The VihoX 120+90+65 PP/PS Triple Co-extrusion Sheet Line is our premier multi-layer extrusion installation engineered for advanced food packaging converters demanding high-barrier protection, multi-material functional laminates, and high-efficiency recycled-core structures. Featuring three synchronized extruders — a primary Φ120 mm core extruder (approx. 90 kW), an intermediate Φ90 mm layer extruder (approx. 45 kW), and an outer skin Φ65 mm extruder (approx. 22 kW) — this plant delivers commercial throughput between 350 and 500 kg/h.
Equipped with a specialized 4–5 layer adjustable co-extrusion feedblock (producing ABCA, ABCBA, and custom structures), a 250CC precision melt gear pump, and a 1000 mm coat-hanger die, the system outputs finished sheet widths from 500 to 1000 mm and calipers between 0.3 mm and 2.0 mm. Downstream calibration is conducted by an enlarged three-roll calender stack (Φ350 / 450 / 450 × 1000 mm) driven by independent AC vector motors, achieving line speeds between 15 and 30 m/min with total installed power of approx. 270 kW.
Factory trial run: VihoX 120+90+65 PP/PS Triple Co-extrusion Sheet Line Running Test
| 5-Layer Co-Ex Parameter | Triple Extruder Configuration | Barrier & Regrind Capability |
|---|---|---|
| Processable Resins | Polypropylene, Polystyrene, Polyethylene & EVOH | High-barrier packaging, multi-colored structures, and functional barrier layers |
| Screw Specifications | Φ120 mm + Φ90 mm + Φ65 mm Extruders | Three independent plasticizing engines providing precise layer ratio control |
| Length-to-Diameter Ratio | Approx. 33:1 L/D | Ensures homogeneous melt flow across divergent polymer viscosity curves |
| Sheet Structure / Layers | 4–5 Layers (ABCA / ABCBA, etc.) | Accommodates barrier resins (EVOH), tie-layers, recycled cores, and virgin skins |
| Finished Sheet Width | Approx. 500 – 1000 mm (Customizable) | Directly compatible with wide-bed cup making and three-station thermoformers |
| Sheet Thickness Range | 0.3 – 2.0 mm | High gauge precision across thin-wall drink cups to deep-draw meal trays |
| Reference Hourly Output | Approx. 350 – 500 kg/h | Heavy industrial throughput supplying continuous multiple thermoforming cells |
| Main Motor Power | Approx. 90 + 45 + 22 kW | Independent high-torque AC vector drives synchronized via central PLC |
| Total Installed Power | Approx. 270 kW | Includes barrel heating zones, co-ex adapter heating, and calender drives |
| Calender Roller Dimensions | Approx. Φ350 / 450 / 450 × 1000 mm | Mirror-finished three-roll stack with independent internal spiral cooling circuits |
| T-Die Lip Width | Approx. 1000 mm (Customizable) | Streamlined multi-layer coat-hanger die minimizing polymer dead spots |
| Production Line Speed | Approx. 15 – 30 m/min | Broad line speed range adapting to thin lid sheet and thick tray roll stock |
| Roller Cooling Architecture | Circulating Water Cooling (Tower/Chiller) | Individual temperature control units (TCU) on each roll for precise quenching |
| Roller Drive Mechanism | Independent Motor Drive | Independent servo motors on each roll preventing surface vibration marks |
| Melt Metering Pump | 250CC Precision Melt Pump | Guarantees pulseless core delivery into multi-channel feedblock |
| Winding Configuration | Two-Station Winding Unit | Heavy-duty dual-station turret winder with automatic tension tapering control |
| Electrical Utility Standard | 380V / 50Hz / 3-Phase | Custom engineered to match client destination electrical grid codes |
| Footprint Envelope | Approx. 13–16 × 2.5–4 × 2.5–3 m | Modular arrangement with overhead mezzanine platform access for hopper loading |
| Machine Weight | Approx. 21 Metric Tons | Heavy-gauge welded structural base isolating high-pressure extrusion forces |
Modern food packaging demands extended shelf life and maximum sustainability. The VihoX 120+90+65 co-extrusion line meets these stringent criteria by combining three independent extruders through a state-of-the-art 5-layer feedblock. Converters can configure an ABCBA structure, where the central B-layer carries up to 70% low-cost crushed skeleton regrind or post-industrial waste, intermediate C-layers act as functional barrier resins (such as EVOH or anti-odor barriers) or adhesive tie-layers, and outer A-layers provide 100% virgin food-contact surfaces. This yields barrier containers that prevent oxygen permeation while reducing total raw material costs by up to 35%.
Managing three extrusion barrels, multiple hydraulic screen changers, melt metering pumps, and calender cooling requires unified automation. The VihoX line incorporates an industrial Siemens/Schneider master PLC with a 15-inch color touchscreen interface. Operators can store hundreds of formulation recipes, recalling exact screw RPMs, melt pump delivery pressures, barrel heat profiles, and calender draw ratios with a single touch, reducing recipe changeover downtime from hours to minutes.
This triple co-extrusion line delivers unmatched versatility across high-demand markets:
The 5-layer feedblock can be configured for 3-layer (ABA), 4-layer (ABCA), or 5-layer (ABCBA) structures, allowing converters to run barrier, tie-layer, regrind, and virgin combinations.
The main Φ120 mm extruder contributes approx. 250–320 kg/h to the core layer, the Φ90 mm extruder supplies 70–120 kg/h to intermediate layers, and the Φ65 mm extruder provides 30–60 kg/h for surface skins.
Yes. The Φ90 mm or Φ65 mm extruder can be equipped with specialized corrosion-resistant bimetallic barrels and low-shear screws engineered specifically for EVOH and tie-layer adhesive resins.
The melt pump stabilizes the dominant core flow from the 120 mm extruder, preventing pressure surges that would otherwise distort the thin barrier and skin layers inside the feedblock.
The central PLC features master line speed ramping. When total line speed is adjusted, all three extruders, melt pump, calender rolls, and haul-off drives adjust proportionally to maintain exact layer ratios.
The equipment envelope occupies approx. 13–16 × 2.5–4 × 2.5–3 m. A minimum ceiling clearance of 4.5 meters is recommended for raw material loading hoppers and overhead cranes.
A dedicated industrial transformer rated at ≥ 400 kVA is recommended to support the 270 kW installed power with adequate operating headroom during full production shifts.
Yes. VihoX dispatches senior mechanical and electrical engineers worldwide for complete on-site positioning, piping, multi-layer recipe calibration, and operator certification.
Obtain custom technical evaluations for 5-layer EVOH oxygen barrier sheet production, adhesive tie-layer distribution, and turnkey thermoforming cells.
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