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PVC/EVA soft bag is developed overcoming the shortcomings of glass bottles, with good chemical resistance, good temperature resistance performance. Main application: blood bag, infusion bag, urine bag, drainage bag and other fields. The production line adopts Siemens man-machine interface and Siemens computer control operating system, which can realize accurate control and humanized operation of the equipment. Special winding machine for soft film can not only ensure the evenness of the edge of the finished coil, but also prevent wrinkling, bulging and stretching of the finished product.
| Model | JWS45/28-1500 | JWS90/28,Jws120/28-1500 | ||
| Material | PVC,EVA | PVC,EVA | ||
| Products Width(mm) | 100-300 | 800-1000 | ||
| Products Thickness(mm) | 0.15-0.45 | 0.15-0.45 | ||
| Designed Extrusion Capacity(kg/h) | 20 | 150-300 | ||
| Note: The specifications are subject to change without prior notice. | ||||
The extrusion process is the core of the medical infusion bag film production, determining the film's thickness uniformity, transparency, mechanical properties, and medical safety. Below is a detailed introduction to the extrusion process, including equipment selection, process parameters, and key control points.
I. Extrusion Process Principles
The extrusion process involves melting PVC or EVA granules (or powder) under high temperature and pressure, continuously and uniformly feeding the melt through an extruder, and shaping it into a film using a T-die (for cast film) or a blown film die. The film is then cooled, solidified, and processed into a medical-grade infusion bag film.
II. Key Components of the Extrusion System
1. Feeding System
Function: Provides a stable supply of raw materials to the extruder.
Equipment:
Automatic vacuum feeder: Ensures continuous feeding and prevents contamination.
Drying system (for EVA): EVA has high moisture content and must be pre-dried at 60-80°C for 3-4 hours to prevent bubbles and surface defects.
2. Extruder
(1) Screw Design
PVC Extrusion (Single-Screw Extruder):
PVC is heat-sensitive and requires a single-screw extruder with an L/D ratio of 25:1-30:1. The screw design should include a long metering section to ensure stable plasticization and material conveyance.
Low-temperature plasticization is necessary to prevent degradation, and venting ports & melt filters are recommended to remove volatiles.
EVA Extrusion (Twin-Screw Extruder):
EVA has poor plasticization properties and requires a high-shear twin-screw extruder to ensure uniform melting and prevent decomposition.
Co-rotating twin-screw extruder (L/D ≥ 30:1) is recommended for efficient plasticization.
(2) Temperature Control
PVC:150-180°C (must be increased gradually to avoid degradation).
EVA:160-200°C (avoiding excessive heat that may cause cross-linking).
Temperature Zones:Low temperature at the hopper → Increased temperature in the compression zone → Maximum temperature in the metering zone for even melting.
(3) Extrusion Pressure & Flow Rate Control
Melt pressure sensors (20-40 MPa) ensure stable extrusion.
Melt pump for precise flow control, improving film thickness uniformity.
3. Melt Filtration System
Function: Removes impurities and unmelted particles to ensure film quality.
Equipment:
Dual-station screen changer (200-400 mesh stainless steel filter) for continuous operation without stopping production.
4. Extrusion Die (T-Die for Cast Film)
Function: Distributes the melt uniformly to form a film with precise thickness and width.
Key Points:
Flow Channel Design: Uses a "coat-hanger" flow channel to ensure uniform melt flow.
Heating Control: Die temperature typically 160-200°C to prevent clogging or degradation.
Lip Gap Adjustment: Controls film thickness (typically 0.2-1.0 mm, adjustable).
Automatic Profile Control (APC): Advanced systems include automatic die lip adjustment for precise thickness control (±3% accuracy).
III. Key Control Points in the Extrusion Process
1. Raw Material Control
PVC requires careful control of plasticizer content (30-40%) to prevent migration.
EVA should have minimal moisture content to avoid bubbles.
Regular melt filter changes to maintain film transparency.
2. Temperature Control
PVC degrades at high temperatures; a controlled heating profile is essential.
EVA requires optimal shear heating for uniform melting.
3. Extrusion Pressure Control
Maintaining pressure at 20-40 MPa ensures stable extrusion.
Below 10 MPa: Poor plasticization; Above 50 MPa: Risk of shear-induced degradation.
4. Die Gap Adjustment
Regularly inspect and adjust the die lip gap to ensure uniform film thickness.
Use an online thickness gauge for real-time monitoring (±3% tolerance).
IV. Advanced Extrusion Technologies
1. Co-Extrusion Technology
Dual-layer or triple-layer co-extrusion (Co-Extrusion) improves barrier properties and heat resistance.
Typical structures:
Dual-layer: EVA/PP (enhanced heat resistance)
Triple-layer: EVA/PVDC/EVA (better oxygen barrier performance)
2. Electrostatic Elimination Technology
EVA films tend to attract dust due to static electricity; an anti-static device is recommended.
