For manufacturers specialising in film blowing—whether it’s high-strength garbage bags, pallet stretch wrap, or protective builder’s film—the choice of raw material is a matter of millimeters, or even micrometers.
The success of your product is judged on its strength, uniformity, and lack of defects. This demanding application highlights the biggest challenge of working with recycled resin: purity. A single unremoved particle can lead to pinholes, tears, and total production failure.
At Polymer Processors, our commitment to premium quality is demonstrated by our investment in the most crucial technical step for film applications: advanced melt filtration.
The Threat of Contamination in Thin Films
When using recycled content, particularly post-consumer soft plastics (LDPE), the material is never perfectly clean. Microscopic impurities—such as dust, tiny paper fragments, or gelled particles (cross-linked plastic that won’t melt)—become serious defects when stretched into a thin film.
These impurities cause three major headaches for film manufacturers:
- Pinholes and Weak Spots: Contaminants act as stress points, resulting in tiny breaks that compromise the film’s protective or structural integrity.
- Web Breaks and Downtime: During the high-speed blowing process, severe contamination causes the molten plastic bubble to rupture, halting production and wasting expensive time and labour.
- Inconsistent Gauge: Unevenly melted or contaminated material can lead to variations in film thickness, compromising the product’s strength and overall quality.
Our Solution: Extreme Melt Filtration
We counter these challenges by integrating multi-stage, fine-mesh filtration systems into our state-of-the-art extruders. This process is the ultimate safeguard for producing the pure, homogenous plastic required for film blowing.
When the pre-cleaned material is melted down, it passes through screens with extremely fine apertures. This acts like a high-powered sieve, physically removing any remaining particles that could compromise the film.
- Purity Guaranteed: We are removing contaminants down to the finest possible level, ensuring the extruded material is clean and uniform.
- Predictable Performance: By removing contaminants, we ensure the material’s Melt Flow Index (MFI) is consistent. This is essential for controlling the bubble in film blowing and maintaining the precise thickness and integrity of the final product.
- Reduced Maintenance: A cleaner pellet means less wear and tear on your own high-value machinery, contributing to lower operating costs for your facility.
The Key Takeaway for Film Manufacturers
For high-speed, demanding film applications, the purity of the recycled pellet is non-negotiable.
Our investment in advanced melt filtration and in-house laboratory testing is your assurance that you are receiving a premium, consistent product. We take on the challenge of processing the difficult inputs so that you can focus on maximising your production line’s efficiency.
Choose recycled pellets that deliver strength, uniformity, and consistency—every single time.
Contact Polymer Processors today to discuss securing a stable supply of film-grade