What is co-extruded multi-layer film?

When two or more Polymers are molted simultaneously to form a single sheet of film, that film is known as “Co-Extruded Multi-Layer Film” and process is known as Co-Extrusion.

In Flexible Packaging, no single Layer of Film can give all required properties. In order to achieve all selected Polymers were melted in such a way that form a film with Unique Properties of all Films.

Co-extrusion is the process where two or more polymers are extruded together to make a composite film.

Type of Co-Extruded Plants

3 Layer (most common)
5 Layer
7 Layer
9 Layer
11 Layer
The selection of layers depends upon end properties required as well as items to be packed.
How to Calculate Trim in Easy step
Trim Waste in kg = weight of roll x trim size in mm / roll size
Weight of Roll = 325 kg
Rolls Size = 875 mm
Trim Size = 15 mm

Trim Waste in kg = 325 x 15 / 875 = 5.57 kg


Trim Waste % = trim size / roll size %
Trim Waste % = 15 / 875% = 1.71%
How Quickly Calculate Cylinder Size Step by step
Basic Calculation for calculating
– Film Size
– Cylinder Face Length & Cirum
– Raw Material required for job
Steps How to Convert Roll OD into kg 
Convert Roll OD to kg
Formula = pi x h x (R² – r²) x film density / 1000000
pi = 3.14
h = film / web / roll width
R² = square of Roll OD Radius (R = OD/2)
r² = square of Roll ID Radius (r = ID/2)
film density = BoPP 0.91, Pet 1.4, Foil 2.7

How to Calculate 2nd Layer kg?
1st Layer – 12µ Pet Density 1.4
2nd Layer – 50µ LDPE/Poly (Natural) Density 0.93


How much 2nd Layer required for 250 kg Pet ?

2nd Layer gsm x printed Quantity ÷ 1st Layer gsm

(50 * 0.93 * 250) ÷ (12 * 1.4) = 691.96 kg

1st Layer Pet 12µ – 250 kg
2nd Layer Poly 50µ – 691.96
2 Ply Job Calculation
Final Laminated Material required 1000 kg

Job Structure 12µ Pet + 50µ LDPE

Pet Density 1.4
Poly Density 0.93

12µ Pet gsm = 12 x 1.4 = 16.8
50µ Poly gsm = 50 x 0.93 = 46.5

Composite gsm = Pet Film gsm + Poly gsm = 16.8 + 46.5 = 63.3

Pet required for 1000 kg Laminate = Pet Film gsm x Total Output ÷ Composite gsm
= 16.8 * 1000 ÷ 63.3 = 265.40 (kg)

LDPE required for 1000 kg Laminate = LD Film gsm x Total Output ÷ Composite gsm
= 46.5 * 1000 ÷ 63.3 = 734.60

Total Laminate (Pet + LDPE) = 265.40 + 734.60
3 Ply Job Calculation (Cylinder)
RAW MATERIAL CALCULATION FOR 3 PLY POUCH JOB (CYLINDER, FILM, INK & ADHESIVE)
NCO + OH Ratio, kg Calculation 
How to calculate NCO & OH required in kg?
Someone asked me if they have Adhesive ratio of 100:55 (Dow 2 component Adhesive).

Adhesive total Quantity required 100 kg for a particular job.
It’s a Very simple and basic Calculation.

NCO : OH
100 : 55

NCO = FINAL QUANTITY X NCO RATIO ÷ ( NCO RATIO + OH RATIO)

100 X 100 ÷ (100+55) = 64.52 kg

OH = QUANTITY X OH RATIO ÷ (NCO RATIO + OH RATIO)

100 X 55 ÷ (100+55) = 35.48 kg
Roll kg to Meter to Square Meter
Convert Roll kg to Meter to Meter Square Flexible Packaging using Excel Sheet.
In any Flexible Packaging job, we have to convert Running Meter or Linear Meter to Square Meter (m²). In this video you can learn and use Excel Sheet to Convert Linear Meter of Film (BoPP, Pet, LDPE etc.) to Square Meter. First we convert roll kg to meter using subjected Roll Width or Coil Size. 

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