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

Our poly films and flexible packaging products are used in industry markets that spectrum from food processing to industrial technologies and all in between. No matter what market we’re serving, we frequently aim to provide the very optimal products and service in the industry—to redefine our clients’ expectations of quality and what to expect from a comprehensive supplier partnership. Our goal is your satisfaction, and we not ever stop working to achieve it.

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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

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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

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Though the Packers and Movers in Chennai will take care of the all shifting process, there are specific tips and tricks to follow while shifting, which will assist in easy moving. Here are a few things you should discuss with your packers and movers about the moving process for a smooth and successful relocation. Ensure about packers and movers availability according to your required dates. Ask your packers and movers about the rates for moving household things like furniture, electronics, kitchen appliances, clothing, etc. Ask your packers and movers about the payment policies like advance deposit, mode of payment, etc. Also check the background and book the packers and movers before verifying their policies, rules, and regulations, thoroughly. It will enable safety shifting and also avoid unnecessary hassles. Ensure that movers and packers offer any transit insurance or not. Though the companies do not demand direct involvement in the insurance process, make sure you are aware of it. Also, on the day of moving, confirm the venue and the new location to the driver. Confirm whether packers and movers Chennai assist you to uninstall and reinstall the AC in your new place. Ensure that packers and movers you booked also provide mail shifting services like Pest control service , Plumbing service , Interior decoration , Electricians service , and Cleaning service.   Ask packers and movers Chennai about the kind of carriers they use for transportation. Polybags, open container or Closed container. Discuss the packing materials used for fragile items like a showpiece, glass tables, kitchen items, pooja articles, mirrours, delicate objects, etc.  Discuss storage and warehouse facilities offered by packers and movers, if required. Ask about additional services like online tracking facilities, unpacking and re-arranging your belongings at the venue. Request for a all invoice and shifting quotes in advance. The relocation services also include bike package service and car transportation service with the damage-free condition. The optimal Packers and Movers in Chennai also avail of pet relocation service. They will be shifted in a caged and safer environment. How to reduce Packers and Movers cost? Plan in advance Planning is probably the crucial part of getting you the pocket-friendly packers and movers Chennai. As you would require a few amount of time to plan meticulously, you cannot afford to rush amid the process of shifting. Planning at the twelfth hour can turn the all situation into a mess. Planning includes deciding the house you would to shifting to, the approximate journey date followed by the items that you wish to take, or discard. These are a few of the criteria the packers and movers in Chennai would be asking before quoting their price. If, in any case, you determine to book the locals movers and packers at the last moment, your options acquire restricted and small. Thus, it creates higher possibilities of the cost-effective packers and movers in Chennai being booked and hired by someone else. Get rid of old unwanted stuff The optimal method to reduce shifting charges is by decluttering your house. Sell old furniture or donate any unwanted and unused stuff to avoid additional charges. Transportation cost is reduced if the items you are going to shift are small and weigh less. Choose the optimal time to shift The season you would be planning to shift, or the date of shifting journey plays a necessary role in getting you the optimal yet cost-effective movers and packers in Chennai. The booking charges of the otherwise cost-effective relocation companies tend to shoot up amid the peak seasons, Polybags, summers. furthermore the rocket-high prices, the availability of superb companies also tends to shrink. To acquire your hands on cost-effective local packers and movers, it is advisable if you can plan your shifting amid the winter or maybe amid the rainy seasons. furthermore this, you must frequently search for movers and packers from a proper platform if you wish on a lookout for the optimal movers and packers in a cost-effective price. Compare and select First, set your shifting budget and contact optimal packers and movers Chennai that meet your requirements. Compare with alternative packers and movers in Chennai to come by the optimal price within your budget. What are the things to avoid amid relocation? Relocating to a new place securely while ensuring that all your products are adequately secured requires proper planning. There are so plenty things to take care of at the same time that it becomes tough to avoid inevitable mistakes. And these mistakes can contribute to a stressful moving experience. So, before hiring the optimal packers and movers in Chennai, here are a few normal errours that you must avoid to ensure a hassle-free relocating experience. No prior planning: No former planning often leads to stress. Take time to plan out your transport schedule and pack your items properly to avoid last-small confusion. Not researching alternative packers and movers in Chennai: Not doing adequate research while selecting a moving company can acquire you in a tough situation. Also, handing above your belongings to a new company can demonstrate to be very dangerous. Not insuring your products: Your relocation can become very expensive if any of the items acquire damaged amid the process. Thus, it is frequently advisable to ensure your products before transporting them. Reliable packers and movers Chennai offer transit insurances to their clients to make the process easy and uncomplicated. Not creating a List: Packing should frequently be a systematic process to avoid confusion. If you do not create a checklist of things that need to be transported, the process will eventually turn into a mess. Printable Checklist for Household moving Using the gross packing materials: Hiring the optimal packers and movers in Chennai can assist you avoid this mistake. They use high-grade packing material to ensure that your products reach