1 Simultaneox Simultaneous orientation for barrier film Presented by Giovanni Stocchetti GAP
2 Driving element Reduce packaging weight up to 4 times Saving packaging cost up to 4 times Increase barrier and transparency Produce a sustainable packaging Helping environment and planet
3 Reduce & Saving cost Practical direction for cost reduction Reduce thickness without change in the mechanical and barrier characteristics Replace aluminum foil on laminate Reduce converting reducing lamination
4 Practical direction to increase barrier and transparency not oriented molecular ball more thickness to get barrier low transparency oriented structure less thickness to get barrier high transparency simultaneoux
5 Active oriented film solution SHRINK BAG (oriented) LIDDING FILMS (oriented) BARRIER SHRINK FILM (oriented) Shrink bags utilized for many perishable food products, such as sub primal meat, smoked and processed meats, poultry, fish and cheese. (50 Micron ) S 250 BA S 600 BA MAP tray lidding applications for all fresh foods, needs of barrier tray High performance, very thin (28 micron) barrier little shrink film S 1300 BA S 2000 TA Antifog barrier shrink film, no need of barrier tray, all the barrier is provide from the shrink film, (25 micron) S 2200 TA S 2200 RA
6 Basic requirement for the application SHRINK BAG (oriented) O2 permeability less than 20 cm3 m2 at 5 C per day at 1 atm 0 RH Strong seals Easy to open Little curlings Good machinability when converting into bags Lids LIDDING FILMS (oriented) Peelable and resealable with the aid of adhesives or other devices Hot sealed Requirements Sealing layer compatible with the material of the tray Good planarity Printable structure depend on printing needs Strong layers adherence Low elongation at break still good memory BARRIER SHRINK FILM (oriented) Barrier to O2, CO2 and moisture Heat sealable Shrink Strong adherence of layers Strong integrity of the seal Abuse resistance Attractive uniform appearance Transparent for visual inspection Barrier for atmosphere in the package Printable if required Maintain red colour of meat through: Enrichment in O2, Atmosphere reduced in O2, CO atmosphere,no atmosphere,co2 atmosphere
7 Coming soon oriented film solution ALUMINIUMLESS (oriented) METALIZEDLESS (oriented) COATEDLESS (oriented) Alumiumless, substitution with proper formulation of lamination foil which includes aluminum foil aprox 150 micron with micron S 1300 BA S 2000 TA Metalizedless, substitution of 12 micron PETm or laminated PET with EVOH film with proper formulation Allow to reduce converting process. S 1300 BA S 2000 TA Coatedless Multiplayer film with barrier material which can be alternative to PVDC, SiOx, ect S1300 BA S 2000 TA
8 Orientation system 3 1 ) EXTRUSION OF THE TUBE 2) WATER COOLING OF THE PRIMARY TUBE 3) RE HEATING OF THE PRIMARY TUBE 4) ORIENTATION 5) AIR BUBBLE COOLING AND COLLAPISING 6) ANNEALING SYSTEM 7) CORONA TREATMENT 8) WINDING
9 Total orientation ratio 40 PPH 30 LLDPE Coextr EVOH PET PA T S R PVC Orientation temperature C
10 simultaneox by double bubble Primary tube extrusion The polymers are extruded through a circular die and immediately waterquenched to form a thick primary tube Primary tube re heating The primary tube is then re-heated up to a suitable temperature and blown to form the main bubble of thin film no-contact simultaneox orientation is achieve thanks to the air inflated during the start up phase. This air allows the transversal orientation while the machine direction orientation is taken simultaneously thanks to the speed different between the stretching nip roll and the tower nip roll. The bubble is cooled by air and then flattened
11 simultaneox by double bubble Additional bubble annealing BA mod The film after orientation can be re blow again and annealed. This is used for medium size film with the possibility to control the shrinkability of the product. Additional tenter annealing TA mod The film after orientation can be annealed completely to a 0-1% residual. Ideal for large machine for lid film. The film can be printed and laminated Additional roll annealing RA mod The film after orientation can be rolled annealed for low annealed level. This is used to let the film having some shrink residual.
