carries filled or recycled material, reducing virgin polymer consumption by 30-60%.

• Producers with access to low-cost CaCO3 compound or post-industrial regrind who can source core-layer material at $200-400/ton below virgin LDPE pricing. The ABA machine monetizes this material cost spread — the wider the spread, the faster the machine pays back.

• Bag manufacturers competing on price in tender markets (municipal garbage bag contracts, retail chain bag supply) where the winning bid is decided by fractions of a cent per bag. The ABA structure's material cost advantage directly translates to a lower bid price without sacrificing bag quality or performance.

• Shops running monolayer LDPE lines who want to access the recycled-content market without the quality problems of monolayer recycled film (surface roughness, gels, pinholes). ABA co-extrusion hides the recycled layer where it doesn't affect appearance or sealing — the customer sees virgin LDPE on both surfaces.

Who Should NOT Buy This Machine

• Producers making only 100% virgin monolayer film with no plan to use recycled or filled content. A monolayer film blowing machine costs less, runs faster, and is simpler to operate. The ABA premium only pays back when the core layer uses a lower-cost material than the skins.

• Converters whose customers specify 100% virgin material and audit for compliance. If your customer contract prohibits recycled or filled content, the ABA structure's core-hiding advantage is irrelevant. Stick with monolayer virgin extrusion.

• Shops producing film above 500 mm lay-flat width. The MYB-600 has a maximum film width of 500 mm. For wider film, a larger ABA machine with a wider die is required — discuss your width requirements during quotation.

• Startups without reliable access to consistent-quality recycled or CaCO3-filled compound. The ABA core layer requires consistent melt flow and filler dispersion — variable-quality regrind produces surging, gauge variation, and bubble instability. Secure your core-layer material supply chain before investing in the co-ex line.

Not sure if ABA recycled-core production saves you money? Send us three numbers and we'll calculate your material cost savings within one business day:

• Your current monthly virgin LDPE consumption (tons) and price per ton

• Your available recycled or CaCO3-filled material cost per ton

• Your typical film structure (gauge and width)

Send your numbers here.

Technical Advantages

ABA Co-Extrusion — Virgin Skins, Filled Core, One Die

Two 50mm extruders feed a three-layer co-extrusion die: the A extruder splits its melt flow to form both outer skin layers; the B extruder supplies the core layer. On a monolayer machine, adding CaCO3 or regrind to the entire melt stream produces film with rough surface texture, reduced gloss, and visible filler specks — the customer sees the cost-saving immediately and rejects the film. The ABA structure encapsulates the filled core between two virgin LDPE skins — both surfaces are 100% virgin for appearance and sealability, while the core carries the cost-reduced material. The customer sees and feels standard LDPE film.

Independent Extruder Temperature Control — Virgin and Filled Materials at Their Optimal Setpoints

The A extruder (virgin LDPE) runs at 150-170°C for optimal melt strength and bubble stability; the B extruder (CaCO3-filled compound) runs at 160-180°C to ensure complete filler dispersion. Filled compounds have higher thermal conductivity than virgin LDPE — they heat faster and require different barrel temperature profiling. Independent temperature control per extruder processes each material at its ideal conditions rather than compromising on a single temperature for a blended melt.

Servo Motor Take-Up — Precise Film Tension from Bubble to Winder

The servo-driven take-up motor maintains constant film tension with closed-loop feedback — no gearbox drift, no belt slippage affecting gauge consistency. On friction-driven take-up systems, tension varies as the winder roll diameter builds from empty core to full roll — film at the start of a roll has different gauge than film at the end. Servo control maintains consistent tension throughout the roll build, producing uniform film thickness from the first meter wound to the last.

Free ABA film structure analysis — send us your material cost data, get back a savings estimate. We'll provide:

• Recommended ABA layer ratio for your target film application

• Material cost per kg comparison: your current 100% virgin vs. ABA recycled-core

• Estimated payback period based on your production volume

No cost. Data-driven analysis using your actual material prices. Send your material data here.

Real Production Issues It Solves

Customer rejects monolayer film with visible CaCO3 specks. When CaCO3 is blended throughout the entire film cross-section on a monolayer machine, filler particles at the surface scatter light differently — producing visible white specks, reduced gloss, and a rough hand-feel. The ABA structure places CaCO3 only in the core — both film surfaces are 100% virgin LDPE with the gloss, smoothness, and clarity the customer expects.

Variable regrind quality causing bubble instability on monolayer machines. Post-industrial regrind varies in melt flow from batch to batch — a regrind-heavy monolayer melt produces fluctuating bubble diameter and frost line height as the extruder processes inconsistent material. The ABA configuration limits recycled content to the core layer only — the A extruder's consistent virgin LDPE flow stabilizes the bubble through both skin layers, damping the effect of core-layer melt variation.

CaCO3 compound increasing melt density — extruder motor overload at normal screw speed. CaCO3-filled LDPE has higher melt density than virgin LDPE — a 30% CaCO3 compound is roughly 20% denser in the melt phase. On a single extruder processing filled material, the higher melt density increases screw torque and can overload the drive motor at normal output speeds. The ABA configuration places filled material only in the B extruder, which is sized and geared for the higher-torque requirement, while the A extruder processes lower-torque virgin LDPE.

Film surface too rough for printing on recycled-content film. Printing inks require a smooth, consistent surface for adhesion and appearance — monolayer recycled film's surface roughness from filler and contaminants produces poor ink transfer and visible print defects. ABA film surfaces are 100% virgin LDPE — corona treatment raises the dyne level uniformly, and flexographic printing transfers cleanly. The customer prints on virgin surface while paying a recycled-core price.

