Courses for the plastics and recycling industry

Introduction to blown film extrusion

The course presents the complete PE film production process: raw material preparation, plasticisation, flow through the die, film bubble formation and cooling, haul-off and winding. It explains how the operation of successive line components affects the quality of the finished roll.

The material is primarily intended for operator onboarding and establishing shared basic knowledge within the team. It also supports cooperation between production, quality control and maintenance.

Skills developed in the course

• How PE blown film extrusion works: from plasticisation through film bubble formation to final winding
• What each production line component is responsible for and how it affects the process
• Which parameters have the greatest impact on film quality and how to control them
• Where instabilities originate and how to recognise them before they become defects
• How process settings translate into the properties of the finished product

Who is this course for?

• Machine operatorswho want to understand the process rather than simply repeat the previous shift's settings
• Production engineers and process engineers developing their knowledge of the mechanics of blown film extrusion
• Quality specialistswho need to link process parameters with product properties
• Production managerswho want the entire team to work from the same knowledge base
• Companies onboarding new employees or commissioning new extrusion lines

Detailed topic coverage

How does blown film extrusion work? The full production cycle: from raw material plasticisation to film bubble formation and final winding.

What are the key components of the production line? The extruder, extrusion die, air ring, screen changers, winding station and control system: how each works and its impact on your film.

Which process parameters have the greatest impact on film quality? Temperature, pressure, screw speed and film bubble stability: how they affect the final product and how to control them.

What are the main challenges in film production? Common production problems, how to recognise them early and how to prevent them.

How do process settings affect downstream processing? The impact of parameter adjustments on film properties, printability, sealability and converting efficiency.

Course format

• Practical PDF materials guiding you step by step through the process logic: from raw material to finished roll
• Video and audio explanations for selected topics, including film bubble formation, stabilisation and real production conditions
• Final quiz assessing understanding of key concepts and process relationships

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Raw materials, rheology and additives in PE film production

The course covers the selection of polymers and additives for blown film production. It connects raw material properties with melt behaviour during extrusion, film bubble stability and product properties.

Particular attention is given to differences between polyethylene grades, batch variability and the interpretation of test results. Participants learn the relationships needed when changing a formulation, supplier or proportion of recycled raw materials.

Skills developed in the course

• How melt viscosity, elasticity and melt strength affect film bubble stability, thickness uniformity and cooling behaviour
• Why LDPE, LLDPE, metallocene LLDPE, MDPE and HDPE behave so differently during film extrusion despite similar datasheet values
• Why metallocene polyethylenes require different processing conditions from conventional LLDPE, and what happens when this is ignored
• How additives (slip agents, antiblocking agents and stabilisers) affect melt behaviour in the barrel and die as well as the properties of the finished film
• How regrind and regranulate change melt rheology and why the same blend can behave differently between batches
• How to make material change decisions based on rheologyinstead of simply compensating for problems with machine settings

Who is this course for?

• Machine operatorswho observe the effects of material changes on the line but do not always know whether the cause is the resin, additives or machine settings
• Production engineers and process engineerswho need to predict how a raw material change will affect the process before introducing it
• Quality specialistswho want to connect laboratory results with actual process behaviour on the line
• Production managerswho need their team to make material decisions based on knowledge rather than trial and error
• Companies introducing new raw materials, blends or regranulate into production

Detailed topic coverage

Polymer melt rheology in film extrusion What rheology means in practice: how melt viscosity, elasticity and melt strength determine film bubble stability, thickness uniformity and cooling behaviour. Why MFI alone is not enough.

Rheological characteristics of polyethylenes used in film extrusion A comparison of LDPE, LLDPE, metallocene LLDPE, MDPE and HDPE: how each behaves differently under shear and extension, and what this means for the process.

How raw material rheology affects film bubble stability and film quality The relationship between melt properties and what you observe on the line: frost line position, thickness variation, mechanical strength and optical properties.

Additives and their impact on melt behaviour How slip agents, antiblocking agents, UV stabilisers and other functional additives affect melt flow in the barrel and die, and the risks of incorrect dosing.

