Made in India: Blown film extrusion line from Rajoo Engineers

Rajoo Engineers debuted its latest innovation, the Proex series. Khushboo C Doshi, managing director of Rajoo Engineers shares the details with Rahul Kumar

 

First things first. Rajoo Engineers showcased its latest innovation, the Proex series, at Balaji Multiflex in Rajkot. The Proex series of five-layer POD blown film line by Rajoo Engineers can produce films at 900-kg/hr, 22-micron thickness and 2,800-mm layflat width. The Relex 4.0 extruders, established for their low-shear heat design, offer optimal energy efficiency and a 30% higher yield. The CSD 4.0 die, the heart of the line, can deliver film thickness from 20 to 200 microns across a wide 2,800-mm lay flat width. This technology enables the production of high-output blown films at wider widths with excellent film quality in terms of strength and gauge variation at effective energy consumption levels.

 

The Proex series operates by melting and homogenising a polymer mix in the Relex 4.0 extruders, with each layer processed at optimal temperatures using a low-temperature screw design to reduce thermal degradation. These materials are combined and shaped into a film through a high-performance CSD 4.0 die, followed by rapid cooling to stabilise the structure. Temperature and other parameters are controlled precisely. The system has an automatic thickness measurement control with integrated sensors for real-time monitoring, ensuring consistent film quality and efficient production.

 

The Proex series of blown film extrusion lines is designed for large-tonnage production capacity processors and FMCG converters catering to applications, such as flexible packaging, agriculture, and industrial uses. This series is ideal for producers who require high quality, high-output films with advanced properties, including high strength and low gauge variation. “The Proex series helps elevate our customers’ product offerings with superior barrier protection, strength, and flexibility aiming to achieve precise control over film production while maintaining high efficiency and quality standards,” says Khushboo Chandrakant Doshi, managing director of Rajoo Engineers.

 

According to Doshi, the Proex series is value for money and is suitable not only for price-sensitive markets like India and other developing countries, but also for developed economies.

 

“The Proex series serves as an European import substitute for the plastic extrusion machinery industry, making it an excellent investment for processors. Due to its energy-efficient design, which includes heat-insulated extruder covers and a low-temperature screw that reduces operational costs, its automatic thickness measurement and control, and high-performance dies, it minimises material waste and ensures high-quality output, contributing to cost savings. The machine’s modular design facilitates easy maintenance and quick adjustments, enhancing operational efficiency and supporting timely delivery. Additionally, real-time monitoring with integrated sensors helps maintain optimal processing conditions, reducing defects and ensuring consistent quality. Its flexible configurations allow manufacturers to cater to diverse market needs without investing in multiple machines, optimizing their investment and helping them stay competitive,” Doshi adds.

 

 

Three Proex series blown film lines are currently operating commercially across the globe, and the beta version of the Proex series has four successful installations in the domestic market.

 

“They seek high-output equipment capable of producing films, with low and consistent thickness while maintaining exceptional film quality. Energy efficiency is crucial, as it helps reduce operational costs. Advanced technological features, such as real-time monitoring, automatic controls, and energy-efficient systems are highly valued. Additionally, a compelling value-for-money proposition is an important consideration. Customers also place significant emphasis on comprehensive support and service, including installation, training, and after-sales assistance. Ease of maintenance and the availability of spare parts is essential to ensure smooth operation and long-term performance,” Doshi adds.

 

The Proex series offers multilayer blown films for a range of applications, including both barrier and non-barrier films across various industry segments, such as flexible packaging for FMCG products, the food and beverage industry, agriculture, and industrial uses. Its versatile configuration allows for the development of innovative film structures tailored to specific needs.

 

The Proex series in blown film extrusion offers several unique selling points. It automates complex lines to help our customers minimize manpower consumption, leading to lower operating expenses. The Relex 4.0 extruders are renowned for their low heat shear design, providing optimal energy efficiency and 30% higher output with maximum productivity. The Relex series of extruders are ergonomically and aesthetically designed for higher output with unprecedented yield and the lowest energy consumption.

 

The CSD 4.0 die-head allows for unlimited polymer stream overlaps, resulting in excellent thickness distribution and faster job changes. Advanced real-time monitoring systems and automatic thickness control sensors, temperature monitoring, and user interfaces have simplified the blown-film process, and reduced production wastage and operational costs. The CSD 4.0 die-head is equipped with an insulated cover to prevent heat loss, ensuring energy efficiency and maintaining consistent processing temperatures.

 

The Proex series is designed for ease of use with its intuitive interface and user-friendly controls. It features a modular design that simplifies maintenance and adjustments, while real-time monitoring systems provide clear and actionable data for operators. The automatic thickness control and advanced temperature regulation systems further streamline operations, minimising the need for manual intervention and ensuring consistent film quality.

 

Rajoo offers extensive service and support for all its products including installation, commissioning, and post-installation technical assistance. “The support encompasses routine maintenance services, troubleshooting, and repair to ensure optimal machine performance. Customers benefit from access to a dedicated service team that provides timely responses and solutions to operational issues,” Doshi explains.

 

Rajoo Engineers, founded in 1986 and headquartered in Rajkot, is a global player in blown film technology, sheet extrusion technology and extrusion coating and laminating lines. Known for its technological advancements, product innovations, and world-class quality, Rajoo offers energy-efficient solutions with sophisticated automation on a global scale. With a presence in numerous countries and a customer base spanning over 78 nations, the company’s exports have increased since its international debut in 1990.