Polythene film manufacturing Polythene film manufacturing

Polythene Film Manufacturing

Polybags is the UK's number one polythene manufacturer.

We produce all of our own polythene packaging on site in our 50,000 sq ft factory, operating 13 blown-film extruders to make the polythene and 12 converting machines to turn it into the huge range of bags and sheets that our customers need.

Polythene extrusion lines work best when they run continually, so we operate 24-hour production to ensure that the quality of your products is first rate. This round-the-clock operation also improves production capacity, allowing us to manufacture and dispatch over 80 tonnes of quality polythene packaging products every week.

What's more, 24-hour production helps us keep costs down and provides us with the flexibility to prioritise key jobs, so your order is not only at rock-bottom price but our lead times are the best in the business.

With Polybags, you can guarantee you'll be getting the best value products on the market. There is a lot of polythene packaging to choose from so, if you are new to the manufacturing process, or just interested in how things are made, our handy guide (below) will give you an good idea of what we produce, how we produce it and the various options available to you.

Of course, you don't need to learn any of this unless you want to. You can always leave the manufacturing side to us and you just choose the product you require. If you have any questions the Polybags customer service team are always on hand to help, so please get in touch.

The polythene manufacturing process The polythene manufacturing process

The polythene manufacturing process

At Polybags we make our polythene packaging through the process of blown film extrusion - one of the most common manufacturing methods, in which an extruder heats and inflates raw polymer like a tubular balloon before cooling and flattening it ready for conversion into a huge range of plastic film or bags.

The diagram below gives an overview of the polythene extrusion process, which we will outline for you here.

Silo-fed raw material

The production of plastic film and bags begins with the raw materials used - granules or pellets of polyethylene, so how these are handled is a fundamental part of the process.

Polybags has eight huge external silos which each store up to 60 tonnes of these raw materials until the extrusion process begins as they are fed from the storage silos into the extruder. The advantages of this method include:

Polythene production chain Polythene production chain

The extruder

The raw polythene materials are fed via a hopper into the extruder - a machine with a long horizontally-mounted barrel 20-30 times as long as its diameter, which contains an Archimedes screw turned by a large electric motor and is heated as it moves.

As the raw material is forced through the barrel via the screw it is melted by both the heater elements and the action of the screw. Once it reaches the end of the barrel, the molten polythene is pushed through some gauze filters and then upwards into the extruder die - which contains 2 circular steel pipes placed one inside the other with a gap of 1mm at the exit.

The polythene exits the die in a circular tube and - aided by a set of nip-rollers drawn up a tower reaching several metres above - forms a tall tubular bubble with the die at the base. Air is forced into the bubble until it reaches the required diameter whilst, at the same time, a high-speed air ring blows cold air onto the polythene to cool it down.

The film continues to cool as it is drawn up the tower, before passing through the nip rollers at the top, which flatten the polythene tube to create a layflat tube. This is then drawn through a series of rollers back down the extrusion tower, during which process it may pass through a treatment point and a printer, which can customise your polythene - most frequently when making bags - with your very own company logo or design.

At this stage, the polythene can be kept in the form of a layflat tube or it can be slit on one or both edges to produce various types of plastic sheeting products (see below). These are all wound onto a roll around a cardboard core ready for dispatch.

Polythene film products Polythene film products

Polythene film products

The layflat tube of polythene that exits the blown film extruder provides versatility as, depending on how it is cut, it can be turned into a range of polythene film products.

The diagram below provides an overview of the main polythene film products available from Polybags, which we will provide further detail on here.

Polythene sheeting Polythene sheeting

As well as these various types of polythene film, the layflat tubing that is created during the extrusion process can also be converted into a range of polythene bags. See our page on polythene bag manufacturing for more information.

