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The production line adopts one-step coating and drying method. The production line has high-speed automation, which reduces the production process, greatly reduces the production cost and improves the production efficiency.
The main components of the equipment are: Raw material dissolving reactor, go through Static mixer and filter the material, there will have material supply system before precision slit coating head, support roller shaft, then the PVA materials casting from die head to coated on steel belt enter the oven, oven drying the PVA as film, then separate the film from the steel belt, customer can optional have thickness gauge, automatic winding and control system windering the PVA film as rolls. Relying on our advanced overall design and processing and manufacturing capabilities, the core components are produced and processed independently.
Production Process of Water-Soluble Film
Water-soluble film (PVA film) is a functional material made primarily from polyvinyl alcohol (PVA), combined with plasticizers, fillers, and other functional additives. It dissolves quickly upon contact with water, making it an eco-friendly option widely used in packaging, medical, and agricultural industries. Below is an overview of the typical production process of water-soluble film:
Production Process of Water-Soluble Film
1. Raw Material Preparation
Main Material: Polyvinyl Alcohol (PVA).
Auxiliary Materials: Plasticizers (e.g., glycerol, propylene glycol), crosslinking agents, lubricants, and other functional additives.
2. Formulation and Dissolution
Add PVA to a mixing tank with deionized water and stir at a specific temperature (typically 80-95°C) to dissolve it into a uniform solution.
Add plasticizers and functional additives to adjust the viscosity and performance of the solution.
3. Filtration and Degassing
Filter the solution to remove particulate impurities.
Use vacuum degassing to eliminate air bubbles and ensure uniform film formation.
4. Casting and Film Formation
Evenly coat the prepared PVA solution onto a casting roller or steel belt using a coating device.
The wet film is formed as the solution spreads across the substrate.
5. Drying and Shaping
Pass the wet film through multi-stage drying ovens (typically divided into low, medium, and high-temperature zones) with a temperature range of 40-120°C to ensure even evaporation of water.
Some processes include crosslinking treatment during drying to enhance the film's mechanical strength and moisture resistance.
6. Cooling and Winding
After drying, the film is cooled to room temperature using cooling rollers to stabilize its dimensions.
The cooled film is rolled into reels or cut into sheets based on customer requirements.
Key Considerations in Production
1. Dissolution and Formulation
Carefully control the dissolution temperature and time to prevent excessive viscosity or degradation of the solution.
Properly balance the plasticizer ratio; too much reduces film strength, while too little decreases flexibility.
2. Drying Process
Rapid drying can increase internal stress in the film, leading to cracks or warping.
Maintain segmented temperature control to avoid overheating and compromising film properties.
3. Thickness Uniformity
Ensure uniform coating during the casting process to maintain consistent solubility and mechanical properties.
Types of Production Processes
Depending on the application and manufacturing requirements, the production process for water-soluble film our machine is steel belt casting method: Ideal for high-transparency and thin water-soluble films.
PVA water-soluble films are innovative materials widely used in various industries due to their unique properties such as water solubility, biodegradability, and excellent mechanical performance. Below are some key applications:
1. Industrial Packaging
Used for packaging pesticides, laundry detergents, and powders, offering safe handling and easy usage.
2. Medical Field
Produces water-soluble sutures and medical films, reducing medical waste pollution.
3. Agricultural Applications
Used for water-soluble seed bags or fertilizer packaging, dissolving directly in the soil without the need for retrieval.
4. Textile and Printing
Applied as embroidery backing or transfer printing substrates to improve production efficiency.
5. Consumer Products
Used in single-use water-soluble bags, such as laundry bags or disposable shoe covers.
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