12 simultaneox by double bubble Model Application Web width Micron Kg/h Annealing S 250 BA Casing & tubing Up to 70 Extra bubble annealing S 600 BA Shrink Bag Up to 130 Extra bubble annealing S 1300 BA Lid film and Shrink Barrier Up to 200 Extra bubble annealing S 2000 TA ** Lid film and Barrier film Up to Mt/y Extra tenter annealing S 2200 RA Shrink barrier film Up to Up to 300 Extra roll annealing ** this line is an ideal alternative to a tenter frame line
13 simultaneox by double bubble Uniformity and balance characteristics in MD and TD Flexibility in the film thickness Application range of material is wider ( heat set shrink partial shrink) Simultaneox orientation easy to get a very transparent barrier film Film heating one time only no need to re heat for second orientation avoiding defect in crystallization. GAP Simultaneox MD et TD orientation
14 simultaneox by double bubble Contactless orientation no need any clips which damage the material and require large trimming. Trimmless process, huge saving cost in the productivity, costly barrier film can not be recycle Bandless with 360 continuox winder rotation especially in important thickness Increase planarity of the film GAP 360 Simultaneox bandless
15 OTR Advantages with non oriented film blown or cast 2,50 2,00 1,50 1,00 0,50 0,00 Orientation TD considering orientation ratio 1 ( typical for blown, cast, water quench technology ) and ratio 4 which is produced by double bubble technology. applying an orientation, the films obtain a wealth of advantageous properties, due to a change in the morphology of the film s molecular structure: excellent mechanical properties, e.g. stiffness, tear, shock or puncture resistance impermeability to moisture and steam high resistance to oils, fats and solvents, as well as to heat and cold dimensional stability and scratch resistance attractive glossy appearance, thanks to brilliant surface quality and high transparency excellent convertibility, printability and saleability
16 Coextrusion section Coextrusion up to 11 layer The polymers are extruded through a circular die,designed for precise melt distribution and produces a tube of uniform thickness The primary tube is immediately water-quenched out side though an external water ring, internally by a dry, water or contactless calibrator which provide a dimensionally controlled tube with the correct crystalline structure. Immediately after waterquenched the primary tube goes to directly to the orientation tower.
17 Die concept Each melt layer is tangentially fed through the relevant feed port and after passing the distributing path is fed toward the die opening, flowing over the inner insert where sequential lamination of the different layers takes place. unique combination of binary splitting and spiral centre distribution concepts, it features remarkable accuracy of different melt stream flows together with minimum residence time of extruded polymers.
18 Orientation system The primary tube is then re-heated up to a suitable temperature and blown to form the main bubble of thin film. Orientation is made simultaneously in both direction. The air inside the bubble allows the transversal orientation ( TD) while the difference of the tower nip and stretch nip speed allows the machine direction orientation ( MD) The bubble is cooled by air and then flattened; In order to randomise any thickness variation of the film, the collapsing frame, nip rollers, are continuously rotating.
19 Anealing and winding In line annealing ( additional bubble annealing, tenter annealing or heated calendar ) controls the important shrinkage property of the film or tube. Tube is split in two web ( trim-less system ) The film passed though a corona treatment station treating one or both side of the web, Finally the film is wound in a specially development centre winders to produce mill rolls of barrier film
20 High quality though special control Gap use a special software for automatic oven temperature control system AOC Software for Orientation process control system. This system keep constant, through the oven temperature closed loop control, the orientation conditions as per pre-set values. In the display control are also monitored external parameters, as factory air temperature, cooling ring air temperature as well as primary tube temperature and bubble size.
21 Auto profile The TBZ zone is a dedicate automatic profile control system using dedicated thickness gauge control and TBZ automatic oven software control The system use the signals generated by the thickness Gauging sensor
22 R&D Gap invest in a new factory of 2500 sqm where a new R&D line simultaneox including additional annealing, electron beam ect is under assembling. This line is capable to produce all the new idea to orient product. The line will have n_layer. Your idea are welcome to become realty.
23 Conclusions Advantages of simultaneous orientation Simultaneous stretching yields better mechanical properties over sequential tensile and modulus Orientation improves barrier properties the thickness of the laminated film can be reduced with no effect on the barrier economical advantage Laminated printed film for lids can be replaced by simultaneously oriented barrier film with printable layer Coated film may replaced by oriented film for microwave heating Orientation and heat treatment increases gas barrier properties at high humidity conditions Fewer converting steps is an advantage towards laminating and coating Better layers distribution control HELP TO REDUCE FILM THICKNESS ON THE FINAL PRODUCT AND SAVING IN RAW MATERIAL.