MANUFACTURING

PROCESS

DIAGRAM
As we see on the diagram to make a plastic possible first we must put the raw material
to the mixer. After putting and filling the raw material to the mixer then it is ready to be
extrude using blown film extrusion machine where the main process is to form the main
component of the plastic bag after the extrusion machine it is then pass to the printing
section which have two main types w/c is the rotogravure where the design is engrave
on the cylinder and the other is the flexographic which is the modern type of printing
machine. After the desired design is printed iti is now ready for the cutting machine note
that at this section it also have the function of punching stocking, blocking, and storing
which in the long run, lessen the cost of production. After those several process our
finish product is now readily made which is the plastic bag.

ANALYSIS OF PROCESS FLOW

In making a plastic bag, it is general goes into three main process which is
the blown film extrusion, printing and cutting process. It is a step by step
process where each process is design to do detailed task to make a good and
quality plastic.
Before the extrusion take place first we need to blend and mix the raw
materials which is

the resins,

a clear LPDE (low density polyethylene)

plastic resins in pellet form is vacuum fed from storage silod and blended
with various additives as required for specific product applications. These
mixes transform the plastic polymer to improve their basics mechanical,

physical and chemical properties into commercial product. Additives combine

to create the desired proprietary blends of clarity, strength, strechability,
sealability, scuff and tear resistance, UV protection, Bacterial protection,
surface appearance, slip resistace and other properties required for the
finished product. if colored film is to be made, colored pellets called master
batch are added in blends from 1% to 25% to achieve different opacities and
virtually any color imaginable. Numerous resins, both LPDE and linear LPDE,
are kept in stock to allow for the many diverse applications that are
manufactured daily. After that preparation, it is now ready for blown film
extrusion, where the blended resins are fed into extruders and, melted at
380F. Screw drives force the molten mixture through a precision die where
air is introduced and a bubble is formed. Air is introduced via hole in the
center of the die to blow up the tube like balloon. Mounted on the top of the
die, a high-speed air ring blows onto the hot film to cool it. The tube of the
film then continuous upwards, continually cooling, until it passes through nip
roles where the tube is flattened to create what is known as a lay-flat tube of
film. This lay-flat tube or collapsed tube is then taken back down the
extrusion tower via more rollers. On higher output lines, the air inside the
bubble is also exchanged. This is known as IBS (internal bubble cooling). The
lay flat- film is then either kept as such or the edges of the lay flat are slit off
to produce two flats film sheets and wound up onto reels. If kept as flat the
tube of fil is made into bags by sealing across the width of film and cutting or
perforating to make each bag. This is done either in line with blown film
process or at later stage. Typically, the expansion ratio between die and
blown tube of film would be 1.5 to 4 times the die diameter. The drawdown
between the melt wall thickness and the cooled film thickness occurs in both
radial and longitudinal directions and is easily controlled by changing the
volume of air inside the bubble and by altering the haul off speed. This gives
blown film a better balance of properties than traditional cast or extruded
film which is drawn down along the extrusion direction only. Then from the
extruders the rolls if the film are delivered to the printing section. Using a

rotogravure printing, the printing cylinder rotates n the ink pan where the
engraved cells fill with ink. As the cylinder rotates clear of the ink, pan any
excess ink is remove by the doctor blade. Further around, the cylinder into
contact with the substrate, which is pressed against it by the rubber covered
impression roller. The pressure of the roller along with the capalliary draw of
the substrate, results in the direct transfer of the ink from the cells in the
printing cylinder to the surface of the substrate. As the printing roller rotates
back into the ink pan, the printed area of the substrate proceeds through a
dryer and onto the next printing unit, which is normally a different color or
may be a vanish coating. Precise color to color registration is made possible
via automatic side and length register control systems. For the web-fed
printing press, after each color has been printed and any coating applied, the
web is rewound into a finished coil. After printing, either plain rolls from the
extruder line or printed rolls form our presses are delivered to the cutting
area. A myriad of sizes and options are available in essentially 3 types of bag
conversion: single bags, on rolls (perforated tear-off) or bags in wire wickets.
Roll stock is loaded unto bag makng machines where repetitive bottom seal
or side seal converting takes place to produce individual bags from large
rolls. Holes, vents, slits, perforations, handle punching, wicket ting, header
sealing and zip locking are some of the many options available in each
prosuction run. Special folding jigs allow for gusseting as required with high
speed. Automatic wire wicketting machines aligned for efficient production.
After the rolls of tubing are converted into one of many styles and types of
bags, the bags are packed into boxes, stacked and wrapped on pallets in
preparations for shipment.