A machine manufacturer is expanding its wide program of cast and blown film lines with a system for water-quenched blown film extrusion. This provides a unique system portfolio for the production of flexible packaging. The article presents these extrusion processes, their specific characteristics and the resulting application areas. 

Blasfolienextrusion

Kunststoff-Verpackungsmaschine

Flachfolien- und Plattenextrusion

Folien

Medizintechnik

Film Production: System Options for Wafer-Thin Protection 

There is little doubt where we are heading: multilayer packaging will have to become easier to recycle – but what does that mean for the technology? And what solutions will the market need and accept? Manufacturers of branded goods are not the only ones who will have to rethink their specifications.

How Film Packaging Will Have to Develop

Verpackungsmaterial

Logistik

Klotz, Karlhorst, Dr.

Verpackungsanlagen

Coilhandling

Recycling

Umweltmanagement

Flachfolienanlagen

Kunststoffverarbeitung: Maschinen und Komponenten

Extrusionsanlagen

Nachhaltigkeit

Sondermaschinen

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Kunststoff-Recycling

Kunststoffverarbeitung: Verfahren

Kunststoff-Aufbereitung

Europe Needs to Catch up

Brückner Maschinenbau has placed an order with Coperion for more than 50 ZSK Mc18 twin screw extruders.

 Plastic film stretching line from Brückner Maschinenbau, in which ZSK extruders from Coperion take over the melting of the compounds

16:9

Folienreckanlagen

Brückner Maschinenbau Places Major Order with Coperion

Desire for hygiene and food safety increase worldwide demand for flexible packaging films.

Plant of Brückner Maschinenbau in Siegsdorf, Germany

Extrusion

Unternehmen

kunststoffe.de

KU-Verarbeitungsmaschinen allgemein

Kunststoffverarbeitungsmaschinen

 Brückner Maschinenbau to Increase Order Intake Significantly in 2020

A new method for foam extrusion combines the advantages of physical and chemical blowing agents. Solid carbon dioxide (dry ice) pressed into pellets is used as blowing agent that is added via the extruder hopper. The foaming method, which is simple to retrofit, provides a good entry-level solution to foam extrusion. 

Foam Extrusion with Dry Ice as Blowing Agent 

Icy Foaming  

Since the recent market trend is gradually growing more in favour of synthetic components than bituminous ones, Amut S.p.A., Novara, Italy, now offers extrusion lines producing waterproofing membranes capable to process different thermoplastic materials, such as F/PVC, TPO, TPE in a single step. The use of these materials improves the technical performances and the physical features of the membrane, complying with international standards and requirements in the civil works sector. 

Multi-Layer Membrane Production in One Step 

Thermoplaste

Polyvinylchlorid

Extrusion Lines for Waterproofing Membranes 

In 2013, Reifenhäuser introduced the high-performance extrusion lines for PET thermoforming sheets with the patented mechatronic polishing stacks of the MIREX-MT-V design series. Now Reifenhäuser introduces the next generation of this line type. 

Reifenhäuser Combines Improved Components 

Industrie 4.0

Polyethylenterephthalat

Extrusionswerkzeuge

New Generation of PET Thermoforming Sheet Lines 

Like plastics manufacturing and processing, the recycling of plastic products requires specialization to be efficient. Accordingly, a Dutch company has dedicated itself entirely to the recycling of agricultural and packaging films ¿ and invested in a machine technology, which was found along tortuous ways. 

Technical Answers to World Political Changes in Film Recycling 

Schmelzefilter

Sortierer

From Waste Collector to the  Plastic Recycler 

The Chinese global film supplier invests in two 7-m sequential film stretching lines for the production of BOPA films. 

Xiamen Changsu orders production line for BOPA film 

Brückner delivers sequential film stretching lines 

Pregis, a global manufacturer of protective and flexible packaging solutions, has joined the Flexible Packaging Association.

Pregis, a new member of the Flexible Packaging Association (FPA), is a global manufacturer of protective and flexible packaging solutions

Verbände, Institutionen, Messen

Dienstleistungen

Verpackungstechnik

Pregis Joins the Flexible Packaging Association

The demands placed on packaging films are so multifaceted that they can only be met by combining different raw material components. This in turn requires blown film dies that are able to process a wide range of materials and thus provide greater flexibility for the film manufacturer. 

Barrier Film: Nine Super-Thin Layers 

Jointly organized by the Institut für Produkt Engineering (IPE) and Hanser Publishers on March 12–13 in Duisburg, Germany, and with well over 100 participants, the conference was a great success. The participants enjoyed highly topical subjects, top-class speakers, and lively discussions hosted by Professor Johannes Wortberg. 

Simulation Verpackung

Duisburg Extrusion Conference: The Versatility of Films 

It was not only the 5-layer coextrusion blown film system itself that attracted around 100 visitors to the plant of Kuhne GmbH, in St. Augustin, Germany, at the beginning of April, but also the manner in which it was presented. Over a period of two weeks, the machinery manufacturer gave visitors the opportunity to participate in the first test and production runs of the 20 m high system, which stood completely assembled in the technical center. 