Regrind and regranulate: impact on rheology and process stability Why regrind changes melt properties, why the same blend can behave differently between batches, and how to minimise instability when working with secondary materials.

From rheology to production decisions How to interpret process behaviour when changing raw materials, additives or regrind content, and make decisions based on melt properties rather than guesswork.

Quality control and laboratory results in context Which laboratory tests actually matter for blown film production, and how to connect measurement results with observations on the line.

Course format

• Practical PDF materials covering raw material rheology, additives and process behaviour in the context of real blown film production
• Video and audio explanations for selected topics: melt behaviour, film bubble stability and material comparisons
• Final quiz assessing understanding of key relationships between material, rheology and process

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Part 1 gives the team an understanding of process logic. Part 2 provides material logic. Together, they form the foundation for everything that follows: line construction, process optimisation, multilayer technologies and troubleshooting.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Film extrusion line construction

The course explains the construction and functions of the components of a blown film production line. It covers raw material conveying and plasticisation, filtration, the die, cooling, film bubble stabilisation, haul-off and winding.

The material helps connect an observed problem with the operation of a specific machine component. It is useful for operators, process engineers and maintenance teams when analysing changes in pressure, output, thickness and roll quality.

Skills developed in the course

• How the extruder works: barrel zones, screw design and compression ratio, and how these affect melt quality and output stability
• How extrusion die distributes the melt and what determines thickness uniformity around the film bubble
• How air ring and cooling system control the frost line, film bubble stability and film optical properties
• How screen changers and melt filtration protect quality and what happens when they are neglected
• How film bubble stabilisation and collapsing systems affect flatness, orientation and downstream processing
• How automation and control systems affect process repeatability and where their limitations lie
• How winding station determines the quality of the finished roll, and why problems at the winder often originate earlier in the process

Who is this course for?

• Machine operatorswho want to understand how every part of the line affects the film, beyond simply knowing where the buttons are
• Maintenance technicianswho need to connect mechanical problems with process behaviour
• Production engineers and process engineers responsible for line setup, optimisation and troubleshooting
• Production managers planning line upgrades, new installations or start-ups
• Companies commissioning new lines or training teams on unfamiliar equipment

Detailed topic coverage

The extruder: construction and operating principle How the screw, barrel and drive work together. How screw geometry affects melt quality, output and energy consumption.

The extrusion die: melt distribution and film formation How the die distributes the melt into a uniform film tube. What causes thickness variations and how die design affects them.

The cooling system: air ring and film bubble stability How the air ring controls the frost line and film bubble shape. The relationship between cooling capacity, production speed and film properties.

Screen changers and melt filtration Why filtration matters, how different types of screen changers work, and what happens to process stability when filters are not managed properly.

Film bubble stabilisation and tubular film guiding How the film bubble is guided, collapsed and spread, and how these systems affect film flatness, wrinkle formation and orientation.

Automation and process control How control systems ensure repeatability: gravimetric dosing, thickness measurement, IBC and their integration with the entire process.

Winding: the final stage that reveals everything How the winding station affects roll quality, tension control and suitability for downstream processing. Why many “winding problems” originate earlier in the process.

Course format

• Practical PDF materials covering line construction, component functions and their impact on process behaviour
• Video and audio explanations for selected topics: extruder operation, extrusion die function and cooling dynamics
• Final quiz assessing knowledge of line construction and component interaction

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Part 1 gives the team process logic. Part 2: material logic. Part 3: machine logic. Together, these three courses provide a complete foundation for process optimisation (Part 4) and everything that follows.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Process optimisation and troubleshooting

The course addresses identifying the causes of film defects and unstable line operation. It covers the sequence for checking raw materials, settings and equipment when problems occur with the film bubble, thickness, surface and winding.

Participants learn to analyse a symptom, check possible causes and evaluate the result of a correction. Actions at the machine should take account of the manufacturer's documentation and the plant's safety rules.

Skills developed in the course

• Diagnose the most common film defects: thickness variations, surface defects, film bubble instability and winding problems, and connect each to its root cause
• Distinguish between machine, material and process problems: because the corrective actions are completely different in each case
• Apply a systematic approach: symptom → cause → correction → prevention, instead of trial and error
• Respond faster and more effectively to production problems, taking account of safety rules and assessing whether the line needs to be stopped
• Understand how screw speed, pressure, cooling and temperature interact and how changing one parameter affects the others
• Eliminate recurring winding defects: wrinkling, conical rolls and film sticking, by addressing the actual cause rather than simply changing winder settings

Who is this course for?

