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| 17.12.2012 |
Open House |
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17.12.2012
Open House
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220 international visitors experienced machine highlights at the Open House event.
3- and 5-layer line
The highlight of the first day of the event on 6 December was the presentation of a 5-layer blown film line which operates with an inline MDO film stretching unit. The system features a patented control system that allows the inline production of MDO film with similar or improved mechanical properties to standard films but which can be up to 50% thinner and with 50% less trim waste compared to offline methods.
When film is oriented in the machine direction a reduction of the film width occurs, referred to as “neck- in”, and the edges of the film become thicker. In order to wind the film successfully around 200mm of film on each side have to be trimmed.
The new TRIO control system creates one or more defined thin points during the blown film extrusion process which coincide exactly with the position of the edge trims on the MDO downstream from the blown film line. To achieve this the thickness profile measurement system on the MDO communicates with that of the blown film line to create the thin points which move in synchrony with the oscillating take-off unit. The result is a film with excellent flatness which is eminently suitable for printing, lamination and FFS applications.
The demonstration showed the production of monoaxially oriented 5-layer PE composite film for compression packaging with a thickness of 35 µm and a layflat width of 1,570 mm (finished product). The pilot line is equipped with five extruders from the HX series with an L/D ratio of 30 and 300 mm die heads.
The first day also featured the demonstration of a new 3-layer blown film line for the production of film with a width of up to 2,600 mm. In reaction to market requirements, the 3-layer line was designed for excellent film quality quality at significantly higher output rates. In order to achieve this, the line was equipped with a total of three extruders of the HX series, two 75 and one 135mm extruder. The main extruder is a new development which enhances the existing extruder range to cater for higher outputs. Like all single-screw extruders of this series, it is equipped with a grooved feed bush, barrier screw and asynchronous drives and have an output capacity of 1,000 kg/h. Special features of this large 3-layer line include a VX cooling ring, which is adjustable in height for optimum cooling. For the presentation, the 3-layer line was used for the production of PE-LD collation shrink film with a width of 2,200 mm and a thickness of 50 µm .
5- and 9-layer line
The second day featured another highlight: the demonstration of the new 9-layer line in our new test center. Equipped with nine extruders and a 630 mm die head, the line is suitable for the production of film with a width of up to 2,600 mm. In order to minimize curling on asymmetrical structures the line is equipped with a water bath.
On 7 December, the 9-layer line produced symmetrical high-barrier film for lamination of food packaging applications made from PE, PA and 1.6 µm of EVOH with a total thickness of 40 µm and a width of 2,300 mm. The line had an output of more than 700 kg/h.
At the same time visitors to the test center were presented with a 5-layer line producing highly demanding laminating film made from different PE grades with a thickness of 45 µm. We deliberately chose a 5-layer line for operation in the test center, as the shift from 3-layer towards 5-layer films seems to continue. This shift is caused by the fact that the thickness of multi-layer film can be reduced at no detriment to the mechanical characteristics, which allows significant material savings. The 5-layer line impressed visitors with its incredible flexibility, as demonstrated during the Open House by its capacity for extremely fast product change-overs. Within only thirty minutes, the line was changed for the production of side gusset stretch film to the production of collation shrink film without side gusset. This fast change-over was achieved by the One-Touch Change System, which runs an automatic start-up with stored production settings.
Hosokawa Alpine’s product range was enhanced by a new reclaim extruder, which was also shown at the Open House. With a maximum output capacity of 70 kg/h, the line recycles waste trim from the MDO unit into reusable pellets. Depending on the film type, these pellets can be reused for producing the central layer – a significant contribution to a more efficient production.
Our new test center offers customers three blown film lines for 3, 5 and 9 layers that cover all test options, be it new layer structures, formulations or film types. The suitable line including all required equipment right down to different winder models are now waiting for customer trials.
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