Complete Agricultural Film Lines
Mulch Film, Greenhouse Film & Silver-Black Mulch

LayerQuestar agricultural film lines are available with lay-flat widths from 1 m to 2 m. When the film tube is opened flat, this produces finished film widths of 2 m to 4 m. For greenhouse covering applications, a 2 m lay-flat machine producing 4 m wide film is the standard configuration. For mulch film, a 1–1.5 m lay-flat machine is typically used, with the mother roll subsequently slit to narrower widths (0.8 m, 1.0 m, 1.2 m) on a third-party slitting machine.

No. Silver-black mulch film requires a 3-layer ABA structure — silver LDPE on both outer surfaces and black LLDPE in the centre core. This cannot be produced on a single-layer machine because the two materials must be co-extruded simultaneously through a 3-channel die head. A 3-layer ABA machine uses two extruders: Extruder A feeds both outer silver layers (the die head splits the melt stream), and Extruder B feeds the black core layer independently. Attempting to blend silver and black masterbatch in a single extruder produces a grey film — not a functional silver-black structure.

Pre-compounding is not required. LayerQuestar agricultural film lines include a gravimetric masterbatch dosing unit at the extruder hopper. UV stabiliser concentrate (typically HALS-based, supplied as pellets) is blended directly with the base resin at the hopper in the correct ratio — usually 1–3% by weight depending on the required service life. The dosing ratio is set at the control panel and is adjustable without stopping the line. This approach is more cost-effective than pre-compounding and allows the operator to adjust UV loading for different seasonal or regional requirements.

The key differences are thickness, width and downstream handling. Greenhouse film is thick (80–200 μm) and wide (2–4 m open width) — it is wound as a single large roll and does not require slitting. Mulch film is thin (8–30 μm) and narrower — it is typically wound as a wide mother roll and then slit to finished widths. The blown film machine itself can produce both film types, but the winding system differs: greenhouse film requires a large-diameter surface winder, while mulch film production requires a mother roll winder followed by a separate slitting rewinder. The additive package also differs — greenhouse film requires anti-drip and anti-fog additives in addition to UV stabiliser.

No. PBAT and PLA blends require a dedicated machine. The processing temperature for PBAT/PLA is 130–160°C — significantly lower than the 180–220°C used for LDPE. Running PBAT on a standard LDPE screw causes thermal degradation of the material, producing discoloured film with poor mechanical properties. A dedicated screw geometry with a lower compression ratio and modified barrier section is required. LayerQuestar's biodegradable film machine is engineered specifically for PBAT/PLA blends. Full specifications are available on the dedicated Biodegradable Film Machine page.

Greenhouse film typically uses LDPE blended with EVA at 5–18% VA (vinyl acetate) content. Higher EVA content improves flexibility and IR heat retention but lowers the processing temperature window. At VA content above 12%, the screw temperature profile must be adjusted — particularly in the feed zone — to prevent premature melting and surging. LayerQuestar's agricultural film machine screws are designed to handle LDPE/EVA blends up to 18% VA content without modification. The OMRON PID temperature control system allows precise zone-by-zone temperature adjustment from the control panel.

LayerQuestar does not manufacture slitting rewinders. For mulch film production, we recommend a third-party slitting machine matched to your mother roll width and finished roll specifications. We can advise on the technical requirements — blade type, rewind tension range, finished roll diameter — and provide an introduction to slitter suppliers we have worked with on previous projects. [NEEDS CLIENT VERIFICATION — confirm whether LayerQuestar has preferred slitter partners to recommend]

Yes, with the right recycling equipment. Used agricultural film is contaminated with soil, sand and moisture — it cannot be fed directly into a blown film machine. LayerQuestar's agricultural film recycling line includes a washing stage, friction dryer and degassing extruder that produce clean PCR pellets from collected waste film. These PCR pellets can be blended into the core layer of a 3-layer ABA mulch film structure at up to 30–40% content, reducing virgin resin consumption without affecting the surface layer quality visible to the end user.

Output rate depends on screw diameter, film width and target thickness. As a general reference, a single-layer agricultural film line with a 55 mm screw produces approximately 80–120 kg/h depending on material and film thickness. Thinner film (8–12 μm) runs at lower line speed to maintain bubble stability, which limits kg/h output. Actual output for your specific configuration is confirmed during the technical proposal stage. [NEEDS CLIENT DATA — confirm specific screw diameter and output range for the agricultural film line]

Installation and commissioning for a single-layer agricultural film line typically takes 7–14 days on-site, depending on factory readiness and local electrical connection requirements. The 3-layer ABA configuration requires an additional 3–5 days for die head calibration and layer ratio optimisation. LayerQuestar provides on-site commissioning engineers and operator training as part of the standard after-sales package. Remote support via video call is available for subsequent process adjustments after the commissioning engineer has departed. [NEEDS CLIENT VERIFICATION — confirm standard commissioning timeline]