Material Matters: Adapting Machinery for Recycled and Bio-Based Films

Sustainability is reshaping the plastics industry, and film producers are under pressure to use more recycled or bio-based materials. These new materials behave differently from traditional polymers, meaning machinery needs careful adjustment to maintain film quality and consistency.

This article explains how to adapt blown film lines for recycled and bio-based resins while keeping efficiency and strength high.

Understanding Material Differences

Recycled materials vary in purity, melt flow, and colour. Bio-based resins often have lower thermal stability or different cooling behaviour. Both require precise control of temperature, tension, and cooling to produce consistent film.

Fine-tuning your process helps prevent issues like gels, uneven gauge, or reduced clarity. Learn more about sustainable film processing in Energy-Efficient Upgrades for Legacy Blown Film Machinery.

Temperature and Cooling Adjustments

Start by checking barrel and die temperatures. Recycled polymers may need lower processing temperatures to prevent degradation. Slow, even cooling helps maintain clarity and reduce surface defects.

Upgrading air rings or adding internal bubble cooling can give better control over melt temperature and film setting, especially for thinner gauges.

Handling and Winding Considerations

Recycled and bio-based films can be more sensitive to stretch or deformation. Precise web guiding and tension management prevent film drift and ensure proper winding.

Swallow’s Turning Bar & Idler Systems are designed to support delicate or multi-material films by maintaining alignment and stability throughout the process.

Testing and Quality Control

Always test new material blends before full production. Measure film strength, sealability, and transparency under different conditions. Adjust extruder speeds or screw design if flow inconsistencies appear.

Monitoring data over time helps establish ideal process settings for each film type and reduces trial-and-error waste.

Final Thoughts

Adapting machinery for sustainable materials takes patience and precision. By optimising temperature, tension, and cooling, manufacturers can meet environmental goals without sacrificing performance.

With the right equipment and support, Swallow helps converters move towards recycled and bio-based production efficiently and reliably. Speak to an expert today.