Single‑Layer vs ABA Co‑extrusion Blown Film Machine: Which Saves More Cost?
1.Introducing
You run a plastic film factory. You want to produce high‑quality film. But you also need to control your production costs. Choosing the right blown film machine is one of the most important decisions you will make.
Two main options exist: the single layer blown film machine and the ABA co‑extrusion blown film machine (also called a 3 layer blown film machine). Each has its own strengths. Each fits different production needs.
Which one saves you more money in the long run? The answer depends on your product type, your raw material strategy, and your production volume.
In this guide, I compare these two technologies side by side. You will learn how they work, their cost differences, and which one fits your factory best.
2.What Is a Single Layer Blown Film Machine?
A single layer blown film machine uses one extruder. It melts plastic pellets and pushes the molten material through a die head. The machine blows air into the molten tube to form a bubble. After cooling, the machine flattens the bubble and winds it into film rolls.
This machine produces film with one uniform layer. The entire film uses the same material throughout. You cannot put different materials in different layers.
2.1 Key features of a single layer blown film machine:
- Lower machine cost
- Simpler operation
- Less floor space required
- Lower electricity consumption
- Ideal for thinner films (7–20 microns)
- Uses 100% virgin material or limited recycled content
A single layer blown film machine works well for fruit bags, vegetable bags, and other products that use mainly virgin materials. It remains the most common type for general bag production.
3.What Is an ABA Co‑extrusion Blown Film Machine?
An ABA co‑extrusion blown film machine uses two extruders to produce a three‑layer film with an A‑B‑A structure. The two outer layers (A) come from one extruder. The middle layer (B) comes from the second extruder.
The outer layers (A) use virgin resin. This gives the film a smooth, shiny surface and good printability. The middle layer (B) can use recycled materials, calcium carbonate (CaCO₃), or other low‑cost fillers.
The ABA structure gives you the "best of both worlds." You get a high‑quality surface. You also get significant material cost savings.
3.1 Key features of an ABA blown film machine:
- Two extruders, three layers (A‑B‑A)
- Up to 75% recycled material in the middle layer
- Film is 30% stronger than single‑layer film of the same thickness
- Virgin material only on thin outer layers
- Suitable for thicker films (20–100 microns)
- Higher machine cost but lower raw material cost
An ABA film blowing machine is ideal for garbage bags, shopping bags, and T‑shirt bags that require higher strength.mers from different industries
4.Key Differences: Side‑by‑Side Comparison
| Feature | Single Layer Machine | ABA Machine |
| Number of extruders | 1 | 2 (A extruder + B extruder) |
| Film layers | 1 layer | 3 layers (A‑B‑A) |
| Machine cost | Lower | Higher |
| Raw material cost | Higher (virgin material for 100% of volume) | Lower (virgin material only for thin outer layers) |
| Recycled material usage | Limited to low percentages | Up to 75% in middle layer |
| Film strength | Standard strength | 30% stronger than single‑layer |
| Typical applications | Fruit bags, vegetable bags, thinner films | Garbage bags, shopping bags, T‑shirt bags (20–100 microns) |
| Operation | Simpler | More complex but versatile |
| Floor space | Less | More |
5.Cost Analysis: Which Machine Saves More Money?
A single layer blown film machine costs less upfront. It has one extruder, one screw, and fewer components. This makes it more affordable for small factories or startups.
An ABA co‑extrusion blown film machine costs more initially. You pay for two extruders and a specialized die head. However, the extra investment often pays back quickly through material savings.
This is where the biggest difference appears.
A single layer blown film machine uses 100% virgin resin (or limited recycled content). You pay full market price for every kilogram of film you produce.
An ABA blown film machine uses virgin resin only on the two thin outer layers. These layers make up a small percentage of the total film volume. The thick middle layer can contain up to 75% recycled material, CaCO₃, or other low‑cost fillers.
