GAP: high experience in extrusion film lines

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John Wade
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Heat shrinkable film up to 11 layer from 1400 mm to 3000 mm Oriented barrier shrink film up to 11 layer

600 mm GAP, Tailor extrusion film line manufactured, specialized in exclusive and dedicated extrusion

up to 700 mm Heat set oriented barrier film for the production of film up to 2000 mm for lid production

New technology up to 11 layer which are address to produce lower thickness, higher transparency film and

New Heat shrinkable LLDPE film line production (double bubble) up to 3000 mm.

extrusion process where different material are laminated by extrusion.

2 Heat shrinkable film up to 11 layer from 1400 mm to 3000 mm Oriented barrier shrink film up to 11 layer from 300 mm to 2000 mm Multilayer barrier not oriented film up to 9 layer from 900 mm to mm GAP, Tailor extrusion film line manufactured, specialized in exclusive and dedicated extrusion film lines for: Barrier shrink bag film line (triple bubble) suitable for the production of barrier bag up to 700 mm Heat set oriented barrier film for the production of film up to 2000 mm for lid production Heat shrinkable oriented barrier film for the production of film up to 2200 mm. New technology up to 11 layer which are address to produce lower thickness, higher transparency film and high barrier with less usage of barrier resin. New Heat shrinkable LLDPE film line production (double bubble) up to 3000 mm. New High Speed Extrusion coating & lamination system a dedicated technique, combination of converting and extrusion process where different material are laminated by extrusion. High speed solution over 500 mt/1 and fast work change for multipurpose production design Dedicated cast film line for CPP, emboss, diapers, stretch film and barrier. Laminate product by extrusion from 1000 mm to 2500 mm Flat film up to 9 layer from 1000 mm to 3500 mm 2 3

SHRINK film Low force SHRINK film Antifog SHRINK film IRRADIATE film This is a very versatile film suitable for a

Best in class for cost and productivity. Durability as high performance overwrap film. High shrink ratio.

This film offer a high transparency and protection to the magazine. Best in Sheen and gloss.

A new antifog shrink fi lm with improved hermetic seals for reliable pack integrity.

This makes it ideal choice for packaged cold foods, fruit and vegetable.

for automatic packaging machine. It makes a clear choice for over-wrapping.

Model Application Width (mm) Thickness (micron) Layers Output Kg/h MHS 22 Packaging and display heat shrinkable

2400 10-35 Up to 11 layer of polyolefin polymers Up to 320 LHS 26 Packaging and display heat shrinkable film 2650

30-90 Up to 11 layer of polyolefin polymers Up to 380 The orientation line works by the so-called double-bubble

is then re-heated up to a suitable temperature and blown to form the main bubble of thin film.

3 SHRINK film Low force SHRINK film Antifog SHRINK film IRRADIATE film This is a very versatile film suitable for a wide range of applications. It s shine, optics and durability. Excellent gloss, clarity, sheen. Best in class for cost and productivity. Durability as high performance overwrap film. High shrink ratio. For application that require a low force shrinkage as for example for magazine. This film offer a high transparency and protection to the magazine. Best in Sheen and gloss. Rugged puncture resistance and durability. A new antifog shrink fi lm with improved hermetic seals for reliable pack integrity. This film offers a unique anti-fog agent that prevents film fogging up under cold storage conditions. This makes it ideal choice for packaged cold foods, fruit and vegetable. Multilayer heat shrinkable film for wrapping application, this is a high performance multilayer film engineered for automatic packaging machine. It makes a clear choice for over-wrapping. Excellent sealing strength, puncture resistance, hot slip property. Model Application Width (mm) Thickness (micron) Layers Output Kg/h MHS 22 Packaging and display heat shrinkable film Up to 11 layer of polyolefin polymers Up to 250 SHS 24 Packaging and display heat shrinkable film Up to 11 layer of polyolefin polymers Up to 320 LHS 26 Packaging and display heat shrinkable film Up to 11 layer of polyolefin polymers Up to 400 TRIBUNE 2000 Packaging and display heat shrinkable film Up to 11 layer of polyolefin polymers Up to 380 The orientation line works by the so-called double-bubble process, i.e. the polymers are extruded through a circular die and immediately water-quenched to form a thick primary tube which is then re-heated up to a suitable temperature and blown to form the main bubble of thin film. The non-contact simultaneous 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; after the trimming of the edge, the two webs obtained rolled up in two reels. By annealing the product obtained on the biorientation equipment, it is possible to obtain heat set film such us: BOPP, BOPA, BOPET and special products. The annealing can be placed in line or off line.partial annealing can also be integrated in the orientation 4 5

