The modern thermoforming and packaging industry demands high clarity, rigid strength, and lower production costs. Reaching all three on a single-layer extruder usually means paying for 100% virgin PET resin. The TZ-machinery ABA PET three-layer co-extrusion sheet line solves this: an ABA structural sandwich lets manufacturers maximize recycled content without giving up surface finish or food-grade compliance.
1. What Is an ABA Co-Extrusion Structure?
In an ABA three-layer co-extrusion system, two extruders split the sheet into three distinct layers:
- Layer A (outer surfaces): thin, high-clarity skins made of virgin PET or functional additives.
- Layer B (core): a thick inner core – up to 70%-80% of total sheet thickness – that runs recycled PET (rPET), bottle flake, or industrial regrind.
Lower-cost or recycled polymer is encapsulated between two virgin outer shells, so the sheet keeps a pristine visual appearance and smooth sealing behaviour while resin overhead drops sharply. If your feedstock is mostly recycled flake, see which PET extrusion machine suits recycled PET for the wider selection logic.
2. Key Advantages of the TZ-machinery ABA PET Line
Significant raw material cost savings
Feeding rPET flake or factory scrap into the primary B-layer extruder cuts raw material cost substantially. The thin A-layers shield the core, hiding the colour variation and minor imperfections inherent to recycled plastic. Resin is the largest variable cost in sheet production, so this is where the payback comes from – the full model is set out in our PET sheet extrusion line investment and ROI guide.
Superior tensile strength and structural rigidity
Co-extruded sheet carries higher impact strength and tear resistance than single-layer sheet. Bonding three layers under controlled thermal conditions gives high mechanical stability, which matters for heavy-duty thermoforming and deep-draw trays.
Food-contact compliance and high visual clarity
For food packaging, fruit trays, and blister packs, safety and appearance are both non-negotiable. The virgin PET outer layers act as a clean barrier, keeping the sheet food-safe while preserving the crystal-clear transparency buyers expect from APET and PETG.
Precision temperature and melt control
Advanced melt pump metering, automatic die heads, and multi-zone temperature control hold gauge uniform across the full sheet width. Consistent gauge control minimizes thermoforming reject rates downstream.
3. Key Technical Specifications
| Caraterística | Especificação |
|---|---|
| Processed materials | APET, PETG, rPET (recycled PET flake) |
| Estrutura em camadas | ABA (surface / recycled core / surface) |
| Extruder configuration | Main extruder (core B) + side extruder (layers A) |
| Output range | 300 kg/h to 1,000+ kg/h (model dependent) |
| Espessura da folha | 0.15 mm – 1.8 mm |
| Aplicações | Thermoformed clamshells, food trays, blister packaging, folded boxes |
4. Main Applications
- Food packaging: clear hinged containers, cold drink lids, bakery trays, and produce punnets.
- Industrial and medical packaging: heavy-duty tool blisters, electronic component trays, and protective clamshells.
- Printing and folding box grade: high-clarity PET sheet for folding cartons and transparent stationery products.
5. Frequently Asked Questions
Qual é a quantidade de PET reciclado que uma linha ABA consegue processar?
O núcleo da camada B pode atingir uma espessura total da chapa de 70%-80%, pelo que a maior parte do volume da chapa pode ser constituída por flocos de rPET, flocos de garrafas ou material triturado internamente, enquanto as camadas externas virgens (A-skins) permanecem finas.
Um núcleo com elevado teor de rPET continua a cumprir as normas relativas ao contacto com alimentos?
Sim. O contacto com os alimentos é determinado pela superfície, e não pelo núcleo. As camadas A de PET virgem constituem a barreira de contacto, pelo que a folha continua a ser segura para o contacto com alimentos, mesmo com uma elevada percentagem de material reciclado no seu interior.
Que espessuras e rendimentos abrange esta linha?
Chapas de 0,15 mm a 1,8 mm, com uma capacidade de 300 kg/h a mais de 1 000 kg/h, dependendo do modelo e da configuração do parafuso.
Uma linha ABA é melhor do que uma linha de camada única?
No que diz respeito aos custos, sim: a resina é o maior custo variável, e uma linha ABA substitui a maior parte dessa resina por matéria-prima reciclada. Quanto ao desempenho, a chapa coextrudida também supera a chapa de camada única em termos de resistência ao impacto e resistência ao rasgo.
Que materiais pode processar?
Lâminas de APET, PETG e rPET. A extrusora da camada A também pode transportar aditivos funcionais, tais como masterbatch de cor ou anti-bloqueio.
Upgrade Your Extrusion Capabilities
An ABA PET co-extrusion sheet line gives high-volume producers a direct cost edge: lower resin cost per kilogram without losing clarity or structural integrity, which shortens the payback period. Review the Linha de coextrusão de chapas de três camadas ABA PET specifications, or compare a running configuration in our 800 kg/h ABA three-layer PET sheet line case. Send your target output, sheet width, and recycled content ratio for a tailored line configuration and quotation.