Project Overview
Client Location: Turkey
Industry: Protective Packaging & Insulation Materials
Machine Ordered: ZTECH 2.2m Wide, 5-Layer Co-extrusion Aluminum Foil Bubble Film Machine
Status: Repeat Customer (Upgrading existing ZTECH line)
Project Background
As a repeat ZTECH client, this Turkish manufacturer has trusted our equipment for years. In 2026, they required a significant capacity expansion to meet the growing demand for high-barrier insulation materials in the European and Middle Eastern markets. They placed an order for a wide-format 5-layer machine to produce premium aluminum foil bubble insulation.
Client’s Specific Pain Points
During the pre-sales consultation, the client emphasized two non-negotiable requirements:
Component Interchangeability: The new extruder screws had to be engineered to be compatible with their old ZTECH machines. The goal was to reduce downtime and unify their spare parts warehouse.
End-of-Line Automation: To combat increasing labor costs, they required a solution to automate the rewinding process and the tape sealing/cutting process, which were previously done manually.
ZTECH’s Customized Engineering Approach
Backward-Compatible Extrusion Unit:
Our R&D team re-evaluated the screw geometry of the new 5-layer machine. We produced a specialized barrel and screw set that maintains the high output of the new wide machine while allowing the client to physically use these new screws in their older ZTECH extruders if needed for maintenance or special production runs.
Automatic Turret Winder & Auto-Taping System:
We integrated a servo-driven automatic turret winder for non-stop roll changeover. Simultaneously, we customized an automatic taping mechanism that precisely seals the film edge and cuts the roll without manual handling. This reduced the required operators on the line from 3-4 down to 1-2.
Results Achieved
Increased Output: The 2.2m width combined with 5-layer capability allows the client to produce complex composite films (Aluminum + PE + Bubble) at high speeds.
Reduced Labor Costs: The automation upgrades saved the client approximately 40% in manual labor for the winding section.
Lower Maintenance Costs: By creating a backward-compatible screw system, the client can now keep fewer types of spare parts in stock, reducing their warehousing burden.
Conclusion
At ZTECH, being a "source factory" means having the engineering flexibility to solve real-world problems. We treat every repeat order as a chance to improve our client's bottom line. Whether it is customizing an L/D ratio for a screw or programming a PLC for complex tape application, we listen to the pain points and build the machine around the requirement.
Need a custom automation or compatibility upgrade for your existing line? Contact ZTECH engineers for a free technical assessment.