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Our Manufacturing
Infrastructure

A dedicated blown film manufacturing facility with end-to-end capability — from raw resin to finished roll. Every machine, every process, optimized for quality and consistency.

🏭 Blown Film Extrusion
⚡ Corona Treatment
🔄 Slitting & Converting
🔬 In-house QC Lab
Facility Overview

Built for Precision,
Engineered for Scale

Our manufacturing facility is focused on a single discipline — blown film flexible packaging. This focused approach means every machine, every process parameter, and every operator skill is optimized specifically for producing the highest quality LDPE and LLDPE films across a 50–200 micron range.

🏭
Blown Film Extrusion Lines

Primary manufacturing machines producing films from LDPE and LLDPE pellets through precise temperature-controlled extrusion and die systems.

⚡
Corona Treatment Station

In-line corona discharge station for surface activation of LD rolls destined for printing applications.

✂️
Slitting & Converting

Precision slitting machines, bag-making lines, and winding equipment for converting master rolls into finished products.

🔬
Quality Testing

In-house QC with thickness gauges, tensile testers, and visual inspection at each production stage.

Manufacturing Unit
50–200
Micron Range
5+
Product Lines
LDPE
+LLDPE
Dual Resin
Any
Custom Color
Manufacturing Process

The Blown Film Process —
Step by Step

Understanding how a pellet becomes a precision film roll — our full manufacturing process explained.

1

Raw Material Receiving & Inspection

LDPE and LLDPE resin pellets are received from approved suppliers. Each incoming lot is visually inspected and checked against material data sheets. Resins are stored in dedicated, moisture-controlled silos to prevent contamination and moisture absorption before processing.

LDPE PelletsLLDPE PelletsLot InspectionControlled Storage
2

Blending & Color Compounding

For standard natural and black films, resin is fed directly to the extruder. For colored films, masterbatch concentrate is blended with the base resin at precise ratios using our blending system. UV stabilizers and other functional additives are incorporated at this stage based on the product specification.

Masterbatch BlendingCustom ColorAdditive DosingUV Stabilizers
3

Blown Film Extrusion

The blended resin is fed into the extruder barrel where it is heated to processing temperature (typically 160–200°C for PE grades). The molten polymer is forced through the annular die to form a tubular bubble. Air is blown into the bubble through the die center to inflate it to the desired layflat width. The bubble rises through a cooling air ring where it is quenched and solidified. The frost line height is carefully controlled to set the film's mechanical properties.

Annular DieBubble InflationAir Ring CoolingFrost Line Control
4

Nip Rolls & Gauge Control

The cooled bubble is collapsed by converging frames and passed through nip rolls. Film gauge (thickness) is continuously monitored using scanning thickness gauges. Automatic die bolt adjustment or manual correction is applied to maintain gauge uniformity across the film width — critical for consistent performance in customer applications.

Nip RollsThickness GaugingGauge ControlUniformity
5

Corona Treatment (for LD Rolls)

For LD rolls destined for printing applications, the film passes through an in-line corona discharge station. High-frequency electrical discharge creates free radicals on the film surface, oxidizing it and increasing its surface energy from ~31 mN/m to 38–42+ mN/m. This dramatically improves ink wettability and adhesion for printing processes.

Corona DischargeSurface Activation38–42+ mN/mPrinting Grade
6

Winding & Slitting / Converting

Master rolls are wound on 3" or 6" cores to specified roll weights and lengths. For slit rolls, master rolls are transferred to our slitting lines where they are slit to the exact customer-specified width. For linear bag pouches, the film passes through our bag-making machines for sealing and cutting. Shrink film undergoes controlled orientation before winding.

Master Roll WindingSlittingBag MakingCustom Dimensions
7

Quality Control & Final Inspection

Every finished roll or bag lot undergoes systematic quality checks: thickness verification with calibrated gauges, visual inspection for gels, holes, and contamination, and tensile/elongation sampling where required. Only lots that pass all QC parameters are cleared for dispatch. Rolls are labeled with batch ID, product spec, and weight for full traceability.

