Blown Film Die Repair
We are the world leader in extrusion die repair and we offer the best warranty in the industry, a full 12 to 24 months covering plating, maintaining polish finish, minimal carbon build up, die lines, pitting, corrosion, etc. Your multilayer blown film extrusion die will perform like new. Our repair methods exceed OEM guidelines for plating thickness and overall finish. While other repair shops sub contract their plating and have no control over thickness and plating process, we do it all ourself and are in complete control of plating technique, plating thickness, polishing, grinding and we are a contract (polisher) and chrome/nickel plater for some of the largest extrusion manufacturers.
How much will my blown film die repair cost? Call us with the make, model and size of your die. The amount of work needed determines the final cost. Simple sizing ring/pin adjustments will always be cheaper than a complete rebuild with chrome or nickel. Let us know how many layers or how many parts are to your blown film die, we can get you a price right over the phone and follow up with email and fax. You'll speak with an extrusion tech who can answer any questions regarding your blown film die repair or other extrusion/converting machinery. We’ll beat any competitor’s price by 10% or more with a better warranty and faster delivery time.
How long will it take for my blown film die repair service? Normal delivery is 7 to 14 days. If you send in a die that is free of any plastic and fully cleaned, we can start stripping the chrome immediately. A plastic free, cleaned die can be fully rebuilt in 5 to 7 days. A die that is full of plastic can take 2 to 3 days to melt all the plastic and another 2 to 3 days to clean, approximately one week before we can start the stripping process. Stripping can take 1 to 3 days. Polishing and plating can be done in 3 shifts and we gladly work holidays and weekends on expedite service. We deliver your die on your schedule, when you need it.
What if I only need one or two pieces repaired on my extrusion blown film die? We can quote single pieces or complete dies. From sizing pin & ring adjustments to single components. We'll do whatever is needed to get you back in production on your schedule. A single piece for a blown film die isn’t a problem, there is no minimum.
We can make spare sizing rings and pins for any size blown film extrusion die. Provide us a print, drawing or sample and we'll make you a superior sizing ring and pin for your blown film die that will exceed all OEM specs/tolerances & guidelines. We use D2 tool steel that is through hardened for superior strength then precision grind, polish then prep for plating. A stronger base material means stronger, more durable plating that will resist die lines, chipping, pitting, peeling, etc. Our replacement sizing rings/pins are made of a superior material, through hardened then plated to military spec. We’re capable of holding +/- .0001 over 30” and +/- .0003 up to 90”
When we perform a repair or rebuild a blown film die, we exceed OEM specs/tolerances for the thickness of chrome, brightness of the polish finish, tolerances of the gap setting, etc. We have over 40 years of experience in blown film die repair, extrusion dies, rotators, extrusion screws, etc. Our goal is to be your go to source for any extrusion or converting equipment repair.
Blown film extrusion trouble shooting experts! Explain the problems you are experiencing with your extrusion line and our team of experts will help solve any problems or issues you are having. We'll assign a team to research your issue free of charge, whether you give us the repair project or not. Our staff has over 40 years experience with blown film extrusion process and we'll gladly share information with the end user.
Are there any requirements for blown film die repair services? You can send us any die in any condition. We prefer that you send in a die free of any plastic that is already cleaned so we can start stripping immediately. By doing this, you will speed up the repair process by 5 to 7 days. If it’s full of plastic or not cleaned, it’s not a problem, we can easily provide those services but it will delay your delivery time by up to one week or more.
Blown film die repair procedure: (we provide photos, videos via email)
1: We completely burn off all existing plastic off of your blown film die to prepare it for opening and disassembling. You can save time and money by sending us a plastic free die that is already cleaned.
2: Careful disassembly using overhead crane, not to ding any of the parts.
3: Complete cleaning of all spirals, housing, ports, inlets, every surface of your blown film die that comes into contact with plastic is cleaned using high speed non-abrasive pads. We will provide photos of the cleaned extrusion die to show you the extent of wear and work needed.
4: Stripping all the plated material off of your existing parts. We can chemically strip in 50/50 muriatic acid or electronically strip in a tank with reversal technique for a faster stripping process. Electronic stripping can cause minor “etching” of your base material, which will be polished and ground away.
5: Vapor blast and chemical dip to clean all parts. Dye penetrate is used to locate any pits, chips, cracks, dings. If any are found, they are repaired with welding and blended in using high speed hand tools. All work is double checked, the smallest pinhole can lead to blown film die repair failure.