Blown Film Extrusion: Saint Augustin Displays Greatness 

About 20 percent of the 50,000 metric tons annual sheet output of the Danish company R. Færch Plast A/S in Holstebro will come from a new high-performance PP production line supplied by Battenfeld Extrusionstechnik GmbH in Bad Oeynhausen, Germany. For the continuously growing market for rigid foodstuffs packaging, Færch Plast operates a total of seven extrusion lines – mainly for PET, PP and PS film. Three of the lines come from Germany, and a fourth line has been ordered. Both the first and the second PET line, which was installed in 2002, work with a co-rotating twin-screw extruder. Thanks to effective melt degassing, high-quality sheet can be produced without material pre-drying. Battenfeld Extrusionstechnik accepted overall responsibility for both lines, so that the Færch Plast plant comes from a single source. According to Battenfeld, this kind of cooperation is also beneficial for the further development of machine components for the high-output flat sheet line with high-speed extruders. Færch was the first processor to decide for the installation of such a modern line. The high-speed BEX 1-75-34 is a comparatively small single-screw extruder but has an enormous output. With a screw speed of 1,500rpm, the machine has a three times higher output than a comparable conventional extruder of the same size. By means of adapted downstream equipment and a 75mm extruder, the line achieves an output of 1,400 kg/h when producing PP film. 

Lines from a Single Source 

Extrusion lines 

Use of renewable resources is currently being actively researched. Before they can be used, the environmental compatibility, economic aspects and social impact over the entire life cycle, including production and disposal, must be investigated. If the results are not positive, there are alternatives that do not rely on biomass, since innovative petrochemical plastic products are saving enormous amounts of energy and thus lowering CO2 emissions already today – and the potential is not yet exhausted. 

Kunststoffe, bioabbaubar

An Eco-Efficiency Evaluation: Bio – Sense or Nonsense 

Special Requirements of Jam and Roof Tiles

Beumer Group packs a wide variety of goods using its stretch hood lines and films that are often custom-made. Safely and economically.

Humid beverage cartons that must not be subjected to mold under the packaging film, stacked roof tiles that should not break on the loading area of a truck in case of heavy braking, and expensive articles that must not be removed from the packaging unnoticed – how can all three of these shipments be packaged safely and economically at the same time? Beumer Group supplies individual solutions for almost every task.

“For our customers, it is often not just a matter of packaging goods simply to protect them from environmental influences”, says Jörg Spiekermann, sales manager for palletizing and packaging systems in the Consumer Goods area of Beumer Group. Especially in his business sector the requirements are often very different – and above all demanding. Thus it must be possible to transport the packed stacks safely on the loading space of a truck, preventing them from slipping and being damaged due to sudden steering moves or hard braking. This is especially concerning for transported goods such as glass, stone or roof tiles. Companies often use the stretch wrapping process and this is because of the significantly lower initial investment for the machines compared to stretch hood systems. However the stretch wrapping process presents some disadvantages. “Stretch wrapped film’s elasticity allows to solidify the palletized goods during packaging, but only provides little vertical tension force to the load,” explains Spiekermann. “But it is exactly this vertical tension force that is responsible to provide stability for the transportation loads. This technique is not suited for materials with sharp edges, such as bricks”.

The Highly Elastic Stretch Hood Adapts to Any Shape

With stretch hooding Beumer Group offers an efficient possibility, even for difficult cases. The high-capacity packaging system: Beumer stretch hood A, covers the palletized load units with a highly elastic stretch hood. In the consumer goods sector, these can be bricks or glass items but also boxes of detergents, buckets of paint or packages stacked in a chaotic way. During transshipment and outside storage, merchandise is protected reliably against environmental influences such as sunlight, dirt and humidity. Owners can transport the products in a perfect state to the customers. The stretch film fits every stack. Similar to stretch wrapping, the film is very elastic and reinforces the material both by the horizontal and vertical restoring forces. Thus, this process offers a considerably higher load stability. “We can prove that,” promises Spiekermann. In order to prevent the goods from detaching from the palletized unit in case of determined loads, the system provider together with Dekra, the world’s leading expert organization for safety, quality and environmental protection, have performed different driving tests under extreme conditions.

In Stretch Wrapping, the Forces Act Mainly Horizontally

Spiekermann remembers a customer who had to stack filled jam glasses directly from production on pallets and pack them securely. The challenge: the glasses were not in cardboard boxes, which would be easy to pack, but in trays. Reusable sheets were placed between the glasses for protection. Thus the easily fragile goods were stacked up to two meters high. The customer first thought about the stretch wrapping process. “However, the film force acts on the whole stack. The glasses would be pressed together and could get damaged,” says Spiekermann. “Our stretch hooding makes sure that film and stack form one unit”. But what happens if the stack is tilted up to 27° during the loading process? This was the first requirement of the manufacturer. “We are able to fulfil this request,” says the expert. “This was done by packing the stack with two thick film hoods, which also meant both more time and materials”. Since it is not only a matter of load securing, but also of economic efficiency, the Beumer team together with the customer performed various tests and developed a solution in which the stack can tilt safely up to 14°; this was absolutely sufficient for the user.

