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Individual Layer Foaming now an Option on Macro’s Cast Film Coextrusion Line




cast extrusion of multilayer barrier film with foam injectionFilm and sheet extrusion systems supplier Macro Engineering & Technology Inc. (Canada) has added the option of including gas foaming into any layer of the multilayer film structures produced on its cast film coextrusion line.


Macro’s cast barrier film coextrusion system is used to produce multilayer film structures up to 11-layers and up to 3 m wide using a variety of materials including PA, EVOH and PVdC. The films produced are most typically used in food and medical packaging applications.  “The addition of individual layer foaming broadens the possibilities of end-use applications”, states Andrew Erskine, Macro’s Marketing Manager. “Not only can foaming reduce weight and lead to raw material savings, but it can also create favourable properties in the film. By foaming one or more layers embedded in the coextruded film, thermal and sound insulation can be improved, flexibility and conformability can be enhanced, and opacity can be obtained without using fillers.”  With the addition of foaming technology the applications for Macro’s cast barrier film line can be extended to thermoformed trays, insulation pouches, value-added lamination materials and stiffer, glossy films for shelf appeal.


Individual layer foaming is achieved with nitrogen gas injection through a sophisticated feed-block that distributes each layer of the melt flow. The feed-block’s design alleviates the need for a multi-manifold system that can add significant cost to the system. 


The line can operate with or without foam injection, providing processing flexibility for the film maker to switch between conventional multilayer films and foamed films without changing machinery configuration. “Versatility is a driving motivation for us”, states Erskine. “Supplying systems with inherent flexibility helps our customers adapt to changing market demands. It also helps mitigate risk on their capital investment”.

Macro recently installed a 7-layer cast coextrusion line in Europe that produces high barrier films with layer foaming in two of the seven layers and inline embossing to create an optimized product for the user’s end application.


For more information, please contact us.


Learn more about Macro's barrier cast film coextrusion line.


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About Macro 

Macro Engineering & Technology is a global supplier of film and sheet extrusion systems that specializes in barrier film lines and custom engineered extrusion systems. Founded in 1978, Macro’s approach is to help film and sheet producers reach their production goals through a project-oriented philosophy and an uncompromising commitment to developing innovative technologies. 


Macro manufactures blown, cast and biaxially-oriented coextrusion lines for multilayer films up to 13-layers. The company also supplies sheet extrusion lines for specialty applications, along with extrusion coating and laminating lines. Macro also specializes in developing customized winding solutions and supplies winding equipment to meet the needs of complex requirements. 

Macro’s equipment is used throughout the world to manufacture value-added products in the food packaging, medical, and industrial markets. 


For more information about Macro Engineering & Technology Inc. contact us.