• Machine operatorswho face production problems every day but often address symptoms rather than causes
• Production engineers and process engineerswho need a systematic troubleshooting method beyond relying on experience and guesswork
• Quality specialistswho want to connect defects with specific process conditions
• Maintenance teamswho need to distinguish mechanical problems from process problems
• Production managers and plant directorswho want to reduce downtime and waste, and have a team that solves problems instead of repeating them

Detailed topic coverage

The most common film defects and how to eliminate them A structured overview of the problems most frequently encountered on blown film extrusion lines and the diagnostic logic behind each one.

Uneven film thickness What causes thickness variation around the film bubble and in the machine direction, and how to correct it through die and cooling settings and process parameters.

Surface defects: orange peel, streaks and discolouration How to identify whether the cause is temperature, material, contamination or a mechanical factor, and how to proceed in each case.

Film bubble instability: drift, oscillations and collapse How cooling, pressure and melt properties interact to destabilise the film bubble, and how to regain control.

Mechanical damage to film Scratches, deformations and stress marks: where they arise in the process and how to prevent them.

Optimising cooling: avoiding deformation and internal stresses How cooling rate and uniformity affect film structure, flatness and properties in downstream processing.

Screw speed and pressure: their impact on quality How these key parameters affect melt homogeneity, output stability and the final properties of the film.

Rapid correction of process errors during production How to make effective corrections while following safety rules, assessing whether the line needs to be stopped and avoiding new problems.

Winding defects: wrinkling, delamination and conical rolls Why most winding problems do not start at the winder, and how to find their actual source earlier in the process.

Film sticking: why thin film sticks and how to prevent it The role of temperature, additives and process conditions in film blocking and sticking.

Course format

• Practical PDF materials based on real production problems, each analysed using the sequence symptom → cause → correction → prevention
• Video and audio explanations for selected topics: film bubble behaviour, defect identification and practical process adjustment
• Final quiz assessing the ability to diagnose problems and select appropriate actions

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

This course is the turning point of the series.

Parts 1-3 give your team understanding. Part 4 provides the ability to act in practice. Every subsequent course, covering supporting technologies, multilayer technologies, recycling and cost analysis, builds on the troubleshooting skills developed here.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Technologies supporting film production

The course covers equipment and systems that support process operation: dosing, thickness measurement, profile control, IBC cooling and melt filtration. It explains their functions and limitations.

Participants learn the relationships between system readings and actual process conditions. The material helps assess whether equipment is operating correctly, needs calibration or servicing, or is compensating for another problem on the line.

Skills developed in the course

• Understand gravimetric versus volumetric dosing and how dosing errors cause process instability that looks like a machine problem
• Assess blend homogeneity: why the blend in the hopper does not always match the blend in the melt
• Correctly interpret online thickness measurement: what the system actually measures, what it does not detect and where its practical limitations lie
• Recognise when automatic profile control improves thickness distribution and when it masks an actual die or cooling problem
• Understand how the air ring and IBC cooling affect film bubble stability, frost line position and film properties, and when IBC introduces instability instead of eliminating it
• Make informed decisions about screen changers and melt filtration: screen selection, replacement frequency and their impact on pressure stability and film quality
• Know when system cleaning (screw, barrel and die) is necessary, and how to avoid material degradation caused by improper cleaning

Who is this course for?

• Machine operatorswho work with these technologies every day but do not always know when a system supports the process and when it creates a new problem
• Production engineers and process engineerswho need to assess whether a supporting technology actually improves output or simply adds complexity
• Maintenance teams responsible for screen changers, cleaning schedules and system calibration
• Quality specialistswho need to understand the limitations of measurement and profile control systems
• Production managers and plant directors assessing technology investments: this course helps distinguish solutions that pay for themselves from those that deliver no benefit

Detailed topic coverage

Gravimetric and volumetric dosing systems How each type works, what affects dosing accuracy, and how dosing errors propagate through the process unnoticed.