the last destination without bearing a single scratch on them. Not carrying necessary items with yourself: It is necessary to create a separate box that includes the most necessary items. These can be anything, like medicines, toiletries, baby food, etc. This can basically be like your survival box that carries items you require on a daily basis. Not labelling the boxes: People generally forget about this. Labelling the boxes is very necessary to track down your belongings at the time of unpacking. Besides, labelling assists to provide better protection to fragile items. Not hiring packers and movers in Chennai: Sometimes, people think that they can schedule the shifting process on their possess, without any professional assist. This is a big misconception that will only increase the troubles. Without proper assist, the relocation process will become even more cumbersome. Not doing mail-transport clean-ups: Whether you are leaving a rented apartment or your possess house, it is necessary not to leave a mess behind. Apart from vacuuming and mopping, make sure to switch off the lights and other power switches to ensure the safety of all. These are a few of the most normal mistakes that you must avoid amid relocation. Make sure to hire a skilled and proper packers movers Chennai who can guide you through the process and ensure a hassle-free shifting experience. 9 Things to do before hiring moving company in Chennai Get the list of packers and movers - Search the packers and movers in Chennai through the Online or advertisement. Search in the depth of the packers and movers list. Filter out the moving company which is close to you. Know the trustworthiness of the packers and movers company - While browsing for packers and movers, first of all, know the moving company years of experience in the market. Check whether the relocation service provider is close to you. And also acquire the view of the packers and movers service from your friends and relatives. Read the reviews of the selected moving company - Check the reviews twice from the previously booked users. It will certainly give you a transparent view about the packers and movers company. If it is potential means to acquire the contact detail of the previously booked clients then contact them personally. Plan your Budget for the relocation - Allocating the Budget is a big part of the relocation. If you are going to relocate within the city it means it will cost approximately 2000 – 6000 only. Moving charges may vary according to the products you want to relocate. So plan the charges previously. Reduce the no. of products if potential. It will reduce the cost of relocation services. Finalise the packers and movers - From the above mentioned 4 points, you can select the optimal packers and movers which is very adequate for your relocation. Now you can finalise your decision. Get the contact details of the selected company - Once you determine the packers and movers means then acquire the contact details of the company. Then you can call them or give your contact details to them. Communicate with them and collect information from them. Ask them to visit your place if potential. Then the moving company will calculate the estimated cost for relocation service. Study the contract form thoroughly - While moving, the packers and movers company will make a contract. In that contract form they mentioned each and all detail about the packages, charges, insurance, worker wages, toll charges, a place to place moving details, etc., So read carefully and then sign in the contract. Verify the packers and movers team strength - Judge the packers and movers strength by their working potential. Check the moving company workers while packing. Some companies may provide less number of workers for shifting. You can ask for more crew members for the shifting service. Also, check the vehicle they sent you for the transportation. Supervise the packers and movers team while packing - Supervision on shifting service is the most crucial part of the relocation process. Be attentive all time. Don’t let the packers and movers company crew to steal or miss lead your household items. Track them with the app for all 1 hour. Also, ask them for the warehouse facility. Tips and tricks for easy moving Shifting to a new place is not as easy as it sounds. One has to concentrate on all small detail of packing and moving, which is a tedious process. But not to worry, the optimal Packers and Movers in Chennai, who are the service providers in Sulekha, will provide their clients with professional services in moving. With this assist of Packers and Movers in Chennai, the clients can avail hassle-free shifting. Tips for easy moving suggested by Packers and Movers in Chennai Though the Packers and Movers in Chennai will take care of the all shifting process, there are specific tips and tricks to follow while shifting, which will assist in easy moving. They are: 1. CHECK IT & BOOK IT Before fixing the service with a Packer and Mover in Chennai, verify their policies, rules, and regulations, thoroughly. Especially checking the company’s insurance policy is necessary. It will enable safety shifting and also avoid unnecessary hassles. 2. COMMUNICATION On the day of shifting, double-check if the company will provide all the services. Though the companies do not demand direct involvement in the insurance process, make sure you are aware of it. Also, on the day of moving, confirm the venue and the new location to the driver. 3. SEGREGATION Either packing the things on possess or the Packer and Mover in Chennai is supposed to pack the items, organising all the households will reduce the confusions while unpacking. For example, segregating the household items below big types like kitchen items, pooja articles, clothes, delicate objects, etc., will assist in avoiding confusion. Dividing and labelling will save the Packer and Mover in Chennai from confusions. 4. AVAIL NEEDED SERVICES The optimal Packers and Movers in Chennai offer a wide assortment of services. Always stay on the safer side by availing pet services if there are pets at home. They will be shifted in a caged and safer environment. The optimal Packers and Movers in Chennai even transport a terrace garden or a handful of saplings, when the plant shifting service is chosen. If there are numerous delicate items, then opt for special packaging services offered by professional Packers and Movers in Chennai. The relocation services also include shifting the vehicles below damage-free condition. 