MACHINERY | EXTRUDER DEVELOPMENTS
Right:
Italy-based Gualapack uses an Evo Ultra Flat blown film line on a laminate production plant
It is designed for the production of polyolefin films and suitable for processing post-consumer recycled (PCR) resins. The line has recently been redesigned and optimised. Some notable features include:
n A user-friendly graphical interface for the software;
n Good control of film tension and winding speed through the use of brushless motors;
n Very low thickness tolerances; and, n High production capacities. During the event, it produced a number of
products from “highly rich metallocene formula- tions”. One was a 55-micron laminated film, with a 2300 layflat width, produced at 550-650 kg/h, depending on the format. The thickness tolerance was 2.5-3%.
It also made 230-micron silo bags that were 5m
in circumference – at a production rate of 650-750 kg/h, 25-micron agricultural stretch film at 400-500 kg/h, and 50-micron collation shrink film – at a rate of 700-800 kg/h. The company recently ran a series of tests on the
Polyblown five-layer POD extrusion line and managed to extrude shrink film using up to 75% PCR resin.
At the same time, the line set a new standard for
energy efficiency, says Colines. With a recorded energy consumption of 0.32-0.38 kWh/kg, it claimed to outperform other available options on the market – reducing both operational costs and carbon footprint.
Five-layer line Reifenhäuser of Germany has developed a new five-layer cast polypropylene (CPP) line that will be ready for delivery in March next year. The line claims to deliver “outstanding perfor- mance and high-quality CPP film” with a relatively short lead time. It includes five single-screw extruders, has an output of 1200 kg/h and a net film width on the winder of up to 3300mm. It
28 FILM & SHEET EXTRUSION | October 2023
includes the company’s patented five-layer Reicofeed Professional feedblock, enabling precise adjustment of each layer in-line during production. The line is built with energy-efficient compo-
nents, helping to minimise power consumption and overall environmental footprint. In addition, thickness regulation and product changes are performed automatically by PAM adjustment. This further reduces energy consumption for the hot part by 99.9%, it says, and cuts material waste compared to thermobolt systems. The company has also won a number of recent
contracts to supply its Evo Ultra Flat blown film line. Evo Ultra Flat is the flattening device that improves film flatness, which eliminates bagginess, curling and film camber thanks to four thermo-controlled rolls and a stretching unit. In one instance, it has supplied a line to Italy- based Gualapack at its laminate production plant in Piacenza. “Ultra Flat will allow us to improve the efficiency
of the next converting process and the final quality of our products,” said Nicola Zancan, global technology innovation & operational excellence director of Gualapack At the same time, Jordan-based Jafra Plastic Industries has taken delivery of a similar system – which will produce technical films, lamination film, collation shrink-wrap, flexible packaging and barrier film for local markets and the Middle East region. The system is integrated directly into the take-off
to produce flat film. This helps to speed up later printing and lamination, and saves adhesive and printing ink. This makes film production faster, cheaper and
more sustainable – and leads to end products with better visual appearance. “We chose the Ultra Flat technology because it
provides the best film quality that will save costs on many levels,” said Naji Abu Shehab, managing director of Jafra Plastics Industries.
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IMAGE: REIFENHAUSER
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