Dosing errors and their impact on the process How to recognise when dosing instability causes problems that resemble temperature, pressure or material issues.

Blend homogeneity: when the blend is not what it seems Why the ratio in the hopper does not always match the ratio in the melt, and how this affects film properties and process repeatability.

Online thickness measurement systems What these systems actually measure, how sensor position and calibration affect results, and where the practical limits of measurement lie.

Automatic profile control When the system actually improves thickness distribution and when it compensates for a die or cooling problem that should be addressed at its source.

Air ring cooling and film bubble stability How air ring design and settings affect the frost line, film bubble shape and film quality, and how to optimise cooling without destabilising the process.

IBC: internal bubble cooling When IBC increases output and stability, and when it causes oscillations, pressure fluctuations or uneven cooling that creates problems downstream.

Screen changers and melt filtration How different types of screen changers work, how screen selection affects pressure and quality, and how to manage filter changes without interrupting the process.

Screen selection in practice How to select the right mesh for the material, film thickness and process conditions, and how filter management affects production continuity.

Cleaning the plasticising system (screw, barrel and die) When cleaning is necessary, how to recognise signs of contamination, and how to avoid degradation caused by improper cleaning.

Purging compounds: when they help and when they do not How to recognise when purging compounds solve the problem and when they merely mask the actual causes.

Course format

• Practical PDF materials covering each supporting technology: operating principle, impact on the process, and when it helps or masks problems
• Video and audio explanations for selected topics: dosing systems, thickness measurement and cooling dynamics
• Final quiz assessing the ability to evaluate technologies and make process decisions

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

This course directly continues Parts 1-4.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Shrink film and stretch hood production

The course connects load securing requirements with the selection of raw materials, formulations and production conditions. It covers shrink films and stretch hood films, which differ in how they are applied and stabilise the pallet.

The relationships between stretching, shrinkage, strength and processing conditions are discussed. The material is intended for those responsible for producing and assessing the properties of these films.

Skills developed in the course

• Understand the fundamental difference between shrink film and stretch hood: thermal shrinking versus mechanical stretching and elastic recovery, and why each requires a completely different production approach
• Select appropriate raw materials for shrink film (LDPE, LLDPE and EVA) and understand how each resin affects shrinkage, transparency and processability
• Select appropriate raw materials for stretch hood and understand what determines load stability, puncture resistance and elastic recovery
• Understand how EVA content and additives modify film behaviour during shrinking and when they improve properties or cause problems
• Control film orientation (MD/TD) as a key parameter for shrink direction, uniformity and mechanical strength
• Set process parameters specific to shrink film: temperature, BUR and cooling, and understand how each affects the final shrink result
• Set process parameters specific to stretch hood and understand how they differ from shrink film production
• Maintain film bubble stability with demanding formulations: higher EVA content, specialist blends and their impact on process behaviour
• Understand how cooling rate and uniformity affect the internal structure of the film and its performance properties
• Connect mechanical test results with process conditions: tensile strength, elongation and shrink force, and use them for optimisation as well as reporting

Who is this course for?

• Machine operators producing shrink film or stretch hood who need to understand why the process settings for these films differ from those for standard PE film
• Production engineers and process engineers responsible for formulation, process settings and achieving specified performance properties
• Quality specialistswho need to connect laboratory test results (shrink percentage, tensile strength and puncture resistance) with process conditions and raw material selection
• Production managers and plant directors in companies producing shrink film or stretch hood, or planning to add these products to their range
• Companies receiving complaints about film performance at the customer's site: shrink uniformity, load stability and film failures during application

Detailed topic coverage

Shrink film versus stretch hood: differences in technology and application How each type works, why the production approach is fundamentally different, and what this means for raw material selection, process settings and quality control.

Raw materials for shrink film: LDPE, LLDPE and EVA How each resin type affects shrink behaviour, optical properties and processability, and the trade-offs between transparency, shrink performance and process stability.

Raw materials for stretch hood What determines load holding force, puncture resistance and elastic recovery, and how material selection differs from shrink film.