What people in the street might say about polythene

"This is superb news for the environment and all Europeans who expected the EU to take ambitious action on plastic bags." Environment Committee chair Giovanni La Via said: "We are pleased with the green light for this necessary dossier. The European Commission's new come demonstrates a necessary sense of responsibility. "We called upon the Commission to act as a proper facilitatour between the two legislative institutions. Parliament and Council have done a superb job for the Environment and the European citizens." Affecting markets The European plastics industry has expressed concern that a ban on plastic bags could create trade barriers and hinder the EU internal market. PlasticsEurope executive directour Karl-H. Foerster said: "The possibility to ban plastics bags goes against the normal principle of the Packaging and Packaging Waste Directive. It is about as it opens the door for Members States to ban not only plastics bags nevertheless other types of packaging as well. "Such an inconsistent political framework that would enable Member States to introduce alternative regulations on packaging would hinder investments and innovation and would create barriers to trade in packaged products in Europe." The industry does, nevertheless, assist the imposition of a tax on all carrier bags of any material, as a method to assist raise consumer awareness of the waste created by unwanted bags. Foerster said: "A mandatory charge is the optimal option as it has been proved to be an effective tool to reduce the above-consumption of lightweight plastic bags. We should understand that plastics are also valuable to be thrown away. "Charging for bags can have a positive effect on raising consumers' awareness of the economic value of the resources that have been used to manufacture the bag." UK opposition Despite Northern United Kingdom, Wales and Scotland already having adopted a 5p carrier bag tax, and a charge in England due to commence in 2015, the UK and a few other member states have opposed binding targets at European level . Auken said: "As front-running countries have demonstrated, dramatically reducing the consumption of these disposable bags is easily achievable with a consistent policy. Swiftly phasing out these bags is a readily-implementable solution to the pervasive problem of plastic waste in the environment." The Times reported now that Scotland's recently imposed plastic bag tax has resulted in a 90% in the use of bags by shoppers. World Wildlife Fund (WWF) Scotland directour Lang Banks welcomed the news, saying it proved that the charge is 'working well'. He said: "This is big news for Scotland's environment and wildlife, and proof that incentives like these can have a certainly positive impact for our planet. "We hope it will not be long before we rival nations like United Kingdom where, after a charge was introduced in 2003, each person now uses only four plastic bags annually on normal - the lowest plastic bag use in Europe." Anthony Brimelow, commercial directour of polythene suppliers manufacturer polythene suppliers manufacturers, investigates how technology is helping to 'green' polythene suppliers, which is often viewed as an environmental 'L'Enfant terrible' . --Carrier bag charge: In numbers-- Lois Vallely

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1000 - 8X10" 120g FOOD GRADE BAGS SANDWICH BAG polythene suppliers PLASTIC CLEAR QUALITY

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Builder's plastics are Damp Proof Membrane (DPM), Damp Proof Coarse (DPC) sheeting and Temporary polythene suppliers Sheets.

Coloured polythene suppliers Bags The most broadly used plastic is polythene suppliers or polyethylene. It is primarily used within the packaging industry and has an annual production of around eighty million tons. Although polyethylene is commonly called polythene suppliers in the United Kindom, it is not a scientific name. Classified into several alternative types, it is based mainly on its branching and density, and its properties rely on variables like the type of branching, the molecular weight and its crystal structure. When manufacturing coloured polythene suppliers, the first stage is to make the polythene suppliers film. Virgin polymer granules are mixed with colouring agents, and if required alternative other additives. The blend of cool granules and colouring agents are then conveyed to a film extruding machine, and the granules are then hot until they melt, and forced through a die which results in a vertical molten tube of polyethylene tubing. Air is then pumped into the molten tube until it inflates, and it resembles an elongated balloon. This air pumping process causes the tube to stretch outwards. At the same time the tube is pulled by a pair of nip rollers which stretch it in the opposite direction. Cold air is moncler wien blown onto the tube to cool it as it emerges from the nip rollers, and it is then hurt onto a plastic or carton tube. Coloured, transparent or packaging manufacturers suppliers is used in a wide spectrum of industries including: Agriculture: Apparel: Bakery: Dry Cleaning: Electronics: Hotel: Food: Hardware: Hosiery: Gardening: Composting: Housewares: Mailers: Manufacturing: Medical: Pet food: Poultry: Promotional: Retailing: Tradeshows. They can be manufactured in almost any colour like: Blue: Pink: Purple: Magenta: Orange: Red: Black: Green: Brown: Yellow: Navy: Cyan: Biege: Grey: Maroon, etc. These coloured bags may be “solid” denying visibilty of contents, or “transparent” allowing visibilty of contents, and they are on offer in a big spectrum of shapes and sizes, like: Light duty bags: Medium duty: Heavy duty: Plain grip seal bags: Grip seal panel bags: Heavy duty grip seal bags. polythene suppliers bags assist to keep safe products from moisture, and the inherent properties of this material make it a popular selection for plenty packaging applications.

