The document discusses the production process of biodegradable polyethylene bags. It involves mixing raw materials like LLDPE, LDPE, HDPE and d2w additive. The mixture is extruded and printed with designs. Then the film goes through a bag making process involving cutting and sealing to form final bags. The bags contain recycled compound and are made biodegradable by the addition of d2w additive during production. The production process aims to reduce and reuse materials while effectively recycling plastic waste.

1. Biodegradable Polyethylene Bag Production
Thesis Group No. - 7
173011 - Md. Faruque Hossain
173057 - Md. Mehedi Hassan
173058 - Md. Sahaydul Islam

2. Industry
RFL Industrial Park, Mulgaon, Kaliganj, Gazipur
Biodegradable Polyethylene Bag Production

3. Biodegradability and d2w
Biodegradable plastics are plastics that can be decomposed by
the action of living organisms usually microbes, into water,
carbon dioxide, and biomass
Symphony Environmental Technologies PLC has invented
d2w additive, which is added during the production process of
plastic - making it “oxo-biodegradable”.
Biodegradable Polyethylene Bag Production

4. Biodegradable Polyethylene Bag Production
Biodegradability and d2w
Source: https://ecopolyauae.com/d2w.html

5. Production Processes
Mixing of Raw Materials
Extrusion
Printing
Bag Making
Biodegradable Polyethylene Bag Production

6. Process flow chart of APBL
Enter
order into
System
Order
receive
Store
Raw
materials
Mixing
Section
Extruder
M/C
quality
?
Recycle
No
Non
Print
Cutting
Bag
Making
Packagin
g
Print
Cutting
Packaging
Bag
Making
Quality
Approve
d ?
No
Yes
Is
quality
?
Is
quality
?
Distributio
n
Distribution
Yes
No
No
Yes
Yes

7. Mixing Process
Raw Materials :
LLDPE- Linear Low Density Polyethylene
LDPE - Low Density Polyethylene
HDPE - High Density Polyethylene
Master Batch – Color Ingredient
Recycle Compound
d2w additive
Biodegradable Polyethylene Bag Production

8. Mixing Process
Recipe:
Garments Bag
LLDPE 10%
LDPE 5%
HDPE 79%
Filler 5%
d2w ≤1%
Transparent Bag
LLDPE 35%
LDPE 30%
Recycle 35%
d2w ≤1%
Biodegradable Polyethylene Bag Production

9. Mixing Process
RM Put into Hopper
Mixing by Screw barrel
Heating RM at 60-70 degree
temperature
Pop out mixing RM
Fill up Sack
Biodegradable Polyethylene Bag Production

10. Cycle time : 80 minutes
Maximum Output :
Biodegradable Polyethylene Bag Production
Mixing Process
Source: APBL Factory, Gazipur

11. Mixing Process
Biodegradable Polyethylene Bag Production
Source: http://www.wensui.com/en/Products/Show_124.html

12. To put it simply, plastic extrusion is a
high volume manufacturing process
in which raw plastic is melted and
formed into a continuous profile.
Plastic extrusion machinery is useful
for speeding up workflow and
volume.
Extrusion Process
Biodegradable Polyethylene Bag Production

13. Extrusion Machine
Biodegradable Polyethylene Bag Production
Source: https://www.azom.com/article.aspx?ArticleID=13566

14. Extrusion Machine
Screw Design:
As material gets fed into one end of the plastic
extruder (a hopper), it is gradually melted by the
heat and energy created from turning screws.
Feed Zone: This is where the plastic composite
material gets fed into the extrusion machine.
Melting Zone: The next section in the screw
design is where the plastic gets melted.
Metering Zone: Finally, the metering zone is
where the last bits of plastic are melted and mixed
to create a uniform temperature and composition.
Biodegradable Polyethylene Bag Production

15. Extrusion Machine
Hopper Loading
RM Heating into
Screw barrel
Die
Filter
Air Ring
Guide Plate
Take off roller
Embossed Roller
Surface treatment
Winding Unit
Biodegradable Polyethylene Bag Production
Source: APBL Factory, Gazipur

16. Extrusion Process
Biodegradable Polyethylene Bag Production

17. Extrusion Process
Biodegradable Polyethylene Bag Production
Source: APBL Factory, Gazipur

18. Printing Process
1.Gravure Printing
- inline
- die is fixed on roller
2. Flexo Printing
- Design Block is installed in the
roller (like as rubber stamp seal)
Biodegradable Polyethylene Bag Production

19. Gravure Printing Process
Biodegradable Polyethylene Bag Production
Design Cylinder
Cylinder Setup
Pour Ink
Mixing Solvents
Film Setup
Adjust Roller
Print Registration
control
Quality Check
Source: APBL Factory, Gazipur

20. Gravure Printing Process
Biodegradable Polyethylene Bag Production
Source: https://www.azom.com/article.aspx?ArticleID=13566

21. Design Block
Make Block
Block set up on
cylinder
Mixing Solvents
Adjust Roller
Pour Ink
Qualilty Check
Flexo Printing Process
Biodegradable Polyethylene Bag Production
Source: APBL Factory, Gazipur

22. Air Shaft Setting
Tension Setting
Feeding Roller Setting
Servo Roller
Measurement setting
Clamp Setting
Hot Punch Setting
Punch Cutting
Conveying Belt
System
Punch Cutting
Biodegradable Polyethylene Bag Production
Bag Making Process

23. Biodegradable Polyethylene Bag Production
Bag Making Process
Air Shaft Setting
Tension Setting
Feeding Roller Setting
Servo Roller
Measurement setting
Clamp Setting
Hot Punch Setting
Punch Cutting
Conveying Belt
System
Punch Cutting
Source: APBL Factory, Gazipur

24. Biodegradable Polyethylene Bag Production
Bag Making Process (Cutting and Sealing)
Source: APBL Factory, Gazipur

25. Final Product with Recycle Compound
Biodegradable Polyethylene Bag Production
Source: APBL Factory, Gazipur

26. Final Product
Biodegradable Polyethylene Bag Production

27. Recommendation
Biodegradable Polyethylene Bag Production

28. Recommendation
Reduce , Reuse , Recycle
.
d2w re-usable bags are commonly used nowadays
ordinary plastic and recycled plastic can now be made oxo-biodegradable using d2w
additive. Conversely, d2w products can also be recycled effectively.
Biodegradable Polyethylene Bag Production

29. Thank You!