The role of EVA and additives in shrink films How EVA content and functional additives change the film's response to heat, and when their use improves performance or creates new problems.

Film orientation (MD/TD): the key to shrinkage and strength How process settings control the direction and degree of shrinkage, and why orientation is the most important factor affecting film performance.

Process parameters for shrink film production Temperature profiles, BUR and cooling settings: how each parameter affects the degree of shrinkage, uniformity and final film quality.

Process parameters for stretch hood production How process setup differs from shrink film, and which parameters determine elongation, elastic recovery and load stability.

Film bubble stability with demanding formulations How higher EVA content and specialist blends affect film bubble behaviour, and how to maintain process stability with these materials.

Cooling and its impact on film structure How cooling rate and uniformity affect crystallinity, orientation and the mechanical properties that determine film performance.

Mechanical testing and process optimisation How to use tensile strength, elongation, shrink force and puncture resistance test results to identify problems linked to specific process conditions, and how to solve them.

Course format

• Practical PDF materials structured around the relationships between process settings, raw materials and film performance
• Video and audio explanations for selected topics: orientation behaviour, shrink mechanics and stretch hood application
• Final quiz assessing the ability to connect process decisions with product properties

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Multilayer technologies in film production

The course presents multilayer blown film coextrusion. It discusses layer functions, material selection, their proportion in the structure and their impact on the properties of the finished film.

Topics cover both structural design and process operation. Participants learn the relationships between layer formulations, extrusion stability, product quality and raw material costs.

Skills developed in the course

• Understand the function of each layer: outer (surface properties, printability and resistance), core (stiffness and stability), inner (sealability, slip and adhesion), and how they work together as a system
• Analyse typical 3-layer and 5-layer film configurations: symmetrical and asymmetrical, and understand why each structure was designed in a particular way
• Understand coextrusion: how the melt is distributed in a multilayer extrusion die and how the layers are formed into a single tubular film structure
• Control layer ratios and understand how the percentage of each layer affects film properties, process stability and material cost
• Recognise how film bubble formation and cooling differ between multilayer and monolayer blown film extrusion, and what this means for the frost line, thickness uniformity and film quality
• Make rational material allocation decisions: placing the right resin in the right layer to optimise both properties and costs

Who is this course for?

• Machine operators operating 3-layer or 5-layer blown film extrusion lines who want to understand how the layer structure affects what they observe on the line: film bubble behaviour, thickness and film properties
• Production engineers and process engineers responsible for layer structure design, material selection and process settings on multilayer blown film extrusion lines
• Quality specialistswho need to connect film performance problems with specific layers in the structure
• Production managers and plant directors planning new multilayer extrusion lines, expanding multilayer production or analysing changes in layer design to optimise costs
• Companies currently producing monolayer PE filmthat want to understand multilayer blown film technology before investing in new equipment

Detailed topic coverage

Blown film types: monolayer, 3-layer and 5-layer When each type is appropriate, what determines the addition of further layers, and the logic of selecting a film structure according to product requirements.

Layer functions: outer, core and inner What each layer is responsible for and how it affects film properties: mechanical strength, surface quality, sealability and processability.

Typical 3-layer and 5-layer configurations Symmetrical and asymmetrical structures used in blown film production: how they are designed, why certain combinations work, and the trade-offs involved.

Coextrusion: how multilayer blown film is made How melt from several extruders is combined in the extrusion die and distributed into a layered tubular film structure, and where problems can arise during coextrusion.

Film bubble formation in multilayer blown film extrusion How the presence of multiple layers affects film bubble stability, frost line behaviour and cooling, and why multilayer film bubbles behave differently from monolayer ones.

Designing layer ratios for optimum properties How the percentage of each layer affects film properties, process stability and raw material costs, and how to find the right balance between quality and cost.

Rational use of raw materials in multilayer structures How to allocate PE resins across layers to maximise performance while minimising costs: using expensive resins only where they actually add value to the final product.

