{"id":12439,"date":"2026-05-11T12:30:42","date_gmt":"2026-05-11T10:30:42","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/blownup\/"},"modified":"2026-05-12T15:56:56","modified_gmt":"2026-05-12T13:56:56","slug":"blownup","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/blownup\/","title":{"rendered":"BlownUp"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_0342f16a0349707613bcd4159b9c9b7b .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_0342f16a0349707613bcd4159b9c9b7b .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_0342f16a0349707613bcd4159b9c9b7b\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                    Efficient operating point identification by scaling the blown film extrusion process                <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        To counteract the fluctuating material quality of post\u2011consumer recyclates (PCR) in production, film manufacturers are currently forced to run extensive test campaigns on large\u2011scale lines to maintain product and process stability, at extremely high cost. It would therefore be highly attractive to identify robust operating windows on smaller laboratory lines instead of on full\u2011scale production equipment. In the \u201cBlownUp\u201d project, launched in November 2025, IKV is developing a practical scale\u2011up protocol that enables efficient identification of stable processing conditions for PCR in blown film extrusion.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/24300N.jpg\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/24300N-748x499.jpg 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/24300N-1536x1024.jpg 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/24300N-768x512.jpg 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"1024\" alt=\"24300N\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: In the BlownUp project, a strategy is being developed to enable reliable scale\u2011up between different line scales in blown film production.<\/figcaption><\/figure>\n\n\n<p class=\"wp-block-paragraph\">Since laboratory\u2011 or pilot\u2011scale processes behave differently from full\u2011scale production, these discrepancies are first quantified in terms of machine and line settings as well as characteristic film properties. To represent the processing of PCR, model recyclates are produced whose composition reflects that of a typical film packaging structure. A defined degradation state is adjusted by repeated compounding, and the resulting material damage is evaluated on the basis of shear and extensional viscosity measurements.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Trials are conducted on three different line scales. First, two defined film products made from the model recyclate are produced on an industrial line (500 kg\/h) at an IKV partner company, recording machine settings and monitoring resulting process parameters. From these data, dimensionless similarity numbers are derived. In parallel, a mini blown film line (4 kg\/h) is designed, engineered and built, on which the influence of individual process variables is quantified by means of a statistical design of experiments. The die geometry is determined through a combination of analytical calculations and numerical simulation. Drawing on the first two series of experiments, the most influential figures are identified and used to construct the scale\u2011up model, which is subsequently validated on a laboratory blown film line with a throughput of 50 kg\/h.<\/p>\n\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the BMWE for funding the IGF project (funding code 24300 N) and the project partners for their cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 01.11.2025 &#8211; 31.10.2027<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Promotion:<\/p>\n\n\n<section id=\"logo-bar-block_01326cd1372b23193cadb1378dcb3647\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png 500w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo-335x335.png 335w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"500\" height=\"500\" alt=\"BMWE-Logo\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>In order to be able to compensate for the fluctuating material qualities of post-consumer recyclates (PCR) in production, film manufacturers have to carry out extensive series of tests on large systems to stabilize quality and processes in production, which is extremely costly. It would therefore be advantageous to be able to use a smaller laboratory facility instead of the production facility to identify the stable process points. In the &#8220;BlownUp&#8221; project, IKV has been developing a scale-up regulation for efficient process point identification for the processing of PCR in blown film extrusion since November 2025.<\/p>\n","protected":false},"featured_media":12407,"parent":0,"template":"","tags":[1521,885,993,1168,1522],"research_fields":[856],"class_list":["post-12439","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-blown-film","tag-extrusion-en","tag-filmextrusion-en","tag-process-parameters","tag-process-point-identification","research_fields-extrusion-en"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>BlownUp | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"To counteract the fluctuating material quality of post\u2011consumer recyclates (PCR) in production, film manufacturers are currently forced to run extensive test campaigns on large\u2011scale lines to maintain product and process stability, at extremely high cost. It would therefore be highly attractive to identify robust operating windows on smaller laboratory lines instead of on full\u2011scale production equipment. In the \u201cBlownUp\u201d project, launched in November 2025, IKV is developing a practical scale\u2011up protocol that enables efficient identification of stable processing conditions for PCR in blown film extrusion.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ikv-aachen.de\/en\/rp\/blownup\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"BlownUp | IKV-Aachen\" \/>\n<meta property=\"og:description\" content=\"To counteract the fluctuating material quality of post\u2011consumer recyclates (PCR) in production, film manufacturers are currently forced to run extensive test campaigns on large\u2011scale lines to maintain product and process stability, at extremely high cost. 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In the \u201cBlownUp\u201d project, launched in November 2025, IKV is developing a practical scale\u2011up protocol that enables efficient identification of stable processing conditions for PCR in blown film extrusion.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/ikv-aachen.de\/en\/rp\/blownup\/\" \/>\n<meta property=\"og:site_name\" content=\"IKV-Aachen\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/profile.php?id=523026911193540&amp;_rdr\" \/>\n<meta property=\"article:modified_time\" content=\"2026-05-12T13:56:56+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/24300N.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1800\" \/>\n\t<meta property=\"og:image:height\" content=\"1200\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Estimated reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/blownup\\\/\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/blownup\\\/\",\"name\":\"BlownUp | IKV-Aachen\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/blownup\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/blownup\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2026\\\/04\\\/24300N.jpg\",\"datePublished\":\"2026-05-11T10:30:42+00:00\",\"dateModified\":\"2026-05-12T13:56:56+00:00\",\"description\":\"To counteract the fluctuating material quality of post\u2011consumer recyclates (PCR) in production, film manufacturers are currently forced to run extensive test campaigns on large\u2011scale lines to maintain product and process stability, at extremely high cost. 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