Global requirements for film properties are in high-quality barrier packaging applications.
As demand for barrier film is increasing, producers are demanding high production
flexibility to serve the market with different products. Reifenhäuser Blown Film develops
a highly flexible and efficient 11-layer blown film line to respond to rising performance requirements.
Thanks to the variable choice of layer structures offered producers by an 11-layer blown film line,
there is no need for the time-consuming and costly laminating step in the conversion of some products.
What’s more, the greater flexibility achieved with more layers often results in a higher overall performance
when processing polyolefins. Reifenhäuser has developed a screw design for extruders that can
effortlessly handle almost every polyolefin type and every barrier raw material without
modification of the machine.
Product changeover becomes as simple as child’s play: purging the line, changing to a new recipe and
just watching another barrier film being conveyed to the winder. In this way, also comparatively small
lot sizes of speciality film can be economically produced.
Another special feature of the 11-layer line is its innovative design. A skilful choice of an
asymmetric high-barrier structure by the producer can almost completely prevent curling of
the film without using a normally required water bath (critical with regard to hygienic
production conditions). Curling of the film edges is caused by the different speeds at which
raw materials cool down. Furthermore, the specially developed EVOLUTION Ultra Flat haul-off ensures
high winding quality and fast, smooth further processing, such as conversion, laminating and printing.
Thanks to a minimized stretching of the film via heating-cooling rolls, a perfect flatness of the web
can be achieved with this technology.
EVOLUTION haul-off units create perfectly flat film.
For an optimum distribution of the eleven layers Reifenhäuser Blown Film has developed a special die head
based on the proven Reifenhäuser technology. The individual adjustment of layer thicknesses allows
for an ideal distribution of the raw materials depending on the product. The well though-out operation
of the line facilitates easy handling of the eleven film layers and the large amount of line data:
Operators have direct access to all important parameters via a 24" touchscreen. Handling is as easy
as using a Smartphone. This concept which Reifenhäuser also uses in
other lines is particularly useful for eleven layers.
This is also valid for the energy efficiency measures Reifenhäuser Blown Film offers for their 11-layer line
under the keyword “Blue Extrusion”. Investments in these optionally selectable measures pay off very fast
due to the required high operating temperatures of 200 to 270°C. For example, producers who opt for
highly efficient electric motors and gearboxes, insulation/damping of cylinders and heater bands, or the
customized design of a complete production line with a focus on targeted energy optimization,
can save energy and reduce production costs.