Course format

• Practical PDF materials covering multilayer blown film logic, layer functions, coextrusion principles and layer structure design
• Video and audio explanations for selected topics: coextrusion flow, layer formation and structural analysis
• Final quiz assessing knowledge of multilayer construction and its impact on film properties and process behaviour

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Film production from recycled raw materials and recycling in-house films

The course discusses the use of regranulates and regrind in film production and the recovery of in-house production waste. It explains the importance of raw material origin, variability and preparation for processing.

The material covers problems related to contamination, changes in flow properties, colour and film consistency. Participants learn to assess the impact of recycled raw material on the formulation, settings and quality control.

Skills developed in the course

• Understand how regrind and regranulate differ from virgin PE resin: in melt behaviour, contamination levels, moisture content and batch-to-batch variability
• Assess regrind quality before it enters the extruder: MFI, moisture, contamination and homogeneity, and learn which parameters matter most for film extrusion
• Distinguish between post-industrial (PIR) and post-consumer (PCR) regranulate and understand why the source determines what you can and cannot produce
• Set the right blend ratio of regrind to virgin raw material: balancing cost savings with process stability and film quality
• Adjust blown film extrusion line process parameters (temperature, screw speed and pressure) specifically for processing recycled materials
• Recognise how regrind affects film bubble stability and why problems with regranulate often look like machine faults when the real cause is material variability
• Understand how regranulate content affects film properties: mechanical strength, optical clarity and surface quality, and which trade-offs are acceptable for your application
• Apply the principles of design for recycling: designing film structures that enable effective recycling after use, closing the loop from production to the product's end of life
• Implement quality control systems that ensure production repeatability despite variable incoming raw material

Who is this course for?

• Machine operators working with regranulate every day who need to understand why the process behaves differently with each new batch of recycled material
• Production engineers and process engineers responsible for setting blend ratios, adjusting process parameters and maintaining film quality when using regranulate in blown film production
• Quality specialistswho need to assess incoming regranulate quality and connect material properties with final film performance
• Production managers and plant directors under pressure to increase regranulate content while maintaining product quality and production efficiency
• Companies implementing internal recycling programmes or increasing their use of post-consumer and post-industrial PE regranulates

Detailed topic coverage

How regranulate differs from virgin PE resin Fundamental differences in melt behaviour, contamination, thermal history and variability, and why treating regranulate like virgin material causes problems on a blown film extrusion line.

Sources of regranulate: PIR versus PCR How the origin of regranulate affects its quality, consistency and suitability for blown film extrusion, and why post-consumer regranulate requires a completely different approach from post-production regrind.

Assessing regrind quality: key parameters Melt flow index (MFI), moisture content, contamination levels and homogeneity: how to assess the raw material before introducing it to the blown film extrusion line.

Material variability and its impact on process stability How differences between regrind batches translate into process fluctuations, and how to recognise whether instability comes from the material, machine or settings.

Establishing the right blend ratio How to determine the optimum proportion of regrind to virgin raw material: balancing cost, quality and process stability without exceeding the capabilities of the blown film extrusion line.

Adjusting process parameters for regranulates Which temperature, screw speed and pressure settings need to change when processing regrind, and why standard settings for virgin raw material do not work.

The impact of regrind on film bubble stability and film formation Why blown film extrusion with regranulate presents specific challenges: melt inhomogeneity, frost line shifts and thickness variations, and how to address them.

Properties of film containing regranulate How regranulate affects mechanical strength, optical properties, surface quality and sealability, and what level of change is acceptable for different applications.

Design for recycling: closing the loop How to design blown film structures that can be effectively recycled at the end of their life: material and additive selection, and structural simplification.

Quality control in production with regrind Methods for monitoring the quality of raw material and finished film, and how to maintain production repeatability as the raw material changes.

Course format

• Practical PDF materials covering regrind assessment, blend design, process adjustment and quality control in film extrusion with regranulate
• Video and audio explanations for selected topics: material variability, film bubble behaviour with regrind content and quality monitoring
• Final quiz assessing the ability to evaluate regranulate quality, establish blend ratios and maintain process stability

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

Recycling is more than a sustainability objective. It is a production skill.

Parts 1-7 give your team a complete foundation in blown film extrusion: process, materials, machines, optimisation, supporting technologies, specialist films and multilayer structures. Part 8 enables working with variable raw material: a skill that is becoming increasingly important as industry requirements for regranulate content grow.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.

