Energy-Efficient Upgrades for Legacy Blown Film Machinery

Blown film machines use a lot of power, especially older ones. Over time, this can push up your running costs and lower efficiency. Buying a new line is expensive, but you don’t always need to replace the whole system. By retrofitting key parts, you can cut energy use, save money, and extend the life of your trusted machine.

Why Energy Efficiency Matters

Power is one of the biggest costs in film production. Heating, cooling, and drive systems are the main energy users. Older machines were not designed with today’s standards in mind, so they often waste power. By upgrading, you lower costs and reduce your carbon footprint. This helps with customer demand and meeting environmental rules.

Retrofit Options for Blown Film Machinery

1. Variable Speed Drives
Variable speed drives (VSDs) let motors use only the energy they need. This avoids waste when loads are light. They also give you better control of the process, which improves product quality.

2. Modern Heating Systems
Heating the extruder and die takes huge amounts of power. Old heaters lose energy and heat up slowly. New heating bands or infrared systems are faster and more precise, so less energy is wasted.

3. Smart Control Systems
Upgrading controls helps you track power use in real time. Operators can spot problems early and keep the line running smoothly. For more on efficient processes, see How the Blown Film Process is Done Efficiently and Sustainably.

4. Efficient Cooling Solutions
Cooling uses a lot of power too. Old fans and chillers draw more energy than they should. Upgrading to high-efficiency motors or new cooling designs keeps film quality high while lowering costs.

Benefits of Energy-Efficient Upgrades

• Lower costs: Reduced power bills mean the upgrades pay for themselves.
  
  
• Longer machine life: New parts ease the strain on older systems.
  
  
• Better product quality: Steadier heating, cooling, and drive control give more consistent results.
  
  
• Sustainability: Cutting energy use helps meet green targets and boosts customer trust.
  
  

When to Retrofit

Some signs show it is time to think about upgrades:

• Energy bills rising without higher output.
  
  
• Inconsistent film quality linked to old systems.
  
  
• More downtime and repairs.
  
  
• Pressure from customers to go greener.
  
  

If you see these issues, retrofitting is often the right choice.

Choosing the Right Components

Not all upgrades work the same way. It is best to look at your exact line and output first. Swallow offers modern handling components that improve energy use. A good example is the Turning Bar & Idler, which reduces friction and helps film move smoothly. Pair this with updated web-guiding and tension control for the best results.

Why Work with Experts

Retrofits work best when they are planned around your needs. Swallow’s team checks your current setup, energy profile, and production goals. Then they fit the right mix of drives, heaters, controls, and handling gear. This ensures you save power and avoid costly downtime.

Final Thoughts

Energy-efficient upgrades are a smart way to keep legacy blown film machinery competitive. By fitting new drives, heating systems, controls, and handling parts, you save money, improve quality, and meet sustainability goals.

For advice on upgrades that fit your line, speak to Swallow’s retrofit experts today.