Choosing the Right Cooling System for Blown Film Production

Efficient cooling is one of the most important parts of blown film production. It controls film clarity, strength, and thickness while also affecting line speed and energy use. Choosing the right cooling setup can make a big difference to both product quality and operating costs.

This guide explains the main types of cooling systems used in blown film production and how to select the best one for your process.

Why Cooling Matters

As the molten film leaves the die, it needs to cool evenly to set the bubble shape and achieve the right mechanical properties. Poor cooling can cause film haze, thickness variation, or weak spots. The right setup helps you run faster and reduce waste.

Learn more about process control in How the Blown Film Process is Done Efficiently and Sustainably.

Air Ring Cooling

Air ring systems blow cool air evenly around the bubble to set the film’s thickness and shape. Dual-lip air rings offer precise airflow control and are popular for high-output lines. They’re a reliable choice for most standard packaging applications.

However, airflow balance is key. If air distribution isn’t uniform, it can lead to wrinkles or uneven film. Regular cleaning and inspection help maintain performance.

Internal Bubble Cooling (IBC)

IBC systems cool the film from inside the bubble as well as from the outside. This provides faster, more even cooling and better control of film gauge. It’s ideal for thicker films or high-speed lines where standard air rings struggle to keep up.

While more complex to install, IBC can improve film clarity and boost output rates. It’s also more energy-efficient than increasing air ring speed alone.

Dual Cooling Systems

For demanding applications like multi-layer film, combining internal and external cooling offers the best results. Dual systems maintain film symmetry and reduce defects caused by heat imbalance between layers.

When running co-extrusion lines, it’s worth assessing how airflow interacts between layers. Automated controls can help maintain balance and stability.

Final Thoughts

Choosing the right cooling system depends on your film type, thickness, and output speed. Whether you use a standard air ring, IBC, or a combination, the goal is consistent cooling and stability.

Upgrading your cooling and handling setup can boost film quality while saving energy. Swallow’s Blown Film Handling Systems support efficient production and smooth film control from extrusion to winding. Speak to an expert today.