5. POST SHIFT SCREENING Once the items being and unpacked and re-arranged, make sure all has found their proper place. Check if all the connections are appropriately given. Notably, electronic items should be checked with additional care. Along with them, check if all the dismantled furniture is correctly set. Screen if all the pipe connections are correctly given. Moving checklist for optimal relocation To-do One week before moving Shortlist the packers and movers and finalise the movers Sort through household items and acquire rid of unwanted items Pack all the valuable things you have Cancel newspaper and milk supplies connection Disconnect gas cylinder connection Update new address to all the services you have subscribed like packaging manufacturers, courier, govt documents in your new home. To-do One day before moving Defrost refrigeratour and transparent out the fridge Pack your necessities things including set of dress, Toothbrush, soap, etc., in a separate bag Click photographs of your household items that are prone to damage Confirm the time of arrival with the packers and movers To-do On a moving day Label and number the packed boxes  Close water taps, windows and turn off switches Note down all the details of the packages Collect the transit insurance papers Cross-check the documents before signing Note down the vehicle details Ask for online tracking details Verify the delivery details with the moving company To-do After the packers and movers delivery Check the number of boxes delivered Cross-check for damages while unpacking Contact the moving company’s agent to claim insurance if any Make the last payment on delivery Collect a bill with seal and trademark of the company FAQ - Choose Best Packers and Movers in Chennai 1. How to come by the optimal packers and movers Chennai? Shortlisting a proper packer and mover can be a tedious task. At Sulekha, acquire attached to the top moving companies that optimal match your requirements by filling the form given above. For superior packing & moving service assistance, avail Sulekha’s easy book & transport facility. 2. What do packers and movers transport out? Professional packers and movers in provide stop to stop packing and moving services. They offer residential shifting, vehicle shifting, and even office shifting services locally, domestically and internationally. They expertise in packing products securely, handling and moving them with care & lastly delivering the belongings without damage to the mentioned destination. 3. Do packers and movers cost any concealed charges? Usually, packers and movers in Chennai aren’t any concealed costs associated with moving costs. It is frequently advisable to acquire the offer with a breakdown of costs from the service provider in writing. You can ask about any potential concealed charges before you hire them. 4. What are the benefits of hiring packers and movers? Hiring a professional packer and mover makes your all moving experience stress complimentary for you. You not only save time and effort nevertheless also acquire stop to stop perfect relocation services from experienced experts. They assist in swift, secure packing, loading, unloading, insurance, and transporting your belongings timely, be it local shifting or domestic shifting. To avoid any mess and moving trouble, it is advisable to acquire an expert moving company on board. 5. Do moving experts assist with unpacking also? Certain top moving companies provide unpacking services also. You can ask the service provider to assist with unpacking if needed. In a few cases, additional unpacking services might attract additional shifting charges. 6. How can I reduce my shifting charges? Affordable shifting requires a few clever planning and execution. Advance booking of professional experts ensures that you acquire quality services at cost-effective rates. Discard unwanted things, sort and pack your belongings yourself is another clever method to reduce shifting charges. Lastly, plan your transport on weekdays to avoid unwanted peak in service costs. 7. How much do packers and movers cost for local shifting in Chennai? Professional shifting charges in Chennai are determined by several factours like shifting type, distance to be covered, vehicle & transportation cost, labour charges, insurance, and other value-added services if any. Here is an estimate list of packers & movers charges in Chennai. 1 BHK local shifting in Chennai beginnings from Rs.6000 and may proceed up to Rs.9,000 depending on the volume of products and the distance to be covered. 2 BHK local household shifting in Chennai can attract approximately Rs. 7,500- Rs.12,000 8. How to select local packers and movers in Chennai? Sulekha is a platform that assists you connect with the optimal service providers that meet your specific requirements. You can come by verified experts to transport your products locally or from Chennai to any other state. Here is how you can use our services to come by proper movers in your locality, Fill a form: Fill the form with your basic requirements to come by verified service providers to shift your belongings within the city, within United Kingdom or internationally. This only assists in a better view of the proper requirement and saves time. Call back: You would acquire a call back from the most uniform service providers based on the requirements filled out in the form. Discuss: Talk with them in detail about your requirements, budget, and specifications on things to be relocated, etc. You can frequently customise your shifting requirements. Compare: Look through reviews, ratings and the Sulekha score to shortlist a few before finalising one. Compare these factours for a better and make a decision. Shortlist: Ensure that the chosen service provider offers transit insurance and also assists you with a/c installation, furniture dismantling, storage, etc. if required. 9. What kind of packing materials are used for shifting? Professional experts use multiple layers of packing for fragile items like cling wraps, bubble wraps, polythene suppliers sheets and packing tapes depending upon the delicacy of items. 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The point is where to beginning from? A perfect ban on plastic may not be potential now. But starting from single use of plastics which comprises almost 40 percent of the all plastic manufactured can be easily done away with. But the reality in United Kingdom is absolutely alternative from what Modi claims. The campaign and target on plastics reduction should not drop flat as it did for one of the flagship programmes-the Swachh Bharat Mission (SBM). There is a perfect ban on coloured polythene suppliers bags in the country, nevertheless one can come by them in abundance in almost all part of the country. Just in the backyard of the Prime Minister's residence in Delhi one can easily come by such coloured bags from the grocery shops and other vendours. So where is the will to implement the decisions taken?

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: