Extrusion Lines for Optical Films
The manufacturing of a film is nothing special. However, the creation of a high quality polished flat film of minimal thickness is a different matter altogether.
With the BREYER OptiFlex line you are staying always flexible.
Both side polished, mat and structured film with optical properties can be produced.
The production of ultra-thin, low-tension films of high optical quality in particular, is quickly separating the men from the boys. We can boast an unbeatable combination of superior know-how, gained over many years and excellent extrusion technology.
Special Line Features
Thanks to our special calender techniques, tensions in these films can be kept to a minimum.
The particularly precise, reproducible adjustment of the roll gap combined with the high stability of the calender rolls is an essential prerequisite for the successful production of minimum film thicknesses.
It is not without reason that people rely on BREYER technology time and time again. And of this, we are more than a little proud.
Smoothed film thicknesses : 0.08 - 2.0 mm
film widths : 750 - 2000 mm
output rates : 300 - 700 kg / h
material : PC, PMMA, PET, PES, COC, EVA, HIPS, PP, etc.
versions : Mono and co-extruded, smooth, frosted, structured
- Energy saving and powerful single screw extruders
- Processing without pre-drying
- Quick start up by our patented meltpump control
- Automatic controlled dies
- Calenders with precision gap adjustment (distance and pressure controlled), automatic film thickness change
- Polished, mat and structured as well as cast film can be produce with the same machine
- Solid roll design in highest quality for lowest tolerances
- Easy and rapid adjustment of film flatness
- LCD and TV-monitors
- IMD, IML films
- Passport and credit cards
- Mobile phones
- Instrument panels
- Decorative film
- Ski and snowboards
Complete Solution for Optical Film Extrusion
One of the core components of every extrusion line is and remains the extruder itself. From the start, BREYER relies on quality and sophisticated technology.
BREYER extruders are single-screw machines with high efficiency. Most thermoplastics are processed. The extruders are available in the following sizes: 30, 35, 45, 60, 75, 90, 105, 120, 150, 180, 200, 250 mm screw diameter.
The discharge capacity is depending on the size up to 2000 kg / h.
Our specialty is extruders with vacuum degassing . These extruders work particularly economically, since the energy efficient pre-drying of the granules omitted. By separating the remaining monomers, the quality of the melt and thus of the end product is increased. The extruders also have a high specific output. The machines also work reliably in the ejection areas, where other manufacturers must already be dried.
BREYER extruders are designed in such a way that they require very little energy during operation.
The control cabinets are equipped with a Siemens control as standard. The operation is conveniently carried out on the color display. Equipped with solid state relays, single current measurement for each zone, durable ceramic heating tapes (with fast connection plug-in connection), safety temperature monitoring and detailed error analysis.
Three-phase motors are used for the drive technology. On request, particularly quiet running, water-cooled motors are used. Likewise, high-torque motors without gears are available as direct drive in various sizes.
High customer value
- Brushless, maintenance-free drive technology
- High specific output
- Low energy consumption
- effective degassing
- No pre-drying necessary
- Compact size
Flat Sheet Dies
BREYER flat sheet dies are developed with state-of-the-art software, built in 3D design, and manufactured on CNC machines. They get their high-quality finish through the selection of materials and coating depending on the application, combined with a professional polish. Decades of experience and control of the complete extrusion process enable this perfection.
The program includes single layer and multi-layer dies, with widths of up to 2800 mm. The dies are used for manufacturing flat films (typical thickness range of 0.05 - 1.5 mm) and also for sheet production (thickness of 1 - 25 mm).
All common thermoplastics as well as so-called engineering plastics can be processed. BREYER dies are used in BREYER extrusion lines but also in systems from other manufacturers.
BREYER film and sheet dies are available with the following additional equipment:
- Rapid lip gap adjustment
- optimised die shape
- Restrictor bar
- Deckling systems
- Collision protection
- Thickness measuring systems
- Control system
- Die suspension
- Die carriage
A system is only as good as its components.This especially applies to extrusion lines. For this reason, we at BREYER have given special attention to each and every component of the system – especially calender technology. It is decisive for the final quality and performance of a system. Our specialists have come up with innovative solutions for the drive system, which avoids surface distortions or lateral marks.
Maintenance-free servomotors and precision gears provide sustained top-quality results. Thanks to the modular design of the individual system components, the special calender technology made by BREYER is highly flexible and can therefore be practically used for any extrusion or co-extrusion process.
Whether flat film or clear sheet – with BREYER you're always one step ahead of your competition when it comes to the important production step of «calendering».
The advantages of the BREYER calender technology at a glance:
- Simple user interface
- Rapid change of sheet thickness with the servo-hydraulic gap adjustment
- Smallest thickness tolerances when using BREYER solid calender rolls
- Flexibility in sheet thickness and cooling process – with the slewing device of the calender
- High operational reliability by using maintenance free drive technology
- Rapid conversion with the roll change system for embossing rolls
- Automatic calender roll recognition after roll change
- Collision protection system
- Digital position display for fast set-up of the calender system
Sometimes form alone outshines the competition the market. It is therefore not without good reason that superior winding technology represents another major part of our scope of supply.
One such example is the fully automatic winding machine. These machines are always in demand wherever there is a need for precise, straight edge winding, even when the production speeds are high.
This type of machine can also be equipped with a semi-automatic winder spindle or bale handling system.
Or let’s consider the large roll winder with a preceding accumulator, which permits winder diameters of up to 2000 mm. The drives are either electric or hydraulic. On request, they can also be used directly on the secondary processing machine, as a realistic and low-cost alternative to the winding machine. Both winding systems can also be fitted with length and cross cutting equipment.
The BREYER monitoring system fascinates with its simplicity in operating. The operator is navigated intuitively by the system to the required information and achieves his aim quickly.
The system contains a multitude of features which help the user to
control and survey the production process and quickly access data.
For our worldwide clients the system will be delivered in the required
national language. Via remote access we can keep an eye on your line and are able to assist you, any time and in any case.
- Fast analysis of process data – trend and alarms
- Wizard controlled formula compilation
- Visual supported detail diagnosis (PDF-documents, 3D pictures, circuit diagrams)
- Live cams for additional process monitoring
- Dual-screen solution for optimized plant transparency
- Online documentation
- Server-client application
- Integration of external systems
- Connection to existing networks
- Online language change (e.g. Asian, East European, Arabic, etc.)
- Remote diagnosis via modem and internet
- Modern ergonomic design