SHRINK BAG LIDDING film BARRIER SHRINK film CURING BARRIER BAG Vacuum shrink bags are the perfect

technology used. High performance, very thin (28 micron) barrier shrink film.

This film offers a unique antifog agent that prevents film fogging up under cold.

shrinkable film and lid 500 30-90 Up to 11 layer with EVOH, PA Up to 50 Tritube 700 Barrier heat

shrinkable film and lid 1500 30-90 Up to 11 layer with EVOH, PA Up to 200 The orientation line

4 SHRINK BAG LIDDING film BARRIER SHRINK film CURING BARRIER BAG Vacuum shrink bags are the perfect packaging medium for many perishable food products, such as sub primal meat, smoked and processed meats, poultry, fish and cheese. Ideal solution for all MAP tray lidding applications of all fresh foods, irrespective of sealing technology used. High performance, very thin (28 micron) barrier shrink film. A new antifog shrink film with improved hermetic seals for reliable pack integrity. This film offers a unique antifog agent that prevents film fogging up under cold. The high sealable presentation and curing barrier bag for smoked and processed meats, cheese and fresh meats. Model Application Width (mm) Thickness (micron) Layers Output Kg/h Tritube 500 Barrier heat shrinkable film and lid Up to 11 layer with EVOH, PA Up to 50 Tritube 700 Barrier heat shrinkable film and lid Up to 11 layer with EVOH, PA Up to 90 Tritube 1500 Barrier heat shrinkable film and lid Up to 11 layer with EVOH, PA Up to 200 The orientation line works by the so-called Triple-bubble process, i.e. the polymers are extruded through a circular die and immediately water-quenched to form a thick primary tube which is then re-heated up to a suitable temperature and blown to form the main bubble of thin film. The non-contact simultaneous 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; The third bubble is annealed by ovens with ceramic infra-red heater The final product can be wind in tube or fat film 6 7

MEDICAL THERMOFORMING VACUUM packaging BARRIER Medical application for blood bags, high puncture

Thermoforming film with deep draw applications up to 9 cm deep Structure: with PP/EVOH/PA ect

Most of the food will need vacuum package such like meats, cheese, sea foods.

Barrier not oriented film excellent film with good transparency, which makes it the optimal solution

Structure: Nylon/tie/Nylon/ EVOH/Nylon/tie/PE PP/tie/Nylon/EVOH/Nylon/tie/PE Nylon/tie/Nylon/tie/PE

Web Width (mm) Thickness Layers Output Kg/h WQ 700 Packaging 700 25-200 Up to 11 layer with EVOH,PA etc

1600 25-200 Up to 11 layer with EVOH,PA etc Up to 350 The molten resin is extruded in a tubular form

In the path between the die and the pulling rolls, the tube is inflated until it tangencies the sizing

Right after it, the film goes out of the die passing through an Air Ring, then suffering a pre-cooling