Production Scenarios

Production Scenarios and Recommended Setups

How It Works

1. Material feeding: Virgin LDPE pellets feed into the A extruder hopper; CaCO3-filled compound or recycled LDPE feeds into the B extruder hopper. Materials remain segregated from hopper to die.

2. Independent melting: The 50mm A extruder melts virgin LDPE at 150-170°C; the 50mm B extruder melts filled/recycled compound at 160-180°C — each at its optimal temperature profile.

3. ABA co-extrusion in the die: The A extruder melt splits into two streams and forms the outer skin layers; the B extruder melt forms the core layer. The three-layer melt tube exits the die with virgin LDPE on both surfaces and filled material encapsulated in the center.

4. Bubble formation & cooling: The three-layer melt tube inflates into a bubble. The air ring cools the external surface; bubble diameter is adjusted to achieve 500 mm lay-flat width.

5. Collapsing & winding: The collapsing frame flattens the bubble. The servo-driven take-up motor pulls film at controlled tension. The single friction winder produces finished rolls.

Customer Case

Location: Lagos, Nigeria — garbage bag manufacturer
Machine: MYB-600 ABA Film Blowing Machine, 2×50mm extruders
Film product: LDPE garbage bags with 25% CaCO3 in core, 0.03 mm × 450 mm lay-flat
Before: Monolayer LDPE machine producing 100% virgin film. Virgin LDPE cost: ~$1,250/ton. Monthly consumption: 22 tons. Monthly material cost: ~$27,500.
After: ABA machine with CaCO3-filled core. Virgin LDPE in skins: ~40% of structure. CaCO3 compound in core: ~60% at $650/ton. Blended material cost: ~$890/ton. Monthly material cost: ~$19,600. Film appearance and strength maintained — customer's garbage bag drop-test performance equivalent to 100% virgin product.
Payback: 10 months from material cost savings of ~$7,900/month.

Why Choose MINGYANG

• 15+ years manufacturing blown film equipment in Jiangyin, Jiangsu — machines running in 30+ countries.

• CE-certified electrical and safety systems on all export machines. Each ships with wiring diagrams and spare parts catalog.

• Pre-delivery FAT on every machine: We run your film structure at production speed before crating. Test data and video provided before dispatch.

• 2-year warranty on main drives, 1 year on electrical. Critical spares stocked — shipped within 48 hours.

• Remote video-guided commissioning as standard; on-site engineer available. Training covers ABA layer ratio setup, CaCO3 compound processing, and preventive maintenance.

Frequently Asked Questions

Performance and Material Compatibility

What materials can the B extruder process for the core layer?

CaCO3-filled LDPE compound (up to 40% filler loading), post-industrial LDPE regrind, and off-spec LDPE film scrap. The core material must have melt flow characteristics within 30% of virgin LDPE for stable co-extrusion. Not suitable for heavily contaminated post-consumer waste, mixed-polymer scrap, or materials with moisture content above 0.1% without pre-drying.

What is the maximum CaCO3 percentage in the core layer?

Up to 40% CaCO3 by weight in the core layer, depending on the compound quality and carrier resin. At 30% CaCO3 loading with good dispersion, film mechanical properties (tensile, elongation, dart drop) remain within 85-90% of virgin LDPE values. Above 40%, bubble stability decreases and the core layer may delaminate from the skins under stress.

Does the ABA film look and feel like virgin LDPE film?

Yes — both outer surfaces are 100% virgin LDPE. The film has the same gloss, smoothness, and clarity as monolayer virgin film. The CaCO3 or recycled content is physically encapsulated in the core layer and does not contact either film surface. Customers cannot distinguish ABA film from virgin monolayer film by visual inspection or hand feel.

Purchasing and Delivery

What is the typical delivery lead time?

Standard: 35-50 working days. Sea freight: Southeast Asia 7-10 days, Middle East 15-20 days, Africa 20-30 days, South America 25-35 days.

What information do you need to configure and quote?

Target film width and gauge range, core layer material type and CaCO3 percentage, target output (kg/h or tons/month), and film application. Share your core material specifications — CaCO3 compound grade or regrind source — for screw configuration confirmation.

Installation and Maintenance

Is the B extruder maintenance different due to CaCO3 processing?

CaCO3 is mildly abrasive — the B extruder screw and barrel experience roughly 20-30% faster wear than the A extruder processing virgin LDPE. Bimetallic barrel and hard-faced screw are recommended for the B extruder and extend service life to 25,000-30,000 hours. Screw inspection every 2,000 operating hours for wear measurement.

Can the machine also run 100% virgin LDPE in all layers?

Yes — both extruders can process virgin LDPE. The machine can run ABA with different LDPE grades per layer or the same material in all layers for monolayer-equivalent film. This allows both recycled-core production and 100% virgin film on the same machine.

What operator training do you provide?

Training covers: ABA layer ratio setup, CaCO3 compound processing, temperature profiling for filled materials, bubble stability tuning, and preventive maintenance. Written SOPs in English. Free refresher within warranty.

Get Your ABA Recycled-Core Film Blowing Machine Quote

Tell us your film requirements — we'll configure and quote within 3 working days.

• Target film width and gauge range

• Core layer material: CaCO3 compound, regrind, or other — and target percentage

• Target monthly output: tons/month

• Film application and key performance requirements

• Factory electrical supply and floor dimensions