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Layflat tubing Layflat tubing

Types of polythene film

As the UK's number one manufacturer, Polybags can not only offer the range of polythene film products listed above, but we also offer a huge range of sizes, thicknesses and types of polythene film to meet your exact needs.

We can manufacture film from as narrow as 25mm (1") to as wide as 1.4m (55") and varying in thickness from thin 20 micron (80 gauge) film in special high melt films, through to 250 micron (1,000 gauge) heavy-duty films.

Our main types of film are listed below but please note that all film is available in a wide range of grades and colours and with blends and additives to order.

We take bespoke requests and manufacture film to a huge range of specifications so, if you have particular requirements for your polythene film, then please get in touch.

Standard Melt 2 Low Density Polythene (LDPE) - Polybags' standard film blend produces products that are easy to open or handle and are food-grade approved. Contains both an anti-blocking agent and a slip agent to help during the extrusion process. Used for: General packaging applications

High Melt 4 Low Density Polythene (LDPE) - This soft and flexible film has limited strength properties, which makes it perfect for light-duty applications and means we can produce our very thinnest films - as slender as 20 micron (80 gauge) thick. This allows us to save on the amount of film used in production, thus keeping costs down for the customer. Used for: Garment film and dust covers

Garment covers Garment covers

Low Slip Melt 1 Low Density Polythene (LDPE) - Less slippy than standard LDPE film, this blend is useful for making heavy-duty sacks and other products that will be stacked. Its higher molecular strength also makes it suitable for shrink applications. By expanding the film whilst still molten and then quickly solidifying it, the polythene structure means it contracts when heated by shrink gun or heat tunnel. Used for: Shrink films and sack applications

High Tensile Films - This blend of polymers, which include Medium Density Polythene (MDPE), provide the maximum strength to thickness ratio - i.e. films that are both strong but thin. High tensile films have a rough, crinkly feel with reduced clarity and flexibility, but the material is ideal for thin food-grade tint sheets and other tinted or coloured films. Used for: Food bags and food sheeting

Electroconductive Blends - This electrically-conductive film is designed to protect electronic components which may be sensitive to static electricity. A blend of highly-conductive carbon and Low Density Polythene (LDPE), these products can be used for everything from protecting electrical devices to storing explosive devices. Used for: Protective antistatic packaging

Metallocene Blends - Films produced with metallocene - polyethylene raw material manufactured using a metallocene catalyst - are strong and of very high clarity. The films are more expensive than regular polythene due to the cost of manufacturing metallocene but, when you see the clarity of the finished product, you'll understand why. Used for: Premium high-clarity films

Reprocessed Films - Polythene produced with recycled raw material will not produce a product as high in quality as when using virgin polymer, but the resulting film offers an eco-friendly and low-cost packaging solution. Polybags recycles whatever raw material we can and we will always offer to extrude processed film when we can, although lack of supply is often our biggest problem. Used for: Low-cost and reduced-quality products

