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2-Ply Extrusion Technology

Increase the Percentage of Recycled Material in Your Film




Conventional methods for producing bags with high amounts of recycled material generally require the reclaim to be buried in the core layer of a coextruded structure, between skin layers of mostly-virgin material. The issue with this method is that defects, such as gels/pinholes, that may originate from impurities in the recycled materials of the core layer tend to migrate through all layers of the structure.

Macro’s 2-Ply extrusion technology creates a two-ply film by joining two films immediately after extrusion. This configuration adds strength to the overall film structure as weak spots in each layer are reinforced by the complimentary layer.

To block the film the bubble is collapsed before the melt cools.



Macro has tested blends of post-consumer recycled materials with virgin resins as well as structures comprised of 100 % in-house scrap. The tests found that both tear strength and tensile strength were consistently 25% better than a single layer film structure.

The technology will allow a range of 0.5% to 100% reclaimed plastic material to make up the final film structure.

For more information on new and retrofit opportunites, please contact us today.