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This section provides an overview for film processings as well as their applications and principles. Also, please take a look at the list of 9 film processing companies and their company rankings.
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Film processing refers to a method of enhancing the strength of films by thinly molding resin materials, such as plastics, and adding features like coatings.
There are various processing methods for film processing, but this article will primarily focus on explaining fundamental molding techniques.
Molding techniques for films primarily include melt extrusion molding, solution casting molding, and calender molding. Each of these is explained below.
Melt extrusion molding includes methods like the T-die method and the inflation method to form coatings. It involves melting thermoplastic polymers and extruding them through a die slit.
Solution casting molding is a process where polymers dissolved in a solvent are extruded through a die slit.
Calender molding involves passing heated rollers over polymer or resin materials, thinning and molding them.
In the film manufacturing process, stretching films is a crucial step to alter their characteristics. The primary stretching methods for films are flat film stretching and tubular film stretching, which can further branch into uniaxial stretching and biaxial stretching for flat film stretching.
In the usual flat film stretching process, heat is applied to thermoplastic resins to melt them, and then they are stretched to align the film molecules in a specific direction. Before processing, the molecules in the resin are irregularly arranged, indicating non-oriented characteristics. However, introducing orientation improves the film's properties.
Uniaxial stretching aligns the resin molecules in a specific direction, enhancing characteristics in that oriented direction. Typically, uniaxial stretching is categorized into wet stretching (water tank stretching) and dry stretching.
Wet stretching involves heating the water in a tank and using it to heat and stretch the film. Although this method applies heat evenly across the film, it has temperature limitations due to the heated water, making stretching challenging. To address this, additives may be introduced when stretching at high temperatures to attempt to resolve the issue.
Most films available today are manufactured using this method. Films are processed through flat film sequential biaxial stretching or tubular film stretching. In some cases, flat film simultaneous biaxial stretching is utilized. Films produced through biaxial stretching have more features than uniaxially stretched films.
Flat film sequential stretching involves stretching the film in both vertical and horizontal directions. Multiple rolls are commonly used for this stretching process, with two-stage stretching referred to as vertical-horizontal stretching or horizontal-vertical stretching, and multi-stage stretching called multi-stage or post-type stretching.
Flat film simultaneous biaxial stretching also stretches the film in both vertical and horizontal directions simultaneously. While sequential biaxial stretching is advantageous for high-speed film formation, simultaneous biaxial stretching allows molding with less energy consumption since it simultaneously stretches in both directions.
Another processing method is tubular film stretching. This method includes stretching techniques such as static pressure, flow pressure, octopus type, and horseshoe type.
*Including some distributors, etc.
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Filmquest Group Inc. based in Bolingbrook, Illinois, U.S.A., is a manufacturer of polyester films for various industrial and commercial applications. The company provides different kinds of polyester films such as coated films, soft touch matte, no gloss matte, high barrier, and heat sealable films that have applications in chemical treatments, flexible packaging, industrial manufacturing, electrical & electronics, and imaging & graphics sectors. The company also offers converters that print, coat, laminate, and metalize all grades of polyester film as well as slitting and rewinding services.
PolymerFilms, a company established in 1968, based in Charlotte, North Carolina, USA, is a distributor and supplier of plastic sheet, rod, tube, and film products. The company provides various products such as cast acrylic, aluminum composite material, HDPE, marine grade PVC foam sheet. These products are used for various applications such as signage, oil and gas, graphics, food processing, and marine. It also offers services such as cut to size, fabrication, film conversion, and sustainability.
Professional Plastics, Inc. (PPI) is an American supplier of industrial plastic parts that was established in Fullerton, California in 1984. The company primarily offers plastic films, sheets, tubes, and rods. These are fabricated from various plastic materials including acrylic, PVC, and ultra-high-molecular-weight (UHMW) polyethylene, as well as branded plastic compounds like Techtron and Plexiglass. Its supplied parts are commonly used in the manufacture of goods such as medical trays or tools, scuba diving equipment, and panes for golf cart windshields. PPI serves clients in a wide range of industries, including in the construction, marine, and food processing sectors.
Curbell Plastics, Inc., founded in, Orchard Park, NY, in 1942 is a supplier of plastic materials such as Plastic Sheet, Rod, Tube, Films, Tapes, and Adhesives. The company's product portfolio includes Prototyping Materials, Orthotic and Prosthetic Sheets, sealants and fabricated plastic parts. The company serves markets including Medical and Healthcare, Aerospace and Defense, Consumer Goods, Industrial Manufacturing and Construction and Building. The company also offers customer services that include support, prototyping, custom research projects and customized services.
Xamax Industries, Inc. is a paper insulation supplier founded in 1948 in Seymour, Connecticut. The company’s product catalogue offers solutions for the electrical, industrial and medical markets. It includes laminates, technical papers thermoplastic films, nonwoven fabrics, and 100% organic cotton. It also provides custom contract converting services such as spooling, precision slitting, and rewinding. In addition, the venture counts with multiple domestic and foreign patents in places like Canada, China and Europe.
Mitsubishi Chemical America, Inc. (MCA) is a chemical products manufacturer and distributor based in Greer, South Carolina. The company was established in 2017 as one of four regional headquarters of the Mitsubishi Chemical Corporation (MCC), which supplies North American companies like Boeing, Tesla, and Bemis Company, Ltd. The company produces, imports, and distributes MCC products such as ion exchange resins used for metals recovery or water processing, optical reflective sheets used in liquid crystal backlights, and various monomers and polymers used in infrastructure and transportation. MCA serves a wide range of industries including aerospace and defense, energy, and construction.
Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
5 | 100.0% |