3. Online Quality Monitoring
Thickness gauge or X-ray thickness gauge ensures real-time thickness monitoring for consistent quality.
V. Summary
1. PVC extrusion is best suited for single-screw extruders (L/D 25:1-30:1) with low-temperature plasticization to prevent degradation.
2. EVA extrusion requires twin-screw extruders (L/D ≥ 30:1) with high shear to ensure uniform melting.
3. Temperature must be precisely controlled (PVC: 150-180°C, EVA: 160-200°C) to prevent degradation or bubble defects.
4. A coat-hanger flow channel design and adjustable die lips ensure uniform film thickness.
5. Advanced extrusion systems incorporate Automatic Profile Control (APC), melt pumps, and online monitoring for high-quality film production.
6. Co-extrusion technology enhances barrier properties and heat resistance, making it suitable for advanced medical applications.
Advantages of Jwell PVC/EVA Medical Infusion Bag Film Extrusion Equipment
Jwell PVC/EVA medical infusion bag film extrusion line features: High precision, strong stability, and a high degree of automation, ensuring increased production efficiency and stable product quality to meet the strict requirements of the medical industry.
1. High Precision Control for Stable Film Quality
High-Precision Extrusion Control System:
PLC + Touchscreen Smart Control for precise regulation of temperature, pressure, and flow rate, ensuring film thickness uniformity within ±3%.
Servo-driven melt pump for stable melt delivery, eliminating flow fluctuations and enhancing film thickness consistency.
Automatic Thickness Detection System (APC):
Laser or Beta-ray Thickness Gauge for real-time monitoring of film thickness with automatic die gap adjustment for closed-loop control.
2. Advanced Extrusion Technology for Uniform Plasticization and Reduced Material Waste
Optimized Screw Design for High-Efficiency Plasticization:
PVC extrusion: Uses a single-screw extruder (L/D 25:1-30:1) for low-temperature plasticization to prevent degradation.
EVA extrusion: Uses a high-shear co-rotating twin-screw extruder (L/D ≥30:1) for uniform mixing and superior melt quality.
High-Efficiency Melt Filtration System:
Dual-station screen changer allows for automatic filter switching, ensuring continuous production with minimal downtime.
3. Energy Efficiency for Lower Production Costs
Intelligent Temperature Control System:
PID temperature regulation for precise heating control, reducing energy consumption and preventing overheating, which improves material utilization.
Low-Energy Consumption Motor System:
Servo-driven motor reduces energy consumption by 15%-25% compared to traditional motors, lowering operational costs.
Optimized Flow Channel Design for Reduced Waste:
Coat-hanger flow channel T-die ensures uniform melt flow, reducing thickness deviations and material waste.
4. High Automation for Easy Operation
One-Touch Start, Fully Automatic Operation:
Integrated system for automatic feeding, extrusion, screen changing, die adjustment, traction, and winding, reducing manual intervention and increasing efficiency.
Intelligent Fault Diagnosis System:
Real-time monitoring of temperature, pressure, and flow, with automatic alarms and troubleshooting suggestions to minimize downtime.
Touchscreen Interface with Remote Control:
Supports remote debugging and monitoring, making maintenance and technical support more convenient.
5. High Cleanliness Standards to Meet Medical Industry Certifications
Stainless Steel Design for GMP Compliance:
304/316L stainless steel is used in material contact areas to prevent contamination.
Dust-Free Design for Cleanroom Compatibility:
Enclosed feeding system prevents dust contamination, ensuring high cleanliness for medical applications and compliance.
Static Elimination System to Prevent Dust Adhesion:
Ideal for EVA materials, preventing finished films from attracting dust and ensuring high hygiene standards.
6. Customizable Design to Meet Diverse Production Needs
Supports Single-Layer and Multi-Layer Co-Extrusion (Dual/Triple Layers):
Customizable solutions such as EVA/PP, EVA/PVDC/EVA enhance barrier properties and heat resistance of infusion bags.
Optional Fully Automatic Winding System:
Automatic tension control prevents wrinkles and improves roll quality.
Compatible with Multiple Materials:
Supports PVC, EVA, TPE, PP, and other medical-grade film materials, making it suitable for different infusion bag applications.
Choosing Our Equipment Offers the Following Advantages
1. High-precision thickness control (±3%) to improve product quality and reduce scrap rate.
2. Optimized screw and flow channel design for uniform plasticization and minimal material waste.
3. Energy-saving design, reducing power consumption by 15%-25% to lower operational costs.
4. High automation with smart control systems, reducing manual intervention and increasing production efficiency.
5. GMP-compliant clean design ensures the safety and reliability of medical infusion bags.
6. Customizable solutions for different layers, materials, and thicknesses to meet diverse production needs.
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