Custom Stretch Film

As an experienced LLDPE stretch film manufacturer in the United States, with over ten years of industry experience, we are dedicated to delivering high-quality packaging solutions. Our products feature exceptional tensile strength, tear resistance, and superior clarity, making them suitable for various industrial and commercial applications. We offer a range of thicknesses and colors to meet diverse market demands. With advanced production facilities and a stringent quality control system, we ensure that every roll of stretch film meets the highest performance standards, providing reliable protection for our customers’ products.

1. Products

1.1 Main Material

Linear Low-Density Polyethylene (LLDPE) is a thermoplastic polymer made from the copolymerization of ethylene. Compared to traditional Low-Density Polyethylene (LDPE), LLDPE offers higher tensile strength, impact resistance, and better puncture resistance.

1.1.1 High Toughness and Extensibility

Due to its unique polymer structure, LLDPE exhibits excellent toughness and extensibility, making films or containers made from it less likely to break.

1.1.2 Good Chemical Stability

This material is resistant to most acids, alkalis, and other chemical substances, making it suitable for packaging chemically corrosive materials.

1.1.3 Superior Low-Temperature Performance

LLDPE maintains good flexibility and tear resistance even at lower temperatures, making it suitable for refrigeration and freezing environments.

1.2 Additives

1.2.1 Antistatic Agents

Antistatic agents are used to reduce or eliminate the accumulation of static electricity on plastic surfaces, effectively preventing dust adhesion and static discharge. Typically added in amounts ranging from 0.1% to 0.5%, these can include phospholipids and amino compounds.

1.2.2 Slip Agents

Slip agents reduce the film’s coefficient of friction, making its surface smoother and easier to handle and process. Common slip agents include fatty acid salts and silicone oils, usually added in proportions from 0.1% to 1%.

1.2.3 UV Stabilizers

UV stabilizers prevent polymer degradation due to ultraviolet radiation, which is especially important for products used outdoors or exposed to sunlight for extended periods. These are generally added in amounts ranging from 0.5% to 2%.

1.2.4 Plasticizers

Plasticizers increase the plasticity and flexibility of the film, making it easier to process and use. Common plasticizers include phthalates and citrate esters, with amounts depending on the desired softness, typically ranging from 1% to 10%.

1.2.5 Fillers

Fillers such as calcium carbonate or talc can enhance the film’s rigidity and thermal stability, while also reducing costs. The amount added can vary widely, from 5% to 30%, depending on the application.

1.2.6 Colorants

Colorants or pigments are added when a colored film is required. These additives are usually in small amounts, generally not exceeding 1%, sufficient to provide uniform and vivid colors.

1.3 Thickness

1.3.1 12 Microns

This is a thinner type of stretch film primarily used for light to medium load packaging. It is suitable for wrapping lighter pallet goods or items that need extra protection without the requirement for extreme strength support. Due to its lighter weight, it helps reduce material usage, thereby lowering costs.

1.3.2 15 Microns

This medium thickness stretch film is suitable for medium load packaging, providing good protection and durability. It is the most commonly used thickness, balancing performance and cost-effectiveness, suitable for most standard packaging needs.

1.3.3 17 Microns

A thicker film, suitable for heavier or unstable goods. 17-micron stretch film offers higher strength and puncture resistance, suitable for packaging heavier items or those with sharp edges.

1.3.4 20 Microns

This is a thicker stretch film, primarily used for heavy loads or applications that require additional strength and protection. 20-micron film is particularly suited for transporting items that may experience significant impact or pressure, such as heavy machinery parts or large furniture.

1.3.5 23 Microns

These are particularly thick stretch films, usually used for special applications such as extremely heavy loads or very sensitive, fragile products. They provide maximum protection and support, suitable for high-risk transport and long-distance shipping.

1.4 Weight

1.4.1 For a standard film of 17 microns (67 gauge), if the width is 500 millimeters (about 20 inches) and the length is 300 meters (about 984 feet), the weight of each roll is approximately between 2.5 to 3 kilograms.

1.4.2 For thicker films, such as 23 microns (91 gauge), the weight of each roll will be heavier, likely between 3 to 3.5 kilograms, at the same width and length.

1.5 Diameter

1.5.1 Roll Diameter

The roll diameter usually depends on the film’s length and thickness. For example, a standard roll diameter might range from 400 millimeters (about 15.75 inches) to 500 millimeters (about 19.69 inches).

1.5.2 Core Diameter

The core diameter refers to the diameter of the paper core at the center of the film roll when rolled up. Common core diameters include 50 millimeters (about 2 inches) and 76 millimeters (about 3 inches).

1.6 Colors

1.6.1 Transparent

Transparent film is the most common choice because it allows the contents to be visible, facilitating the identification and inspection of goods without needing to open the packaging. Suitable for most types of product packaging.

1.6.2 White

White film can reflect sunlight, reducing the buildup of heat caused by direct sunlight, making it very suitable for products that need to be stored outdoors.

1.6.3 Blue

Blue film is often used for specific types of products or as a color code to help distinguish different types or batches of goods.

1.6.4 Red

Red Red film is usually used for applications that require high visibility, such as marking important goods or emergency supplies.

1.6.5 Green

Green is typically associated with safety or environmental friendliness, and can be used in specific industries or to highlight a product’s environmental attributes.

