Company Overview and Technical Collaboration

Windsor Machines Ltd., established as a global player in extrusion machinery, specializes in blown film lines with a strong technical collaboration with KUHNE GmbH, Germany. Since 1992, this partnership has enabled Windsor to offer advanced blown film technology, including monolayer and multilayer co-extrusion lines, with a focus on innovation, cost efficiency, and customer satisfaction worldwide.

Extruder Specifications and Features

• Barrier Design Screw: High-performance barrier screws capable of processing a wide range of polymers including LDPE, LLDPE, HMHDPE, Polyamide, EVA, EVOH, PP, Primacore, and Surlyn.
• Screw and Barrel: Grooved feed design barrels (30D length) with geometries tailored for various polymers; screws nitrided to 65-67 HRC for durability.
• Output Capacity: Up to 800 kg/hr with uniform melt quality at low temperatures.
• Heating and Drives: Fin-type heaters for precise temperature control; AC drives sourced from Europe/Japan; optional imported gearboxes from Europe.
• Mechanical Reliability: High capacity thrust bearings for extended life.

Film Blowing Components

• Air Cooling Rings: Dual lip design for excellent bubble control; options for imported rings from Germany or Canada to enhance performance.
• Calibration Baskets: Multiple options including standard cages, 9-point motorized cages for IBC lines, and scissor design multipoint contact cages.
• Film Blowing Heads: Universal spiral mandrel die designs with streamlined flow paths and CNC machining for precision; mirror-polished surfaces to prevent plastic melt degradation; unique flow paths to achieve differential layer ratios effectively.

Take Off and Haul Off Assemblies

• Collapsing Frame: Rigid structure with longer support guides for stable bubble formation at high output and speed; operator-friendly settings; PBT bushes standard; optional aluminum rollers and motorized slat adjustments.
• Reversing Haul Off: Integral for gauge randomization; horizontal design available up to 3000 mm roller width; variable frequency AC drives; synchronized drives; optional water-cooled nips and slewing ring design.

Film Winders

• Semi-Automatic Winders: Two-station surface winders with online reel changeover, bow roller as expander, and optional auto-tension control.
• Fully Automatic Winders: Capable of handling 1000 mm width and 1000 kg rolls; max line speed 150 m/min; features include automatic reel changeover, web cross-cutting, pneumatic shafts, expander rollers, European gear drives, load cell tension control, vector flux closed-loop drives, and optional hydraulic lowering of rolls.
• Optional Automation Features: Ultrasonic sensors for IBC control, gravimetric dosing or batch blending with yield control, and fully automatic thickness measurement and control.

Product Lines and Technical Data

Duke Series (3-Layer Non-IBC Lines)

• Film layflat width: 600-2100 mm depending on model.
• Film thickness range: 20-150 microns.
• Output capacity: 160-240 kg/hr depending on polymer type and model.
• Extruders: 3 with L/D ratio 30:1; motor ratings vary from 22 kW to 60 kW.
• Gauge randomization via oscillating table or reversing haul off.
• Die lip sizes: 300-425 mm.
• Take off roller widths: 1350-2200 mm with 2.2 kW main nip motors.
• Semi-automatic two-station surface winders with roller widths matching take off.
• Operating power: 146-194 kW; space requirements approx. 16x10x13 to 18x10x14 meters.

Rex Series (3-Layer IBC Lines)

• Film layflat width: 700-2300 mm.
• Film thickness range: 25-150 microns.
• Output capacity: 250-600 kg/hr depending on polymer and model.
• Extruders: 3 with L/D ratio 30:1; motor ratings up to 132 kW.
• Gauge randomization via reversing haul off.
• Die lip sizes: 300-600 mm.
• Take off roller widths: 1350-2300 mm with main nip motors 2.2-3.75 kW.
• Fully automatic winders with max wound diameter 1000 mm.
• Operating power: 288-476 kW; space requirements approx. 18x12x13 to 24x14x14 meters.

Baron Series (5-Layer Blown Film Co-Ex Lines)

• Film layflat width: 900-1500 mm.
• Film thickness range: 25-150 microns; with PA layer 50-150 microns.
• Output capacity: 160-330 kg/hr depending on polymer and model.
• Extruders: 5 with screw diameters and motor ratings tailored per layer (e.g., 55G/40/50/40/55G mm screws; motors 30/11/22/11/30 kW).
• Gauge randomization available.
• Die lip sizes: 350-400 mm.
• Take off roller width: 1600 mm with 2.2 kW main nip motor.
• Winders: Semi-automatic and automatic options with roller widths 1600 mm and max wound diameters 800-1000 mm.
• Operating power: 265-343 kW; space requirements approx. 19x13x14 meters.

Additional Technical and Operational Highlights

• All lines support a wide range of polymers and multilayer configurations including tie layers and barrier materials like EVOH.
• Line speeds vary by model and application, typically from 8 to 150 m/min.
• Windsor offers solutions from monolayer to complex 5-layer co-extrusion lines with full automation options.
• Customization and precision manufacturing (CNC machining, mirror polishing) ensure high-quality film production and easy changeovers.
• Global presence with installations and support across multiple continents including Asia, Africa, Europe, and the Americas.

Contact and Regional Offices

Windsor Machines Limited is headquartered in Ahmedabad, India, with multiple regional offices across India and international sales contacts. The company reserves the right to modify specifications without prior notice.