Biodegradable film Biodegradable film

Biodegradable Film - Polybags' wide range of eco-friendly packaging is made from biodegradable film with an additive blend which provides first oxidative and then biological degradation, typically within 6 - 24 months of being placed in compost or landfill. A fantastic green alternative to regular polythene, this cost-effective, strong and recyclable film offers a superior solution to many other eco-friendly products on the market. Used for: Food waste bags, dog poo bags and other compostable packaging solutions

Top ten common things said about polythene

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Previous studies have documented the effect of long-life bait coatings on palatability amongst both wild and captive rodent subjects. Initial efforts to encase baits within tin foil and self-packaging supplierble polythene suppliers bags only increased the neophobic responses of United Kingdom rats, so decreasing bait palatability. Traditional wax coatings have also resulted in a decrease of palatability for wild house mice. More recently, both naturally occurring and artificially manufactured human food preservatives have been recommended as potential coatings for rodent baits. These preservative coatings enable for the normal properties of the baits relating to smell and taste to remain, whilst protecting against the development of mould and decay.

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The HDPE polythene suppliers Sheets, delivered by us, are tear-resistant and have long working life. We have latest machines and cutting-edge technology so, we ensure that the raw materials used are as per set standards and meet the international norms as well. We transport only quali Polybags

The most commonly used plastics in households were transparent light-duty polyethene (38.7%) and small black medium-duty polythene suppliers (35.3%) bags. the rest were big coloured polythene suppliers bags (13.4%), heavy duty plastics (11%), and sacs (1.3%). Among the households that regularly used plastics, the majority used them for carrying shopping items like food stuffs (79%), for covering food when cooking (10%), to beginning fire amid lighting of charcoal stoves (10%), and as containers for floral plants (0.2%).

No photo this time, it would be of my sore arse! Did 50 miles on Doug's MV, up to Finchingfield. Good biking roads, Fazers etc pissed past me proper as a rock at speed while I jiggled about all above the place. Brakes have improved, found another oil leak, from the base of the barrel at the rocker tube. Parked up next to a load of Jap stuff, very small interest shown in the MV, tasteless wankers the lot of them. Most don't even know who MV are, less know what a kick beginning is! That seat is like a razour blade. Took the barrel off on Monday, replaced the gasket, did a 10 mile blast, seems OK. Still blowing a bit of oil from the breather, gonna machine up a new breather with a long polythene suppliers tube to rear of bike, that should sort it out. Got it up to 55mph on the Polybags(Christ we are not gonna stop!) Polybags

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In a communiqu to the commissioner, DC Yashvir Mahajan has stated that DFO Daljit Singh Brar has not participated in any of the monthly meetings of district administration and nor has been part of the monthly review meetings held below the NREGA. It has also been pointed out that the DFO does not reply to repeated phone calls. In June, the department was sanctioned Rs 5 lakh below the NREGA scheme, nevertheless the department had so far spent only Rs 13,000 to buy polythene suppliers bags for saplings. In the all monsoons, not even a single sapling was planted. Sources revealed that the department had not initiated any efforts to plant maximum number of saplings amid the monsoons. When the Punjab Government, on one hand, was harping on tree plantation drive to ensure increased green cover, such officials were dampening the spirits of these initiatives, said officials. The DC even pointed out that since the day he took charge in August he had not seen the DFO even once. ?He is a government official and is answerable to seniors, nevertheless he has been found guilty of dereliction of duties. I have not ever seen him once amid plenty meetings in the past above two and half months,? said Mahajan while talking to TNS. Senior department officials must initiate an action in this regard, he said. DFO Daljit Singh Brar said he had duly replied to the letter wherein he had stated that he had attended all meetings and phone calls as well. He added that the works below the NREGA were below process.

Exploring financial assist from business houses and administrative assist from district administration to make this potential and replace non-degradable polythene suppliers with paper bags.

Film additives

Polybags can introduce a series of additives to the polythene manufacturing process, blending them during production to give your polythene film or bags the specific properties you need.

We have a huge range of additives that we can add - so contact us if you have any queries - but here are some of the most common requests: