innovating film extrusion Strategic development rising the bar in coextrusion

Transcription

1 Strategic development rising the bar in coextrusion 1

2 Monolayer Performance Films PERFORMANCE RESINS LDPE EVA MDPE HDPE HMWHDPE znlldpe { BUTENE, HEXENE, OCTENE, SUPER HEXENE } mlldpe PLASTOMERS IONOMERS PP PEEL SEAL FILMS PERFORMANCE ADDITIVES SLIP ANTIBLOCK COLOR PIGMENTS ANTI-STAT ANTI-FOG UV-Filters FINISH AGENTS { MICA, PAPERMATCH } PERFORMANCE APPLICATIONS MAY BLEND UP TO 5 DIFFERENT RESINS/MATERIALS WORKHORSE SEALANT FILMS CLARITY SEALANT FILMS HIGH CLARITY SHRINK FILMS POSTAL APPROVED FILMS PEEL SEAL FILMS HOT TACK SEALANT FILMS FROZEN FOOD FILMS BLENDED PERFORMANCE FILMS HIGH QUALITY PERFORMANCE SEALANTS 2

3 3 Layer Co-ex Films A Layer B Layer C Layer 3 LAYER SPECIALTY SEALANT FILMS A / B / C A / A / B A / B / A A LAYER SEALANT LAYER MODIFIED TO PROVIDE LOW, MEDIUM OR HIGH COF MATERIALS AVAILABLE: LDPE LLDPE MLLDPE PLASTOMER EVA SURLYN PEELABLE B LAYER CORE OR TIE LAYER INCORPORATE TRIM / COLOR ADDITIVES MATERIALS AVAILABLE: LDPE EVA HDPE PP LLDPE MLLDPE TIE / ADHESIVE LAYER C LAYER LAMINATION OR HEAT RESISTANT LAYER CORONA TREATMENT COLOR ADDITIVES MATERIALS AVAILABLE: LDPE EVA LLDPE mlldpe PLASTOMER HDPE PP 3

4 5 Layer Co-ex Films A Sealant B Tie Layer C Barrier D Tie Layer E Lamination/structural 5 LAYER SPECIALTY SEALANT / BARRIER FILMS A / B / C /D / E A / B / C / B / A A / B / C / B / C A LAYER SEALANT LAYER MODIFIED TO PROVIDE LOW, MEDIUM OR HIGH COF MATERIALS AVAILABLE: LDPE, LLDPE MLLDPE PLASTOMER EVA SURLYN PEELABLE B LAYER TIE LAYER MATERIALS AVAILABLE: EVA BASED HDPE BASED LLDPE - BASED C LAYER BARRIER LAYER MATERIALS AVAILABLE: HDPE PP NYLON 6 NYLON 6 & AMORPHOUS NYLON BLEND EVOH D LAYER TIE LAYER MATERIALS AVAILABLE: EVA BASED HDPE BASED LLDPE BASED E LAYER LAMINATION LAYER CORONA TREATMENT COLOR ADDITIVES MATERIALS AVAILABLE: LDPE, LLDPE MLLDPE PP EVA HDPE NYLON 4

5 5 layers line layout 5

6 Reasons why for a 5 ply Typical choice for opening/developing markets Intrinsic flexibily of production : Barrier no Barrier Downgauging and cost reduction vs/ 3 ply coex It can be a 3 extruders or a 5 extruder configuration Makes possible a symmetric barrier film production No curling on PA/PE structures Workhorse for barrier substrates in flexible packaging 6

7 Seven layers structures sealant-structural structural-tie tie- barrier tie-barrier tie-barrier structural-tie Sealant -structural -barrier 7

8 7 layers line layout 8

9 Reasons why for a 7 ply Downauge a comparable 5 layers barrier film Provide for more and thinner barrier layers Provide for dual barrier feature Protect moisture sensitive EVOH with PA Optimise slip/antiblock use Bury some off-grade into structural layers 9

10 9 layers line layout 10

11 Reasons why for a 9 ply Softer barrier film than 5 or 7 ply Provide for more and thinner barrier layers Optimised sealant/skin layers Provide for dual/triple barrier feature Extremely heavy layer possibility Protect moisture sensitive EVOH with PA Improved cold strength Ready-made alternative to laminated products Equipment destinated to experienced users 11

12 Macchi. Since 1960 a coex pioneer 12

13 ENERGY SAVING careful selection of screw design, effective I.R. heaters and powerdrive technology 13

14 ENERGY SAVING: TORQUE MOTORS 14

15 Seven layers hardware offerings Pancake Stack Spiral - styles 15

16 COEXFLEX DISTRIBUTION CONCEPT 16

17 CoexFlex distribution concept 17

18 CoexFlex distribution concept COMPACT DESIGN REDUCED BODY MASS FOR QUICK MAKE-READY LESS POLYMER INVENTORY SHORTER RESIDENCE TIME SUPERIOR LAYER-TO-LAYER GAUGE VARIATION BROAD RESIN SELECTION FLEXIBILITY TEMPERATURE INSULATED IBC SYSTEM SELF-CENTERING COMPONENTS FOR EASY MAINTENANCE 18

19 common design philosopy 19

20 Seven layers 500mm DieHeads -same level feed- USA design Macchi design 20

21 About film flatness 21

22 Care for film flatness this is NOT the way 22

23 Bubble Collapsing 23

24 Thickness scanners (non nucleonic ) 24

25 25

26 Gaugemaster 1 Segmented blow-ring 26

27 Gaugemaster 2 Thermal die elements 27

28 Five layers line 28

29 Five layers line 29

30 Five layers line 30

31 Seven layers line 31

32 Seven layers line 32

33 Seven layers line 33

34 Care to DETAILS is not Cosmetic, it is a NEED to shorten make-ready time to ease the operations to provide for process flexibility to facilitate transitions to allow product traceability to improve product quality to minimise scaps 34

35 Care to DETAILS is not Cosmetic 35

36 Care to DETAILS is not Cosmetic 36

37 Perfect winding is a MUST 37

38 38

39 39

40 Coextrusion requires a Threeways view 1- Specialty Films sales serving 5 key industries Food & Beverage PET food Converter (external) Industrial Medical/Pharmaceutical 2 - Distribution sales with focus on the following National Distribution Regional Distribution Niche Market Distribution 3 Vertical Integration for internal converting applications 40

41 Some useful hints to be recognized as a premier supplier of Flexible Packaging Solutions to various industries and markets Develop an outstanding partnership/cooperation with major key accounts. Provide for a dedicated account team works with the clients and their facilities to ensure a thorough understanding of their needs and expectations. Then you can review the specific flexible packaging applications to ensure you can recommend the right product for the application. In many cases you could be in the position are to offer cost saving alternative products by offering value added products. Your strategic objective is to provide their clients with the product they want! Some of the benefits the clients may receive from the above approach :. Significant packaging cost savings Decreased inventories and costly floor space Utilization of a stronger and better performing material that greatly outperforms previous products Reduced production costs due to better machinability of value-added products 41