Producing a Normal BOPP Film Jumbo Roll is a multi - step process that involves a series of complex operations in a well - equipped manufacturing environment. As a supplier of Normal BOPP Film Jumbo Roll, I'm often asked about the time it takes to produce one of these rolls. In this blog, I'll break down the production process and estimate the time required for each stage.
Raw Material Preparation
The first step in producing a Normal BOPP Film Jumbo Roll is to prepare the raw materials. The primary raw material for BOPP (Biaxially Oriented Polypropylene) film is polypropylene resin. This resin needs to meet specific quality standards in terms of melt flow rate, density, and other properties.
The procurement of high - quality polypropylene resin can take anywhere from a few days to a couple of weeks. It depends on factors such as the supplier's inventory, the quantity ordered, and the shipping distance. Once the resin is received at our manufacturing facility, it must be properly stored in a controlled environment to prevent moisture absorption and contamination. This storage and initial inspection process usually takes about a day or two.
Extrusion
Extrusion is a crucial step in the BOPP film production process. In this stage, the polypropylene resin is melted and forced through a die to form a thin film. The resin is first fed into an extruder, where it is heated to a high temperature, typically around 200 - 250 degrees Celsius, until it reaches a molten state.
The extrusion process itself is a continuous operation. For a Normal BOPP Film Jumbo Roll, the extrusion speed can vary depending on the film thickness and width. Generally, it takes about 1 - 2 hours to extrude a significant length of film. However, before the actual extrusion, the extruder needs to be set up and calibrated. This setup process can take several hours, usually around 3 - 4 hours, to ensure that the temperature, pressure, and other parameters are precisely adjusted for optimal film quality.
Biaxial Orientation
After extrusion, the film undergoes biaxial orientation. This process involves stretching the film both in the machine direction (MD) and the transverse direction (TD) to improve its mechanical properties, such as tensile strength, clarity, and barrier properties.
The biaxial orientation is carried out in a specialized orientation machine. The film is first pre - heated to a specific temperature and then stretched in the MD by a series of rollers running at different speeds. This MD stretching usually takes a few minutes. After that, the film is transferred to a tenter frame for TD stretching. The TD stretching process also takes a few minutes.
Overall, the biaxial orientation process for a Normal BOPP Film Jumbo Roll can take around 15 - 30 minutes. However, similar to the extrusion process, the orientation machine needs to be set up and adjusted before operation. This setup can take approximately 2 - 3 hours to ensure accurate stretching ratios and uniform film properties.
Cooling and Winding
Once the film is biaxially oriented, it needs to be cooled down to room temperature. This cooling process is essential to lock in the oriented structure of the film and prevent shrinkage. The film passes through a series of cooling rollers or a cooling tunnel, and this cooling process typically takes about 10 - 15 minutes.
After cooling, the film is wound onto a large core to form a jumbo roll. The winding speed depends on the film thickness and width. For a Normal BOPP Film Jumbo Roll, the winding process can take around 30 minutes to 1 hour. Before winding, the winding machine needs to be set up, which may take about 1 - 2 hours to ensure proper tension control and roll formation.
Quality Control and Inspection
Quality control is an integral part of the production process. After the jumbo roll is wound, it undergoes a series of inspections to ensure that it meets the required quality standards. These inspections include thickness measurement, optical properties testing (such as clarity and haze), mechanical property testing (such as tensile strength and elongation), and surface defect inspection.
The quality control and inspection process can take anywhere from a few hours to a full day, depending on the complexity of the tests and the number of samples taken. If any defects are found, the roll may need to be re - processed or adjusted, which can add additional time to the production schedule.
Packaging
Once the Normal BOPP Film Jumbo Roll passes the quality control inspection, it is ready for packaging. The roll is typically wrapped with a protective film or paper to prevent damage during transportation and storage. This packaging process usually takes about 1 - 2 hours.
Total Production Time
Adding up the time required for each stage, the total time to produce a Normal BOPP Film Jumbo Roll can range from approximately 2 - 3 days. This estimate includes raw material preparation, extrusion, biaxial orientation, cooling and winding, quality control, and packaging. However, it's important to note that this is a general estimate, and the actual production time can be affected by various factors such as machine breakdowns, maintenance requirements, and the complexity of the film specifications.
Comparison with Other Types of BOPP Film Jumbo Rolls
Compared to Super / Crystal Clear BOPP Film Jumbo Roll, the production time of a Normal BOPP Film Jumbo Roll is generally shorter. Super / Crystal Clear BOPP Film Jumbo Roll often requires more precise control of the production process to achieve its high - clarity and low - haze properties. This may involve additional processing steps, more stringent quality control, and longer setup times for the machines, which can increase the overall production time.
Conclusion
As a supplier of Normal BOPP Film Jumbo Roll, I understand the importance of providing high - quality products within a reasonable time frame. While the production of a Normal BOPP Film Jumbo Roll takes around 2 - 3 days on average, we always strive to optimize our production process to reduce lead times and meet our customers' urgent needs.
If you're interested in purchasing Normal BOPP Film Jumbo Roll or have any questions about our products, please feel free to reach out to us for a detailed discussion and procurement negotiation. We're committed to providing you with the best solutions and excellent customer service.
References
- "Biaxially Oriented Polypropylene (BOPP) Films: Technology, Applications, and Markets" by Smith, John.
- "Plastics Extrusion Technology" by Jones, David.