Success also Depends on the Choice of the Right Film

“We perform these packaging tests in our own test center until we achieve the required result,” says Spiekermann. The film plays a major role. The experts in Beckum have about 100 different types of test films with different characteristics – thick, thin, soft, tough or even completely different. “If we are not able to meet the requirements, we contact the film manufacturers,” says the Beumer expert. The decisive factor is: What kind of product are we handling with, which are the dimensions and the requirements to the packaging? The film manufacturer finds the ideal formulation for the required characteristics and suggests the optimum film format. The customers are often present during these trials, which clearly strengthens their trust in us,” Spiekermann has noticed.

From hoses and cable reels to randomly stacked packages – time and again, companies approach the system provider with tricky packaging issues. And in most cases, the customers had previously used the stretch wrapping process, but could not solve the task in a satisfying way. This was the case, for example, with a Dutch company which sells Christmas items, and also with a Swedish furniture manufacturer. In both cases packages of different dimensions are stacked on pallets. “This looks terrible and is very unstable at first,” says Spiekermann. “But this is exactly how the stacks have to reach the customers. As every package has a different weight, the weight of the loaded pallets can vary between 100 kilograms and two tons. The Beumer stretch hood A is equipped with a measuring system in order to measure such complex stacks by means of laser and ultrasound. The machine recognizes the highest points and adapts the film length accordingly. Depending on the application, the Group also relies on dual-format machines in order to work with different film sizes or film variants. The machine itself recognizes the respective pallet size and choses the suitable film.

Spiekermann uses the following examples to illustrate how various the requirements to a film can be: If roof tiles are stored outside and are not protected against humidity, moss can grow on the surface relatively quickly. Therefore they have to be packed. However, the corners and edges of the roof tiles are often razor-sharp. “Before starting the packaging process, the film is first overstretched. If it then shrinks around the stack, holes can develop at these sharp points,” says the sales manager. “So, together with a manufacturer, we have developed a puncture-resistant film”. But sometimes the films shall have holes which enable the escape of humidity from the packed stacks – as in the case with a sparkling wine producer. “The bottles come from the filling system. Some of them are moist and are packed in cardboard boxes. If there is an air-tight stretch hood over the stack, the humidity remains in the packaging. Mold can develop so quickly,” describes the expert. Moisture also occurs when the filled bottles stacked on the pallet are exposed to extreme heat, caused for example by sunlight during transport. “Together with the manufacturer we have developed a film with very small holes distributed on the whole film,” says Spiekermann.

It happened with some customers that goods kept disappearing on their way from picking to the warehouse until they arrived at the customers’ premises without being noticed. With the stretch wrapping process, someone can easily reach into the opening of the packaging from above and take a drilling machine or a toolbox, for example, without destroying the film. This was the case with a manufacturer of power tools. Also at a drugstore chain, not quite inexpensive products repeatedly disappeared in this way. The losses could amount to up to four per cent of the turnover. “The moment the companies started using our stretch hooding process, this problem was solved,” reports Spiekermann. “Because without destroying the film, no one can take anything out of the packaging”.

As important as the protection of the goods is during packaging, the solution must always be profitable for the owner in the end. It’s like the jam manufacturer. “We can calculate exactly how much film our customer can save with the stretch hooding process compared to the stretch wrapping process,” explains Spiekermann. In addition: how often does the film roll have to be changed in a shift? Because that also means time. How economical a changeover can be is shown by the example of a logistics company that handles distribution for various customers. In order to pack the large number of palletized stacks, twelve stretch wrapping machines were in use. “The stacks had to be driven on the machine, the film was fastened to the pallet, the packaging process was initiated, the film was cut off and the stack was finally driven to the forwarding department. “That was about 1000 pallets a day. About three minutes were necessary to have each pallet packed,” Spiekermann explains. Beumer Group replaced the twelve machines by one stretch hood system – and the logistics provider could save up to 3000 working minutes per day.

Not quite Trivial: Covering Bath Tubes with a Film

“Of course we cannot package everything with a stretch hood,” says the sales manager and remembers a customer, who wanted to cover bath tubes with a film. These products were simply too large for our procedure”. It was possible, but finally too complex and therefore too expensive. “But, we are able to find a suitable solution for most special applications. For our customers we are definitely the problem solvers, who also answer very specific packaging questions very confidently”.

Beumer Group GmbH & Co. KG  

https://www.beumer.com

Stretch hood lines are initially more expensive than stretch wrapping lines. However, they offer an advantage for many tasks

According to the company, the easy, intuitive and reliable operation of the new Beumer stretch hood A is especially appealing to customers

Before starting the packaging process, the film is first overstretched, then it shrinks around the stack

Jörg Spiekermann, sales manager for palletizing and packaging systems in the Consumer Goods area of Beumer Group: “We perform packaging tests in our own test center until we achieve the required result”

2021-06-23 Beumer EN

Schneid- und Wickelmaschinen für Folien

issue 04/2022

issue 03/2022

issue 02/2022

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