Blown Film Extrusion: Complete Training Programme, Parts 1–9

Online PE Blown Film Extrusion Courses for Production Teams

Rolbatch Academy offers a nine-part online training programme covering the complete PE blown film extrusion process — from raw materials and extrusion line construction to process optimisation, multilayer films, recycling and production economics.

The programme is designed for blown film line operators, process engineers, technologists, quality specialists, maintenance teams, production managers and company owners. Each course can be taken separately, or the nine parts can be combined into a structured learning path.

The Rolbatch Academy collection also includes a separate management programme on improving EBITDA in blown film production and technical books for plastics industry professionals.

• Browse the Blown Film Extrusion courses and available language versions
• Explore the ROLBATCH Executive programme for management
• Browse technical books on blown film extrusion

What Does the Training Programme Cover?

The nine courses explain how raw materials, machinery, process settings and operator decisions affect bubble stability, film thickness, mechanical properties, optical quality, production waste and manufacturing costs.

The programme follows the same sequence as the production process: understanding the fundamentals, selecting raw materials, operating the extrusion line, diagnosing problems, implementing advanced technologies and evaluating production economics.

The Nine-Part Blown Film Extrusion Course Series

Part 1: Introduction to Blown Film Extrusion – BLFIL-P1-1001

Understand the complete PE blown film extrusion process, from raw material plasticisation and film bubble formation to cooling, collapsing and winding. This course provides the foundation for all the subsequent parts of the programme.

Part 2: Raw Materials, Rheology and Additives in PE Film Production – BLFIL-P2-1002

Learn how LDPE, LLDPE, mLLDPE, MDPE and HDPE behave during blown film extrusion. The course explains how polymer rheology, additives, regrind and recycled materials influence bubble stability, film quality and processing conditions.

Part 3: Construction of Blown Film Extrusion Lines – BLFIL-P3-1003

Explore the construction and operation of the extruder, screw, die head, filtration system, air ring, cooling system, bubble-stabilising equipment, collapsing unit and winder. Understand how every component affects the process and the finished film.

Part 4: Process Optimisation and Diagnosis of Common Film Defects – BLFIL-P4-1004

Learn how to identify the causes of bubble instability, uneven film thickness, surface defects, wrinkles, film blocking and winding problems. The course introduces a methodical approach based on identifying the symptom, finding its cause, applying the correct adjustment and preventing recurrence.

Part 5: Supporting Technologies in Film Production – BLFIL-P5-1005

Understand the role of gravimetric dosing, film thickness measurement, IBC systems, melt filtration, corona treatment and automatic process control. Learn how these technologies can improve repeatability, process stability and product quality.

Part 6: Shrink Film and Stretch Hood Production – BLFIL-P6-1006

Discover how raw material selection, formulation and extrusion parameters affect the production of shrink film and Stretch Hood film. The course connects process conditions with shrink performance, mechanical strength, elasticity and application requirements.

Part 7: Multilayer Technologies in PE Film Production – BLFIL-P7-1007

Learn how multilayer blown films are designed and produced. The course explains layer functions, coextrusion principles, material selection, layer ratios and the relationship between film structure, processing stability, performance and cost.

Part 8: Film Production from Recycled Materials and In-House Recycling – BLFIL-P8-1008

Learn how to assess regrind and recycled PE, develop suitable blends and control variations in secondary raw materials. The course also covers the reuse of in-house production waste and the design of films with recyclability in mind.

Part 9: Economics and Cost Analysis of PE Film Production – BLFIL-P9-1009

Understand how raw material consumption, film thickness, scrap, start-ups, changeovers, energy use, labour and equipment efficiency affect the cost per kilogram of film. Learn how technical production decisions influence margin and profitability.

Which Course Should You Start With?

If you are new to blown film extrusion or want to create a shared technical foundation for your team, start with Part 1.

Parts 2–4 are particularly valuable for teams working with raw materials, process settings, production instability and recurring film defects.

Parts 5–8 cover more advanced production systems, specialist films, multilayer technologies and recycled materials.

Part 9 is intended for people who need to connect production decisions with manufacturing costs and profitability.

You do not have to purchase the complete series. Each course is a self-contained training programme and can be selected according to your current production needs.

ROLBATCH Executive Programme for Management

ROLBATCH Executive: How to Increase EBITDA in Blown Film Production – RBX-01 is a separate management programme for company owners, board members, CEOs, COOs, CFOs, plant directors and production managers.

It explains how raw material use, scrap, overthick film, process instability, changeovers, energy consumption, team organisation, KPIs and investment decisions affect margin and EBITDA.

This is a management programme rather than an operator training course. Its purpose is to connect technical production decisions with the financial performance of the plant.

Technical Books on Blown Film Extrusion

The Rolbatch Academy technical book collection provides practical reference material on PE film production, process optimisation, bubble stability and troubleshooting.

The books can be read as structured technical guides or used to check the possible causes of a specific production problem. Available editions, formats and language versions are shown in the book collection.

Training Format and Certificates

The courses include structured PDF materials as well as video or audio explanations for selected topics. Participants can learn at their own pace and return to the material during the access period.

Individual product pages provide current information about:

• course content and learning outcomes;
• access duration;
• available language versions;
• quizzes, certificates and diplomas;
• individual and group participation.

Certificate and diploma conditions are explained in the Rolbatch Academy training FAQ.

About the Author

The programme and technical books were developed by Dr Magdalena Laabs, a SIMP-certified technical expert in materials engineering and in machinery and plastics processing.

The training draws on more than 20 years of international industry experience, work in more than 12 countries and involvement in more than 200 technology implementations.

The material combines knowledge of polymers, machinery, process engineering, quality control and production economics. Its focus is on practical relationships that can be observed and applied in industrial film production.

Frequently Asked Questions

Do I have to start with Part 1?

No. Every course can be taken separately. Part 1 is recommended for new employees and teams that first need a shared understanding of the complete blown film extrusion process.

Can I choose only the course related to my current production problem?

Yes. You can select an individual course on raw materials, machinery, troubleshooting, multilayer films, recycled materials or production costs.

Are the courses suitable for company teams?

Yes. The programme can be used for individual learning, onboarding new employees and developing the knowledge of production teams. Group options are available on request.

Are different language versions available?

The available language versions are listed on the individual product pages. Additional language versions can be discussed for company groups.

Do participants receive certificates?

Certificate and diploma options are available. The applicable completion requirements are explained in the training FAQ.

Continue Learning

• Browse all Blown Film Extrusion courses and resources
• Explore technical books on film production
• Read technical articles on the Rolbatch Academy blog
• Learn more about Dr Magdalena Laabs
• Read the Rolbatch Academy training FAQ
• Contact Rolbatch Academy

Choose the course that matches your current production challenge, or contact Rolbatch Academy for help selecting a suitable learning path for your team.

Have questions? Not sure which course to start with?

Contact us – we’ll be happy to help you choose the best course for your needs!

Gain practical knowledge and develop your skills in plastic processing!

Check out the full course list and start learning today