Eurotech K3A/K5A/K7A Multi-Layer Co-Extrusion Blown Film Extrusion Line
| Brand | Eurotech |
|---|---|
| Origin | Italy |
| Model Series | K3A, K5A, K7A |
| Screw Diameter | 40–65 mm |
| Die Diameter | 100–300 mm (fixed die) |
| Bubble Cooling | Dual-air-ring IBC system (min. die Ø 180 mm) |
| Winding Width | 600–1200 mm |
| Output Capacity | Up to 250 kg/h |
| Extruder Type | Single-screw XTR (standard) or XTR-WR (wear-resistant alloy barrel & screw) |
| Compatible Polymers | LDPE, HDPE, LLDPE, EVA, biopolymers, PA, EVOH, TPU, PP, PET |
Overview
The Eurotech K3A, K5A, and K7A series represent a modular family of industrial-grade multi-layer co-extrusion blown film lines engineered for high-precision, repeatable production of tubular polymeric films with functional barrier properties. These systems operate on the fundamental principle of simultaneous extrusion of two or more polymer melts through a concentric annular die, followed by controlled bubble inflation, radial cooling via dual-air-ring internal bubble cooling (IBC), and stabilized winding. Designed and manufactured in Italy, each configuration integrates robust mechanical architecture with process-critical subsystems—including wear-optimized extruders, precision-machined fixed dies, and adaptive thickness control—to meet stringent requirements for packaging-grade films used in food, medical, and industrial applications.
Key Features
- Modular co-extrusion platform supporting 3–7 layer configurations depending on model (K3A: 3-layer, K5A: 5-layer, K7A: 7-layer), enabling tailored barrier performance using combinations of structural (e.g., LDPE, HDPE, LLDPE, PP) and functional (e.g., EVOH, PA, TPU, PET) polymers.
- Single-screw extruders from the XTR series (standard) or XTR-WR series (hardened alloy barrel and screw), offering extended service life under abrasive or high-temperature processing conditions typical of engineering thermoplastics and bio-based resins.
- Precision-machined fixed-die heads with diameters ranging from 100 mm to 300 mm; minimum 180 mm required for full IBC integration—ensuring uniform melt distribution and minimal die lip distortion across operating temperature ranges.
- Dual-air-ring internal bubble cooling (IBC) system for rapid, symmetric quenching of the molten bubble, improving gauge uniformity, optical clarity, and mechanical isotropy—critical for high-speed converting operations.
- Winding stations configurable as single- or double-arm turrets (600–1200 mm web width), equipped with pneumatic loading, automatic tension control, and optional edge-guiding systems compliant with ISO 22391 and ASTM D2020 standards.
- Factory-integrated auxiliary options including gravimetric feeders (ASTM D3418-compliant dosing accuracy ±0.25%), automatic gauge control (AGC) with beta-radiation or infrared scanning sensors, corona treatment units (up to 5 kW, meeting ASTM D257), and inline mini-printers for batch traceability per ISO 9001:2015 clause 8.5.2.
Sample Compatibility & Compliance
The K-series accommodates a broad spectrum of thermoplastic resins—including commodity polyolefins (LDPE, HDPE, LLDPE), elastomeric blends (EVA), biodegradable matrices (PLA, PHA), and high-barrier engineering polymers (PA6, EVOH, TPU, PET). All configurations are designed to maintain stable output within ±1.5% thickness variation (measured per ISO 4593) at rated capacity (250 kg/h). Mechanical and electrical safety conforms to CE marking requirements (2006/42/EC Machinery Directive and 2014/30/EU EMC Directive). Optional validation packages support IQ/OQ documentation aligned with GMP Annex 15 and FDA 21 CFR Part 11 when integrated with Eurotech’s TraceLink™ data acquisition module.
Software & Data Management
Control is managed via an industrial HMI running Eurotech’s proprietary FILM-OS v4.2 firmware, featuring real-time PID regulation of extrusion temperature zones, air ring pressure differentials, haul-off speed, and winder torque. Process parameters are logged at 100 ms intervals and archived in CSV/SQL formats compatible with MES platforms (e.g., Siemens Opcenter, Rockwell FactoryTalk). Audit trails include user login history, parameter change timestamps, and alarm event sequences—fully compliant with ALCOA+ principles for data integrity. Optional cloud-enabled remote diagnostics (via TLS 1.3-secured MQTT) allow OEM-level support without direct network exposure.
Applications
These systems are deployed globally for manufacturing high-value flexible packaging films requiring precise layer architecture—such as retortable pouches (EVOH/PA/PP), stand-up pouch laminates (PET/ALU/PE), compostable snack bags (PLA/PHA/PE), and medical-grade sterile barrier films (TPU/PE/EVOH). Additional use cases include agricultural mulch films (LLDPE/UV-stabilized additives), industrial liner membranes (HDPE/geotextile composites), and specialty release liners (silicone-coated PE/PET hybrids).
FAQ
What is the minimum die diameter required to implement the IBC system?
A minimum die outer diameter of 180 mm is required to accommodate the dual-air-ring IBC configuration.
Can the line be validated for pharmaceutical packaging compliance?
Yes—when equipped with TraceLink™ and configured with calibrated radiation-based thickness gauges, the system supports qualification per USP and ISO 11607-1 for sterile barrier materials.
Is retrofitting possible for existing single-layer lines?
Eurotech offers upgrade kits for XTR-series extruders and die adapters, though full co-extrusion capability requires replacement of the feedblock, die, and associated melt-piping manifolds.
What maintenance intervals are recommended for the XTR-WR extruder?
Screw/barrel inspection is advised every 4,000 operational hours; bearing lubrication intervals follow ISO 281 guidelines based on load factor and rotational speed.
Does the system support recipe management across multiple material formulations?
Yes—FILM-OS supports up to 99 stored recipes with version-controlled parameter sets, including thermal profiles, screw RPM, and IBC airflow ratios, all exportable for cross-site standardization.
