BLOWN FILM DIES | MACHINERY


Recent developments to raise product quality include a modular calibration basket, an air ring for form- fill-seal (FFS) film and multi-layer dies to make barrier film at high speed


Boosting blown film quality


Blown film dies – and associated equipment – help to ensure that polymer formulations are converted into film of the highest possible quality. Packaging major Smurfit Westrock recently show- cased a new series of Evo Ultra die heads from Reifenhäuser at an open house event in Spain. The new dies are designed for barrier film


production exceeding 1,000 kg/h on blown film lines. A highlight of the event was the output of over 1,000 kg/h for barrier applications, delivering films with properties including a profile accuracy of better than ±3% at a thickness of 70 microns. This helps to ensure that the thickness of the expensive EVOH barrier layer is closely controlled – which minimises material costs. The final film is recyclable, because the EVOH content is below 5%. To ensure the film’s high tolerance – even at high


throughput rates – the line combines the new Evo Ultra die head with the matched internal bubble cooling system Evo Cool and Kdesign cooling ring technology. Smurfit also used Reifenhäuser’s Ultra Flat System, ensuring perfectly flat film for easy further processing. “The results of the new seven-layer blown film line with the Evo Ultra Die 7 exceeded our expectations,” said Pascual Martínez Pérez, managing director of Smurfit Westrock Spain. “No other supplier achieves the nominal outputs we have achieved.” Smurfit Westrock was able to test and optimise the die and extruder technology in advance, at Reifenhäuser’s technical centre. With the new line, it now operates a three Reifenhäuser blown film


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lines at this location, further expanding its capacity. At the same time, it says the new die heads set new benchmarks in productivity without compromising quality or stability. “The film quality is exceptional,” said Martínez


Pérez. “In addition to tolerance values, its consist- ency, clarity and strength are outstanding, enabling us to meet and even exceed our customers’ requirements.” On the new line, which began production earlier


this year, Smurfit Westrock produces seven-layer films with barrier properties that are used – among other things – for ‘bag-in-box’ packaging. This is a sturdy cardboard box containing a plastic bag filled with liquid. A spout allows the beverage to be dispensed and prevents oxygen from entering. If required, production can be quickly switched


from seven-layer film to five- or three-layer film. Despite the large geometry and high volume of the die head, fast changeover times are ensured thanks to its maintenance-friendly design, says Reifenhäuser. Bernd Reifenhäuser, CEO of Reifenhäuser,


added: “The competitive edge is about more than technology. Every major step we’ve taken in this partnership started with one question: what creates the greatest value for Smurfit Westrock? This demonstration is a perfect example.” At Chinaplas recently, Reifenhäuser subsidiary Kdesign showed a number of related technologies – including its Karat cooling ring, which combines maximum cooling performance, minimal film tolerances and user-friendly operation. With an out- put increase of up to 50% higher than that of


May/June 2026 | FILM & SHEET EXTRUSION 33


Main image: Smurfit Westrock is using Evo Ultra Die 7 heads from Reifenhäuser to make barrier film


IMAGE: REIFENHÄUSER


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