Blown Film Die Repair Service

Our extensive blown film die repair process

• 1. We thoroughly clean your blown film die by removing any remaining plastic residue and preparing it for disassembly and opening.
• 2. We carefully take apart the components using an overhead crane to avoid causing any damage or dings.
• 3. We clean all surfaces that come into contact with plastic in your blown film die using high-speed non-abrasive pads, ensuring a comprehensive cleaning process. We also provide visual documentation of the cleaned die to assess repairs and wear.
• 4. We remove any plated materials from the existing parts using either a chemical strip or an electronic strip, depending on the preferred method, to speed up the process.
• 5. To ensure thorough cleaning, we utilize vapor blasting and chemical dipping techniques for all parts. We also perform dye penetration testing to identify any pits, chips, cracks, or dings, which are then carefully repaired using welding and blending techniques with high-speed hand tools. We double-check our work meticulously, as even the tiniest pinhole can lead to blown film die repair failure.
• 6. The critical polishing stage involves achieving a mirror-like finish (5RMS) on all surfaces that come into contact with plastic, preventing carbon build up and extending the lifespan of your blown film die.
• 7. After polishing, we conduct an inspection to ensure all polished surfaces are flawlessly prepared for chrome plating. If any imperfections are found, we promptly repair and blend them.
• 8. For chrome plating and/or nickel plating, we use an acid solution dip to preserve the polished finish, applying an industrial hard chrome layer with a thickness between .010 and .012.

• 9. Alternatively, if desired, we offer electroless nickel plating, which meets strict Military Spec Mil-C-26074B Class A Grade 1. This process eliminates the need for sandblasting and prepping with an acid dip. When baked at 475°F for 4 hours, electroless nickel plating forms a stronger bond than chrome plating, resulting in enhanced durability.
• 10. We also provide blown film die repairs with an 18-month warranty using a CEB coating, which involves chrome plating, electroless nickel plating, and baking at 475°F for 4 hours. This coating adheres to Military Spec QQC-3 and Military Spec Mil-C-26074B, Class A, Grade 1, offering a robust and long-lasting plating surface resistant to chipping, pitting, and carbon buildup.
• 11. After plating, we subject all parts to a heat-treating process at 475°F for 3 to 4 hours, strengthening the bond and enhancing surface durability. We conduct a thorough inspection of all plated surfaces, ensuring they are free from chips, dings, and imperfections before proceeding to the final polishing stage.
• 12. We buff and polish all plated surfaces, inlets, and parts that come into contact with plastic, achieving a 3RMS mirror finish by hand. After meticulous cleaning and preparation, we conduct a final inspection.
• 13. We carefully adjust the die gap to your precise dimensions, ensuring a tolerance of +/- 0.0003 for all blown film die-sizing rings and pins. If needed, we can also manufacture replacement pins and sizing rings.
• 14. The final inspection involves a comprehensive evaluation of all plated and polished surfaces, ensuring that your blown film die repair not only looks flawless but, more importantly, performs exceptionally well. This comes with a warranty of up to 24 months.
• 15. We conclude the process by professionally assembling your die, securely packaging it in a specially designed crate with metal banding and a foam liner.

Top-tier Repairs, Rapid Turnaround, and Unbeatable Pricing

• Continuing to lead the blown film die repair sector, Hard Chrome Solution remains the premier choice in America. Our ascent to this position is underpinned by our unwavering commitment to delivering excellence across all aspects of service. Be it our unparalleled manufacturing and repair capabilities, our uncompromising repair protocols, our swiftest turnaround times, or our competitive pricing, selecting us for your blown film die rebuild is the logical decision.
• Hard Chrome Solution provides the utmost in repair quality and backs it with the industry's finest warranty for all blown film extrusion equipment. Curious about our quality? Send us a single piece, and we'll undertake the process at cost (no profit) with chrome, electroless nickel, or CEB coating. After using the part for a few weeks, compare our quality to that of your current vendor. We offer this assurance because we are confident that the discernible difference in quality between us and our competitors is nearly imperceptible.
• As we strive for further industry growth, our strategies encompass a range of research initiatives. Among them is a study that enhances our knowledge and imparts valuable insights to our customers. Each rebuilt blown film die is accompanied by our certified inspection report, prepared by our skilled and seasoned team. This comprehensive report includes certified test documents, various media like photos and videos showcasing findings, and our expert analysis. We detail the cause of failure, the nature of the failure, our recommended repairs, the repair process, and the certified test results. Our customers receive this inspection report via email, applicable to all types of extrusion or converting equipment we service.
• Our repair expertise extends to all equipment used in the blown film extrusion process. From melt pumps, extruders, barrels, and blown film dies to rotators, air rings, converting machinery, printing, slitting, recycling systems, and more. Hard Chrome Solution offers a complete solution for all blown film extrusion machinery and equipment needs. Remember, we also specialize in repairing rotators, sheet dies, rolls, gearboxes, and any equipment used in the converting or extrusion processes.