Economics and cost analysis of film production

The course shows how decisions on the line affect the cost per kilogram of film. It covers raw material consumption, actual thickness, waste, energy, working time, downtime and changeovers.

The material is intended for production teams and those responsible for plant efficiency. It supports loss analysis, performance comparisons and the economic assessment of proposed process changes.

Skills developed in the course

• Understand the full cost structure of blown film production: raw materials, energy, labour, depreciation and waste, and which components have the greatest impact on unit cost
• View raw material cost as a function of film thickness, waste rate, process stability and material utilisation, as well as the purchase price
• Calculate the true cost of waste and production losses: the full cost, including material value, energy, machine operating time and lost production volume
• Analyse energy consumption per kilogram of film produced, and identify where energy is being wasted unnoticed
• Understand how downtime and changeover time affect production cost and where the greatest time losses actually occur
• Connect process parameter decisions with financial results: how temperature, speed, cooling and thickness settings translate directly into cost per kilogram
• Assess line efficiency and OEE (Overall Equipment Effectiveness), and understand what these indicators actually mean for production cost and gross margin
• Identify hidden cost driversthat do not appear in standard production reports and reduce profitability
• Make optimisation decisions based on cost impact: knowing which improvements deliver the highest financial return with the least effort

Who is this course for?

• Machine operatorswho influence production cost with every setting and need to understand the financial consequences of their decisions on the blown film extrusion line
• Production engineers and process engineerswho optimise the process for quality but rarely analyse the cost consequences of their parameter choices
• Quality specialistswho need to understand the trade-off between tighter specifications and higher production costs
• Production managers and team leaders responsible for line output, waste levels and production efficiency
• Plant directors, operations managers and business ownerswho need their team to think about profitability as well as keeping the blown film extrusion line running

Detailed topic coverage

The cost structure of blown film production A comprehensive breakdown: raw materials, energy, labour, depreciation and waste. Which cost components dominate, and where the greatest savings potential lies in blown film extrusion.

Raw material cost: the most important factor Why material cost is more than the purchase price. How film thickness tolerance, waste rate and blend ratios determine the actual raw material cost per kilogram of finished film.

The true cost of waste and production losses How to calculate waste costs correctly, including wasted energy, machine time, labour and lost production capacity. Why “2% waste” costs more than most people think.

Energy consumption analysis How to measure and assess energy cost per kilogram of blown film produced, and where energy losses most often occur in extrusion, cooling and auxiliary systems.

The cost of downtime and changeovers How to estimate the true cost of production stoppages, material changes and start-up losses, and which types of downtime have the greatest financial impact on your blown film extrusion line.

Process parameters and their impact on costs How temperature profiles, screw speed, cooling settings and target thickness directly affect production costs, and how to optimise for both quality and economics.

Line efficiency and OEE How to measure and interpret Overall Equipment Effectiveness (OEE) for a blown film extrusion line, and what the difference between actual and achievable OEE means financially.

Hidden cost drivers Losses that do not appear in standard reports: excessive thickness, oversizing, suboptimal regrind utilisation and energy waste. How to find them and estimate their impact on gross margin.

Cost-based optimisation decisions How to assess which process improvements deliver the highest financial return, so the team focuses its efforts where they create the greatest value for your blown film production.

Course format

• Practical PDF materials connecting blown film extrusion process parameters with production cost analysis, structured around actual cost drivers
• Video and audio explanations for selected topics: cost calculation methods, waste analysis and energy consumption monitoring
• Final quiz assessing the ability to identify cost drivers and make economically justified production decisions

A Rolbatch Academy certificate of participation and the opportunity to earn a diploma after a knowledge assessment. The requirements are explained in the FAQ.

This is where the entire series comes together.

Learning arrangements and ordering

The course includes PDF materials and video and audio explanations of selected topics. Participants work at their own pace and can revisit the materials during the access period. Completion, certificate and diploma requirements are explained in the FAQ.

Please include the number of participants, language and preferred date in your enquiry. We will confirm availability, the access period and terms for your team. We accept orders by email. You can combine selected parts, Executive and books in one enquiry.