- ABA machines can reduce virgin material usage by 20–30% or more
- Many producers report material cost savings of 30% or more compared to single‑layer production
- In some markets, producers are replacing mono‑layer extruders with ABA machines specifically to save production costs
"Virgin material is applied mainly on the outer (A‑A) layers which is relatively a small percentage of the film composition. The middle layer, on the other hand, can apply a higher percentage of recycled materials to reduce production costs."
A single layer blown film machine consumes less electricity. It has one extruder motor and fewer heating zones.
An ABA blown film machine uses more electricity because it has two extruders. However, the extra energy cost is often offset by material savings. For high‑volume production, the material savings far outweigh the additional electricity cost.
Total Cost of Ownership
| Cost Factor | Single Layer | ABA Machine |
| Machine investment | Lower | Higher |
| Raw material cost | Higher (100% virgin) | Lower (20–30% savings) |
| Energy cost | Lower | Higher |
| Maintenance cost | Lower (one extruder) | Higher (two extruders) |
| Total cost (long‑term) | Higher for thick films | Lower for thick films, high volume |
6.When to Choose Each Machine
6.1 Choose a Single Layer Blown Film Machine If:
- You produce thin films (7–20 microns)
- You make fruit bags, vegetable bags, or produce bags
- You mainly use virgin materials
- You have a limited budget
- You have limited factory space
- You want simple operation with minimal training
A t shirt plastic bag machine single or a t shirt plastic die cut bag machine single are common examples of single layer configurations for high‑volume T‑shirt bag production.
6.2 Choose an ABA Blown Film Machine If:
- You produce thicker films (20–100 microns)
- You make garbage bags, shopping bags, or heavy‑duty sacks
- You want to use recycled materials or CaCO₃ to reduce costs
- You need 30% stronger film at the same thickness
- You run high‑volume production where material savings add up quickly
Many plastic bag and pouch making machine manufacturers in China now offer ABA configurations because of growing demand from cost‑conscious buyers.
7.Application Examples: Three Types of Bags
- Single layer: Works for thinner T‑shirt bags using virgin HDPE
- ABA machine: Saves 20–30% material cost using recycled material in the middle layer. The outer layers stay smooth and printable
- Recommendation: ABA is becoming the new standard, especially in competitive markets
- Single layer: Limited recycled content, higher material cost
- ABA machine: Uses high percentages of recycled material and CaCO₃ in the middle layer. Produces stronger, more puncture‑resistant film
- Recommendation: ABA is the industry standard for garbage bags in many markets
- Single layer: Basic bubble film production
- ABA machine: Can incorporate EVOH or other barrier materials in the middle layer. Produces stronger, more durable bubble film
- Recommendation: ABA offers more flexibility for specialty applications
8.Conclusion
Choosing between a single layer blown film machine and an ABA co‑extrusion blown film machine depends on your specific needs.
A single layer blown film machine costs less upfront. It works well for thin films and virgin material applications. It is simple to operate and maintain.
An ABA blown film machine costs more initially but saves money on raw materials. It produces stronger film. It allows you to use recycled materials and CaCO₃ in the middle layer. For thicker films and high‑volume production, the material savings quickly outweigh the higher machine cost.
Many factories in competitive markets are replacing single‑layer machines with ABA technology. If you produce garbage bags, shopping bags, or thicker T‑shirt bags, an ABA film blowing machine is likely the better long‑term investment.
Related Resources
Discover our equipment:
- [Single Layer Blown Film Machine] – Affordable solution for thin films and virgin material applications
- [3 Layer ABA Blown Film Machine] – Advanced co‑extrusion for high‑volume production
- [T‑Shirt Bag Making Machine] – Complete bag production line for retail bags
Keep learning:
- Read [What Is an ABA Blown Film Machine?] for a complete technology overview
- Compare [1300 PE Double Winding vs ABA Blown Film Machine] for more technical details
- Check out [How to Choose the Right Blown Film Machine for Your Business] for a step‑by‑step selection guide
Need Help Choosing the Right Machine?
Every factory has unique production targets and material access. Contact our engineering team for a free consultation.eers have produced countless great designs for customers from different industries
We will recommend the right machine type and model based on your actual production volume, target film width, and available material sources.