6: The most important part of blown film die repair process is polishing. We apply a 5RMS mirror finish to all surfaces that come into contact with plastic. A mirror finish is what resists or repels carbon buildup, giving your blown film die a longer production life.
7: Inspection of all polished surfaces, cleaning and prepare for plating. Any imperfections will be welded and blended in perfectly. Again, we will provide photos and videos of all work. Your extrusion die will have a perfect surface, free of any pits, scars, zits, etc.
8: Chrome plating blown film die. While other companies sand blast their surfaces to prep before plating, we dip in acid solution to maintain the polish finish. We apply .010 to .012 of industrial hard chrome. When you chrome plate (or nickel plate) a sandblasted surface, the parts come out "frosted" and require additional sanding and polishing which will remove a majority of the plating (almost half) from your blown film die. An acid dip will clean the die better than chrome and not affect the polished finish.
8A: If you prefer, we can apply an electroless nickel plating (done to strict Military Spec Mil-C-26074B Class A Grade 1) to all surfaces. No sandblasting is needed, acid dip to prep for plating. Electroless nickel done properly can be more durable and last longer than chrome plating on all extrusion die repairs. Please note that electroless nickel costs more than chrome but will last longer. When electroless nickel is baked at 475 for 4 hours immediately after plating, it creates a stronger bond between the plating and base material. It raises the hardness of electroless nickel to be harder than chrome.
9: Immediately after plating, all parts are put into a heat treating oven at 475F for 3 to 4 hours. This strengthens the plating bond to the base material and provides a more durable surface (actually hardens hard chrome and electroless nickel). Parts are allowed to cool overnight.
*Contact any chrome or nickel plater that specializes in aerospace parts, ask for information about electroless nickel baking after plating, CEB coatings, it's a Military Spec required on most parts for FAA and Military parts. It strengthens the bond between base material and plating, including hardening the surface*
10: Inspection of all plated surfaces. Checking for chips, zits, dings, etc. All areas and surfaces of die are blemish free & perfect before final polishing. Checking all ports, spirals for proper & even thickness. Any imperfections, the part is stripped, polished and re-plated. Your blown film die repair must blemish and scratch free after plating.
11: Buffing and polishing all plated surfaces, inlets, all parts that come into contact with plastic. A 3RMS mirror finish is applied by hand and thoroughly cleaned and prepped for final inspection.
12: Open or close the die gap to your exact dimensions, +/- 0.0003 on all blown film die sizing rings and pins. Keep in mind we can make replacement pins and sizing rings for any blown film die repair.
13: Final inspection of all plated and polished surfaces. Your blown film die repair will not only look as good as new but most importantly will perform like new, guaranteed up to 24 months.
14: Assembly and professional crate made with metal banding, foam liner and fully insured ready to ship. Please note we will not tighten bolts or install heating bands on your extrusion die repair.
The end result is a fully polished and chrome plated blown film die repair that will perform like new.
Got a written quotation from another company? We'll slash their price by 10% or more with a faster delivery time and a stronger warranty. Mitchell Precision offers the highest quality repairs with the best warranty in the industry for all blown film extrusion equipment. Want to check our quality? Send us one piece and we’ll do it at cost (zero profit) with chrome, electroless nickel or CEB coating, use that part for a few weeks and compare our quality to the vendor you’re using now.
We can repair all equipment used in the blown film extrusion process. From melt pumps, extruders, barrels, blown film dies, rotators, air rings, converting, printing, slitting, recycling, etc. Mitchell Precision is a turnkey solution to any and all blown film extrusion process machinery & equipment.
Keep in mind we also repair rotators, sheet dies, rolls, extruders, gearboxes, extrusion die repair experts, etc. Any and all equipment used in converting or extrusion.
Please click the links above and feel free to call us with any questions. You'll speak directly to a plastics processing technician who can give you an estimate on cost right over the phone. Nationwide same day pickup is available on any size project!
Keep in mind, we are a used equipment dealer. We buy any and all used machinery working or not. We'll buy your old molds (certificate of destruction and photos supplied) old dies, spare parts, complete lines. Fleet vehicles, forklifts, old gearboxes, we buy anything and everything. Call us with your list or provide photos and let's work out a deal to clean your yard.