Extrusion coating and lamination line
For many years, BG Plast has successfully provided solutions for the extrusion coating sector, thanks to its established expertise in the design and construction of coating and lamination lines for thermoplastic materials. Extrusion coating is now one of the most versatile technologies for producing high-performance multilayer products capable of combining different materials into a single functional composite.
In the extrusion coating process, a molten polymer is extruded directly onto a flat, moving substrate, such as paper, cardboard, plastic film, metal foil, aluminum, fabrics, or nonwoven materials, to create a stable, continuous bond. The goal is to leverage the best properties of each material, achieving a final product with performance characteristics that none of the individual components could provide on their own.
Applications and industries for extrusion coating
The range of applications for extrusion coating is extremely broad. Coated and laminated materials produced on BG Plast lines are used in the automotive industry, the footwear sector, flexible packaging, food and aseptic packaging, and even in the trade show and exhibition market, where solutions have been provided for the production of carpet rolls up to 6000 mm wide.
Applications in food and beverage packaging are particularly significant, such as cartons for milk, juices and wine; wrappers for snacks, soups, and hot foods; as well as packaging for pet food. Extrusion coating is also used for coating aluminum foil, technical lacquering, barrier films, flexible tubes (toothpaste, sauces, preserves), technical fabrics, tarps and nonwoven products.A significant development involves advanced multilayer structures, up to 6 layers, that combine different polymers and natural or technical fibers (such as Kevlar), intended for the production of rigid thermoformable panels for automotive components, such as doors.
Technical specifications of the BG Plast extrusion coating line
The core of the system consists of single-screw extruders engineered to guarantee process stability, melt homogeneity and highly accurate flow control. Our extruders are equipped with direct motor/gearbox coupling, air- or water-cooled AC motors, and, upon request, torque motors without a gearbox. The screws and cylinders, made of heat-treated steels (41CrAlMo7 and 38CrAlMo7), can be nitrided or coated with special anti-wear treatments.
The extrusion lamination unit is designed to maintain a uniform temperature across the roller surfaces, thanks to high-efficiency helical cooling circuits. The configuration includes chrome-plated cooling rollers, rubber-coated pressure rollers with a PTFE non-stick coating, pneumatic pressure control, and automatic adjustment systems for height and machine direction.
The T-head can be equipped with manual or automatic lip adjustment, extrusion width reduction systems and co-extrusion solutions, enabling accurate control of material thickness and distribution.The lines are complemented by unwinders and winders capable of handling reels up to 1800 mm in diameter, with semi-automatic or fully automatic splicing systems and operating speeds that can reach 500 m/min. Water-based or solvent-based primer units, in-line thickness measurement systems and dedicated surface treatments (corona, flame, plasma) are also available, selected based on the substrate.
Extrusion coating solutions for flexible packaging
In the case of extrusion coating and laminating, the extruded layer also serves as an adhesive layer, enabling the in-line lamination of two or more substrates without the use of solvents or chemical adhesives. This technology is particularly valued in food and aseptic packaging, where the absence of solvents offers both technical and regulatory advantages.
With our extrusion coating lines, we offer modular and customizable solutions designed to ensure high performance, process reliability and production flexibility. Our goal is to meet the needs of a constantly evolving market that is increasingly oriented toward high-value-added composite materials.
The future of extrusion lamination, with BG Plast.