Extrusion line for optical-grade sheets and foils
BG Plast’s optical-grade sheets and foils extrusion line was designed to meet the most demanding requirements of the polymer processing industry, where transparency, surface uniformity and dimensional stability are essential criteria. Every stage of the extrusion process plays a crucial role, from material plasticization through calendering to finishing operations.
BG Plast, a leader in the design and manufacture of extrusion and calendering lines for thermoplastics, has developed specific solutions for processing high-performance polymers such as PC, PMMA, PET, PETG, GPPS and SAN, materials that require extremely accurate process control to produce sheets and plates with high optical properties that remain consistent over time.
Applications of optical-grade sheets and films
BG Plast’s extrusion lines dedicated to optical-grade products are used in numerous industries where material transparency, the absence of surface defects, and thickness accuracy are critical factors. In the construction industry, sheets are used for transparent roofing, skylights, roof windows, natural lighting panels and door glazing, where a combination of mechanical strength and high light transmission is essential.
In the industrial sector, optical-grade sheets and foils are used for transparent guards, shielding, sound insulation and technical components, while in the graphic design and visual communication sectors, they serve as an ideal support for applications that highlight the material’s aesthetic appeal. Our solutions also enable the production of sheets with special finishes, such as embossed or corrugated surfaces, to further expand application possibilities.
Technical specifications of the BG Plast optical sheet and foil line
The core of the line is a main extruder equipped with a bimetallic barrel and a coated screw, specifically designed for processing high-performance polymers. Particular attention has been paid to the efficiency of the degassing system, a key element in preventing gas inclusions and imperfections that would compromise the optical quality of the finished product. The high-precision gravimetric feeders, installed upstream of the extruder, provide a constant feed that is synchronized with the gear pump and the screw rotation speed.
A side co-extruder allows for the application of a thin UV-protective layer on one or both sides of the sheet, depending on specific application requirements. The calendering stage, which is particularly critical for this type of production, is handled by a three-roll calender with roll diameters ranging from 410 to 550 mm, delivering an exceptionally high-quality surface finish.
Each cylinder incorporates an internal circuit for circulating the temperature-control fluid, capable of operating at high pressures and temperatures to ensure thermal uniformity and process stability. The variable geometry of the calender, achieved by allowing the upper cylinder to rotate around the central one, makes it possible to adapt the configuration to the thicknesses being produced. The independent motorization of the cylinders, with electromechanical systems designed to eliminate any vibration, is a key factor in achieving optical quality.
The lines allow for the production of foils with thicknesses ranging from 0.15 to 0.20 mm and sheets with thicknesses ranging from 1.5 to 20–25 mm, with usable widths ranging from 1000 to 2050 mm, extendable up to 3000 mm upon request, and a production capacity ranging from 300 to 2000 kg/h.
At the end of the process, sheets and plates are automatically stacked by a suction cup unit, for maximum efficiency.
End product examples
Discover some examples of end products made with our solutions. Each result is the outcome of a precise, flexible, and highly technological process, designed to ensure performance, quality, and reliability in every application.
BG Plast technology for optical grade extrusion
With our extrusion lines for optical-grade sheets and foils, we provide our customers with highly specialized systems designed to ensure high performance, reliability, and production flexibility. The integration of mechanical expertise, process control and attention to detail enables us to support advanced industrial production, where optical quality is not a bonus but an essential requirement.
See – literally – a new level of quality.