5 MEDICAL THERMOFORMING VACUUM packaging BARRIER Medical application for blood bags, high puncture resistance, high transparency. Thermoforming film with deep draw applications up to 9 cm deep Structure: with PP/EVOH/PA ect Thickness: 100 micron microns Vacuum packaging materials, high barrier coex films/ pouches. Most of the food will need vacuum package such like meats, cheese, sea foods. Structure: Nylon/tie/PE/tie/ Nylon/tie/PE PE/tie/Nylon/tie/PE Thickness: 50 microns microns Barrier not oriented film excellent film with good transparency, which makes it the optimal solution for lamination purpose. Structure: Nylon/tie/Nylon/ EVOH/Nylon/tie/PE PP/tie/Nylon/EVOH/Nylon/tie/PE Nylon/tie/Nylon/tie/PE PP/tie/Nylon/tie/PE Thickness: 30 micron - 100microns Model Application Max. Web Width (mm) Thickness Layers Output Kg/h WQ 700 Packaging Up to 11 layer with EVOH,PA etc Up to 100 WQ 1200 Packaging Up to 11 layer with EVOH,PA etc Up to 200 WQ 1600 Packaging Up to 11 layer with EVOH,PA etc Up to 350 The molten resin is extruded in a tubular form through the die. In the path between the die and the pulling rolls, the tube is inflated until it tangencies the sizing ring which defines the width of the film that is being produced. Right after it, the film goes out of the die passing through an Air Ring, then suffering a pre-cooling and then the film passes through a sizing ring immersed in cool water. The cool water provides a thermo shock on the film because of the cold temperature, making the film to acquire brightness and high transparency that are the characteristics of the product. Afterwards the film passes through the pulling rolls, through a drier to eliminate the damp, then it passes by the device of lateral slitting (cutting) of the film and finally the roll is wound in the double winder. 8 9

MILK and JUICE LIGHT FLEXIBLE packaging FLEXIBLE packaging NO WOVEN Multilayer laminated

Specifically design for long shelf life using aluminium in the laminate.

Multilayer product a combination of aluminium, films, metalized film laminated with extrusion.

ect. Extrusion coating and lamination is a well known technique used to produce multilayer

This make this process very attractive. The adhesision of different substrate is done by resin.

been developed with two or even three coating stations in-line and utilising coextrusion on

Model Light flex (LF) Flex flex (FF) HP NWC Width 800-1300 800-1300 800-1500 800-2000 Speed

350 mt/1 170 Unwinder 800 mm 800-1000 - 1300 mm 1200-1500-1800 mm 1500 mm Splice One direction

6 MILK and JUICE LIGHT FLEXIBLE packaging FLEXIBLE packaging NO WOVEN Multilayer laminated product for milk, juice boxes. Specifically design for long shelf life using aluminium in the laminate. Light laminated product with PET outside and PE inside ideal for product containing liquid. Multilayer product a combination of aluminium, films, metalized film laminated with extrusion. Non woven coating with PE an possible lamination with Bopp film for shopping bags, bulk bags ect. Extrusion coating and lamination is a well known technique used to produce multilayer composite laminates in one pass, thanks to the use of coextrusion technologies. This make this process very attractive. The adhesision of different substrate is done by resin. With the increasing demand for more and more square meters, extrusion coating equipment has been developed with two or even three coating stations in-line and utilising coextrusion on one or more of the coating units. Model Light flex (LF) Flex flex (FF) HP NWC Width Speed 200 mt/1 (FF 35) up to 350 mt/1 (FF 50) up to 500 mt/1 (HP 20) up to 200 mt/1 (HP 35 ) up to 350 mt/1 170 Unwinder 800 mm mm mm 1500 mm Splice One direction Two direction adding TDS optional Two direction adding TDS optional Stop and go Extruder assembly Extruders size available Single-coex Single-coex Single coex Single to coex 60 ( 260 kg/h) -75 ( 320 Kg/h) -90 ( 450 Kg/h)-120 ( 530 Kg/h) -130 ( 700 Kg/h) 160 (950 Kg/k) 10 11

GAP Unwinder, Auxially Unwinders and Winder up to 1800 mm winder are specifically designed accordingly to the material to handle like: paper, board, plastic film, aluminum.

Fly splice in one direction on both direction Dedicate splice for aluminum foil Chemical primers will provide the adhesion required particularly in food packaging.

packaging materials since the lower extrusion temperature means a lower degree of resin degradation and therefore less odour imparted to the goods packaged.

The lamination group is design and built to provide a uniform temperature on the chill roll surface with particular water flow circulation.

Pressure roll covered by particular coating heat resistance.