Thickness CheckVisual InspectionTensile TestingBatch Traceability
8

Packing & Dispatch

Finished rolls and bags are protected with stretch wrap or polybag overwrap and stacked on pallets or in cartons as per customer requirements. Dispatch documentation including delivery challan, specifications sheet, and batch details accompanies every shipment. Orders are dispatched via road freight across India.

Protective PackingPallet / CartonDocumentationPan-India Dispatch
Equipment

Key Machinery &
Equipment

The core machines that power our blown film manufacturing capability.

🏭

Blown Film Extruder

The primary production machine — melts and extrudes LDPE/LLDPE resin through an annular die to form the film bubble. Temperature profiles are controlled across multiple barrel zones for optimum melt quality.

LDPE & LLDPE processing
Multi-zone temperature control
Annular die for bubble formation
Output: Multiple roll widths
💨

Air Ring Cooling System

High-efficiency air ring surrounding the bubble at the die exit. Provides uniform, controlled cooling of the film bubble, directly influencing film clarity, gauge uniformity, and mechanical properties.

Uniform air distribution
Frost line height control
Affects optical clarity
Critical for gauge consistency
⚡

Corona Treater Unit

In-line corona discharge unit for surface activation of films intended for printing. Treats both sides or single side as required, with adjustable power output to achieve the target surface energy (dyne level).

In-line or off-line treatment
Adjustable dyne output
Single or double side treatment
For print-grade LD rolls
✂️

Slitting Machine

Precision slitting of master rolls to customer-specified widths. Razor or score-cut slitting with edge trim for clean slit edges. Output rolls wound to specified weight, length, and core size.

Precision width slitting
Clean edge quality
Custom roll weight/length
3" & 6" core winding
🛍️

Bag Making Machine

Produces linear bag pouches with precise seal and cut from LLDPE film. Seal bar temperature, dwell time, and cut position are all adjustable to produce consistent bag dimensions and seal strength.

Side seal & bottom seal
Adjustable seal temperature
Custom bag dimensions
LLDPE film processing
🔬

Quality Testing Equipment

In-house quality lab with thickness gauges for accurate micron measurement, tensile tester for mechanical property verification, and dyne pen / contact angle measurement for corona treatment verification.

Digital thickness gauge
Tensile / elongation tester
Dyne pen for surface energy
Visual inspection station
Quality Assurance

Our Quality Control
Process

Quality is checked at every stage — not just at the end. Here's how we ensure every roll meets specification before it leaves our facility.

1
Incoming Material Check

Raw resin lots are verified against supplier certificates and visually inspected before being approved for production.

2
In-Process Gauge Monitoring

Thickness is continuously monitored during extrusion using scanning gauges. Deviations trigger immediate corrective action.

3
Corona Treatment Verification

Dyne level is verified on treated rolls using dyne pens or ink test to confirm adequate surface energy for printing.

4
Visual Inspection

Each roll is visually inspected for gels, holes, contamination, blocking, and winding defects before being accepted.

5
Final Dimensional Check

Roll width, layflat, gauge, weight, and length are verified against the order specification before clearance for dispatch.

5
Stage QC process from material to dispatch
±2μ
Gauge tolerance target across roll width
38+
mN/m surface energy on treated rolls
100%
Visual inspection on every roll
What We Can Make

Manufacturing Capability
Summary

What our infrastructure allows us to produce — for you.

📏

50–200 Micron Range

Full gauge spectrum from thin films to heavy industrial sheets — all in one facility.

🧪

LDPE + LLDPE

Both resin grades processed — select based on your mechanical and optical requirements.

🎨

Any Custom Color

In-house compounding for any Pantone or customer-matched color film production.

⚡

Corona Treated Rolls

In-line and off-line corona treatment for print-grade LD rolls with controlled dyne level.

✂️

Custom Slit Widths

Slitting capability to produce rolls at any specified width from master roll production.

🛍️

Linear Bags

Bag-making capability for linear side-seal and bottom-seal pouches in LLDPE film.

🔄

Shrink Films

Controlled orientation process for producing shrink films with designed shrink ratios.

📦

Custom Roll Specs

Custom core size, roll weight, roll length, and layflat to match your production line.

Send Us Your Specifications

Our manufacturing team will review your requirements and confirm feasibility, lead time, and pricing.

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