Microex Blown Desktop Single-Layer Blown Film Extrusion Line

Overview

The Microex Blown Desktop Single-Layer Blown Film Extrusion Line is a compact, fully integrated benchtop system engineered for controlled, repeatable production of thin polymeric films under laboratory conditions. Based on the fundamental principles of tubular blown film extrusion—where molten polymer is extruded vertically through an annular die, inflated by regulated air into a bubble, cooled by a precision air ring, and stabilized before being collapsed and wound—the system replicates industrial-scale film formation at a 1:100 volumetric scale. Its core architecture centers on a high-torque, variable-speed single-screw extruder (20 mm screw diameter) with barrel temperature zoning (typically 3 zones + die), enabling precise thermal profiling across thermally sensitive materials including PLA, PHA, PETG, LDPE, LLDPE, and filled or pigmented compounds. Unlike pilot-scale lines requiring dedicated floor space and utility infrastructure, the Microex Blown occupies less than 1.2 m² and operates on standard 230 V / 50 Hz single-phase power, making it suitable for university polymer labs, compounder QC departments, and biopolymer formulation centers where rapid iteration and material screening are critical.

Key Features

• Compact monoblock design integrating extruder, die head, air ring, collapsing frame, haul-off unit, and center-wind winder in a single structural chassis
• 20 mm diameter co-rotating single-screw extruder with hardened steel barrel and nitrided screw, optimized for low-melt-strength resins and high-viscosity masterbatches
• Adjustable 360° radial air ring with independent upper/lower airflow control to fine-tune bubble stability and frost line height
• Digital PID temperature control across four independently monitored zones (feed, compression, metering, die) with ±0.5 °C stability
• Variable-speed DC haul-off (0.5–15 m/min) and torque-limited winder with automatic tension feedback loop
• Modular die assembly allowing quick changeover between standard 20 mm OD/1.2 mm gap and optional 15 mm OD configurations
• Integrated safety interlocks including emergency stop, overtemperature cutoff, and motor overload protection compliant with CE Machinery Directive 2006/42/EC

Sample Compatibility & Compliance

The Microex Blown supports a broad spectrum of thermoplastic feedstocks without modification: virgin homopolymers (PP, HDPE), recycled flake or pellet streams (rLDPE, rPP), color concentrate masterbatches (up to 40 wt%), mineral-filled compounds (CaCO₃, talc), plasticized starch blends, and certified compostable biopolymers (EN 13432-compliant grades). All contact surfaces—screw, barrel, die land, and air ring nozzles—are electropolished stainless steel (AISI 316L) to prevent degradation during extended processing of acidic or halogenated additives. The system is validated for use in environments adhering to Good Laboratory Practice (GLP) frameworks; its digital log files include timestamped temperature profiles, screw RPM, melt pressure (via optional transducer), and winding speed—enabling full traceability for internal audits or regulatory submissions. While not certified as GMP equipment per se, its design aligns with FDA-recommended controls for pre-commercial process development per Guidance for Industry: Process Validation (2011).

Software & Data Management

Operation is managed via a dedicated touchscreen HMI running embedded Linux OS, supporting local data logging to internal SD card (up to 32 GB) and USB export of CSV-formatted process logs. No proprietary cloud platform is required; all parameters—including zone setpoints, ramp rates, dwell times, and speed profiles—are configurable and recallable as named recipes. Audit trail functionality records operator ID (via optional RFID badge reader), parameter changes, and system events with immutable timestamps—meeting baseline requirements for 21 CFR Part 11 compliance when paired with institutional electronic signature policies. Raw data exports integrate natively with MATLAB, Python (pandas), and JMP for statistical analysis of film thickness uniformity (ASTM D892), haze (ASTM D1003), and tensile properties (ASTM D882).

Applications

• Rapid assessment of melt strength and bubble stability for new biopolymer formulations prior to pilot-line trials
• QC verification of color dispersion consistency in masterbatch batches using inline optical density scanning of produced film strips
• Screening thermal degradation thresholds of recycled polymer blends via melt fracture onset analysis at varying shear rates
• Correlation studies between capillary rheometry data (e.g., Bagley and Rabinowitsch corrections) and actual blown film draw ratios
• Educational demonstration of viscoelastic response, draw resonance, and edge-thickness control mechanisms in polymer processing courses
• Supporting ISO 17892-6 (geosynthetic clay liner) and ASTM D7192 (compostable mulch film) prequalification testing protocols

FAQ

What is the minimum sample quantity required to run a valid test?
Typically 300–500 g of dried granulate is sufficient to generate ≥5 meters of stable film for thickness and optical characterization.
Can the system process moisture-sensitive polymers like PA6 or PVA?
Yes—when used in conjunction with an optional desiccant hopper dryer (dew point ≤ −40 °C) and nitrogen purge kit for the die head zone.
Is die lip cleaning possible without full disassembly?
Yes—the modular die features quick-release clamps and a removable land insert accessible via two allen screws; standard cleaning takes <8 minutes.
Does the system support ASTM D2657-compliant bubble diameter measurement?
Yes—integrated laser micrometer ports (optional accessory) enable real-time bubble diameter monitoring at three axial positions per rotation cycle.
Are spare parts and technical documentation available in English?
All mechanical spares (screws, barrels, air ring nozzles, winder belts) and bilingual (EN/IT) operation manuals, calibration certificates, and CE declarations are supplied ex-works from EUROTECH’s Milan facility.