7 GAP Unwinder, Auxially Unwinders and Winder up to 1800 mm winder are specifically designed accordingly to the material to handle like: paper, board, plastic film, aluminum. Winder can be supplied with Pneumatic shafts or shaftless Semiautomatic or fully automatic splice system Fix or movable arms to help roll pick up Roll can be load by lifting platform or crane. Fly splice in one direction on both direction Dedicate splice for aluminum foil Chemical primers will provide the adhesion required particularly in food packaging. In particular use of chemical primers can allow extrusion coating at substantially lower temperatures without loss of adhesion -this is particularly valuable in extrusion coating of food packaging materials since the lower extrusion temperature means a lower degree of resin degradation and therefore less odour imparted to the goods packaged. The primers can also impart certain barrier properties as well as maintaining adequate adhesion under difficult process conditions. The lamination group is design and built to provide a uniform temperature on the chill roll surface with particular water flow circulation. GAP has different size and finish surface of the chill roll accordingly to the out put and to the material to be laminated. Quick removable chill roll easy change. Pressure roll covered by particular coating heat resistance. Adjustable tapes for overcoating In extrusion coating GAP control high extrudate temperature with a high degree of homogeneity to obtain the ideal situation for good coating. In addition, and most important, we are aiming at these conditions over a wide screw speed range The temperature of the extrudate is governed by many variables but the specific ones to consider are screw design, barrel temperature, the polymer viscosity and the extrusion output rate or screw speed. Extruder has been studied to deliver high uniform melt temperature and stable out put 12 13

Cast 1200 Cast 1600 Cast 2100 Cast 2500 Cast 3000 Cast 3000 plus PRODUCT Film

stretch film From monolayer to 11 layer Extruder size 60 90 120 -.

500 mm 2700/3000 mm 2700/3000 mm Chill-roll mechanical speed Net production rate

000 Kg/h Roll face 1000/1200 mm 1600 mm 2000/2100 mm 2400/2600 mm 3500 mm 3500 mm

The cast line works by the so-called Flat die process, i.e. the polymers are

chill roll which forms the final film thickness.

system, corona treatment and oscillating system.

STRETCH film CPP film BARRIER film DIAPERS film Stretch film product for manual

Dedicated multilayer stretch film for industrial use High transparency CPP film

8 Cast 1200 Cast 1600 Cast 2100 Cast 2500 Cast 3000 Cast 3000 plus PRODUCT Film structure Multiplayer CPP film, barrier film, breathable and diapers film, stretch film From monolayer to 11 layer Extruder size Useful width mm mm mm mm 2700/3000 mm 2700/3000 mm Chill-roll mechanical speed Net production rate From 200 to 500 mt/1 From 200 Kg/h t Kg/h Roll face 1000/1200 mm 1600 mm 2000/2100 mm 2400/2600 mm 3500 mm 3500 mm Max reels diameter 800 mm 800 mm 800/1000 mm 800/1000 mm 800/1000 mm 800/1000 mm The cast line works by the so-called Flat die process, i.e. the polymers are extruded through a flat die and immediately quenched in a primary and secondary chill roll which forms the final film thickness. The film passes through a set of idle rolls where are mounted thickness control system, corona treatment and oscillating system. After the trimming of the edge, the web obtained rolled up in a roll. STRETCH film CPP film BARRIER film DIAPERS film Stretch film product for manual wrap, automatic wraping. Dedicated multilayer stretch film for industrial use High transparency CPP film design for lamination or for direct usage. CPP film use for metalizing process, twist and food wrapping. Multilayer barrier film for food application, vacuum pack, lamination lid film. Diapers application for baby diapers, micro perforated film, laminated film with non woven. Hygenic and construction application

9 GAP srl Office: via Verdi S.Pietro Mosezzo (NO) Italy Office and Factory: Via della Natura Trecate (NO) Italy Phone Fax info@gapitaly.com 16

COMPARISON OF CAST FILM AND BLOWN FILM 9 - LAYER BARRIER FILM

COMPARISON OF CAST FILM AND BLOWN FILM 9 - LAYER BARRIER FILM Gerhard Winkler Windmöller & Hölscher / Germany ABSTRACT Above-average growth rates in the field of cast film production and stretch film,