How Is Bubble Wrap Manufactured?

Plastic Resin Is Melted

Pea-sized, plastic resin beads are fed into an extruder. An extruder is a cylindrical machine with a long screw inside of it. This screw turns rapidly, building up heat which melts the plastic resin beads into liquid form. An encapsulated air retention barrier is applied during the extrusion stage. The exact procedure for this is a trade secret of Bubble Wrap's manufacturer, Sealed Air Corporation and, therefore, is not public knowledge.

Plastic Film Is Formed

The liquefied plastic is squeezed out of the extruder cylinder into two, clear plastic film sheets that are stacked on top of each other.

Bubbles Are Trapped in Plastic Film Sheets

The first plastic film sheet is wrapped around a drum that has punch holes in it. Air is suctioned to draw the plastic film into the punch holes. The second plastic film sheet is laminated over the first, and when they adhere, they trap air into the punch holes to form bubbles.

Bubble Wrap Is Complete

The completed bubble wrap is ready to be used in many different applications.

Recycling

Bubble Wrap is recyclable and Sealed Air Corporation has seven recycling locations across the United States. Bubble Wrap may also be accepted for recycling by local, independent recycling stations.

Resources

• Sealed Air Corp.
• www.stevens.edu