2. Production Process

2.1 Material Preparation

We source high-quality Linear Low-Density Polyethylene (LLDPE) resin, which is known for its excellent tensile and tear resistance, making it the ideal material for producing stretch film. Depending on requirements, additives such as antistatic agents, UV stabilizers, or slip agents may also be added to enhance the film’s performance and stability during processing.

2.2 Melting and Extrusion

The LLDPE resin granules and necessary additives are heated to the appropriate temperature (usually between 200°C and 250°C) to melt. Through the extruder’s screw, the molten polymer is evenly mixed and pushed towards the die, forming a continuous film.

2.2.1 Extruder

The extruder is the core equipment in the production of LLDPE stretch film. It heats and melts the plastic granules (resin), then extrudes it into a film through the die head. Extruders are typically equipped with precisely controlled heating zones to ensure the material maintains a constant temperature throughout the process.

2.2.2 Die

The die is a crucial part of the extruder, used to form the film at specific widths and thicknesses.

2.3 Casting

The molten polymer is extruded through a flat die, forming a uniform layer of film. This film is then quickly cooled on a set of large cooling rolls, which ensure the film’s rapid and uniform solidification and also help control the film’s thickness and flatness.

2.4 Stretching and Orientation

After cooling, the film enters the stretching unit, where it is stretched in both the machine direction (MD) and transverse direction (TD). This step is critical as it determines the film’s final mechanical properties and clarity. Stretching can be done at room temperature or slightly higher temperatures to optimize the film’s performance. The stretching equipment typically includes multiple rollers that operate at different speeds to achieve the film’s orientation.

2.5 Rewinding

After stretching and orientation, the film is rewound into large rolls. These large rolls can then be cut into smaller rolls of various widths and lengths according to specific customer needs.

2.6 Inspection

Throughout the production process, we conduct multiple quality inspections, including tests for thickness, width, tear resistance, and clarity to ensure each batch meets our high standards.

2.6.1 Thickness Testing

A thickness gauge is used to measure the film’s thickness, ensuring consistency across the entire batch. Uniform thickness is crucial for the film’s overall performance and mechanical properties.

2.6.2 Tensile Strength and Elongation Testing

These tests measure the film’s mechanical strength and stretching capability. Using a universal testing machine, the film is tested for tensile strength under specified loads and its elongation before break.

2.6.3 Tear Resistance Testing

The film’s resistance to tearing is tested, which is crucial for preventing accidental damage during use. A tear tester is typically used to measure the force required to initiate a tear.

2.6.4 Puncture Resistance Testing

Puncture tests assess the film’s ability to withstand impacts from sharp objects. This test is key to ensuring the packaging provides adequate protection during transport and storage.

2.6.5 Clarity Testing

Clarity is an important aesthetic and functional consideration for customers. A clarity meter is used to test the film’s optical properties, ensuring it is suitable for packaging that requires the contents to be visible.

2.6.6 Static Testing

The film’s static properties are tested, especially important in applications where control of static accumulation is necessary to prevent dust adhesion and issues caused by charge buildup.

2.6.7 Dimensional Stability Testing

The film’s dimensional changes under certain conditions, including temperature and humidity effects, are measured to ensure performance stability in various environments.

2.6.8 Print Quality Inspection

If the film has been printed, the quality of the printing is also checked, including the clarity of patterns, color consistency, and print durability.

2.7 Packaging

After rigorous inspection and testing, the finished film rolls are appropriately packaged to ensure protection during transport, and then shipped to customers.

3. Problem and Solution

3.1 Uneven Film Thickness

3.1.1 Problem

If the extruder screw speed is unstable or the die is improperly adjusted, it may result in uneven film thickness.

3.1.2 Sloution

Use stable ink formulations and ensure thorough and uniform mixing to avoid color deviations caused by different ink batches. Regularly check the ink status and storage conditions to maintain stable ink color.

3.2 Film Breakage

3.2.1 Problem

During stretching or rewinding, the film may break due to overstretching or physical defects.

3.2.2 Sloution

Reduce the stretch ratio, adjust the stretching speed and temperature settings to ensure the film’s physical strength remains within safe limits during processing. Check the quality of raw materials to avoid using defective materials.

3.3 Film Surface Adhesion

3.3.1 Problem

Excessive adhesion on the film surface can cause cleaning problems on rollers and other equipment, affecting subsequent processing or use.

3.3.2 Sloution

Add an appropriate amount of slip agent or antistatic agent to improve the film’s surface characteristics. Regularly clean equipment to reduce contamination on the film surface.

3.4 Uneven Color or Poor Dyeing

3.4.1 Problem

If pigments are unevenly dispersed, it may cause streaks or spots in the film’s color.

3.4.2 Sloution

Optimize the mixing process of pigments and raw materials to ensure even dispersion of pigments in the plastic matrix. Use high-quality colorants and avoid using pigments with uneven particle sizes.

3.5 Insufficient Film Transparency

3.5.1 Problem

Insufficient transparency may be due to too many impurities in the raw materials or inappropriate processing temperatures.

3.5.2 Sloution

Optimize the purity of raw materials, control the temperature and pressure during the processing to ensure the orderly arrangement of polymer chains, thus enhancing the film’s transparency.

3.6 Static Issues

3.6.1 Problem

During production and packaging, static accumulation can cause dust adhesion or make operations difficult.

3.6.2 Sloution

Add a suitable amount of antistatic agent and use static elimination equipment to reduce the impact of static electricity in the environment.