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EVOLUTION – Innovative Blown Film Technology

Sascha Skora, Senior Sales Manager sascha.skora@reifenhauser-kiefel.com

Agenda

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Reifenhäuser Group in in Brief Reifenhäuser Kiefel Extrusion in Brief Market data – Trends and Drivers Magic triangle of Extrusion EVOLUTION Highlights Conclusions

April 2013 .Reifenhäuser Group – „The Extrusioneers“ Focused on Extrusion PET Strapping tape lines 4 10.

Reifenhäuser Group we believe in entrepreneurship 1. April 2013 .200 employees 5 10.

Reifenhäuser Group Focus on R&D All core components are in-house developed 6 10. April 2013 .

Reifenhäuser Group Competence in manufacturing Made in Germany 7 10. April 2013 .

5.Reifenhäuser Kiefel Extrusion in Brief         Focus on blown film only More than 7. April 2013 .2.800 mm In-house design & manufacturing of core components Local service organizations 8 10.worldwide Widest product range Extruder: 50 .350 installed lines .200 mm Die diameter: 120 .000 .500 mm Film width: 1.

Market Data – Trends and Drivers .

7.00 5.Blown Film Production Regional Distribution Middle East 60. 2.Turkey .Saudi Arabia 40.7% 5.00 10.00 4.42 mio.00 Middle East Blown Film Production Worldwide Blown Film Production 50.3% equals approx.78% 30.30% Annual growth approx. tonns Major drivers: .00 20. 2013 .00 Mio Tons 2009 2014 Source: AMI 10 10 April.

7% annual growth in Middle East China 27.89% Africa 3. Tons 10 April.19% Middle East 4.19% Eastern Europe 5. UK 11 45.1 Mio.29% Africa 3.28% 35.33% Eastern Europe 5.13% North America 15.24% Western Europe 16.99% India 4. Tons Source: AMI Plastics.97% China 23.31% 2014F South America 8. 2013 .14% Middle East 5.43% Western Europe 13.63% North America 15.Global Blown Film Production Regional Distribution 2009 South America 8.30% India 5.28% Asia Pacific 16.63% 7.8 Mio.78% Asia Pacific 17.

Blown Film Trends   Increasing number of multi-layer lines  5-. April 2013 . and 9-layer Transfer of traditional 3-layer films to 5-layer structures Increasing number of films with barrier properties Since 2009    increasing number of 5-layer lines  focus of 9-layer lines for high barrier applications MAJOR APPLICATION: FOOD & PACKAGING FILMS 12 10. 7-.

Benefits of Multi-layer Films Down gauging Use of new resin grades Film properties Barrier properties Benefits Opening of new markets Flexibility Broader range of layer distributions Use of cheaper raw materials 13 10 April. 2013 .

April 2013 .Blown Film Production Film Cost Factors COST Source: AMI 14 10.

Global Requirements of Film Producers .

2013 .Converter‘s Film Requirements Major Criteria  Printability/Register accuracy EFFICIENCY  quality  Printing speed  output  Type of films  flexibility Picture: courtesy of Bobst Group 16 10 April.

2013 .Converter‘s Film Requirements Impacts on Film Producer  Quality  surface tension  optical properties  tolerances  skiing of film Output  tolerances  film planarity  waste Flexibility  range of film dimensions  range of materials   Picture: courtesy of Comexi Group 17 10 April.

Magic Triangle of Extrusion Goals of Extrusion 1 : 0 ULTRA RANGE EXTRUDERS (22´) FLEXIBILITY 2 : 0 EVOLUTION ULTRA COOL (48´) OUTPUT 3 1:0 2 Flexibility 3 : 0 EVOLUTION ULTRA FLAT (72´) QUALITY .

) EVOLUTION C with Apps such as  start up assistant  job change assistant   Flexibility  . high slip content.Magic Triangle of Extrusion Flexibility  Ultra Range Extruders processing all materials without screw change Ultra Range Die Heads  broad processing window  low residence time  fast purging properties Ultra Range Winders for all film types (tacky. stiff. etc.

COC. Reclaim. PP. liquid PIB. high efficiency mixer – High Output / Energy Saving. PETG. EVOH. Grooved feed section with unique heating / cooling section . etc. K-resin. CACO3. = Flexibility and Quality Low temperature screws. mLLDPE. as well as PA.EVOLUTION Ultra Range Extruders    Screw design for PE.

Magic Triangle of Extrusion Output  Ultra Range Screws providing low melt temperature Ultra Range Die Heads providing less back pressure allowing high outputs EVOLUTION Ultra Cool   Flexibility .

Ultra Cool – Stable Bubble even at Highest Rates 22 10 April. 2013 .

High Output .High Quality Ultra Flexibility .Ultra Performance Cooling System EVOLUTION ULTRA COOL Ultra Performance .Fast start up & Fast change overs .Wide Product Range Ultra Handling .

Magic Triangle of Extrusion Quality  Ultra Range Screws providing homogeneous melt Ultra Range Die Heads providing perfect gauge variation EVOLUTION Ultra Flat Take Off EVOLUTION Ultra Stretch Take Off EVOLUTION Ultra Range Winders for perfect roll quality    Flexibility  .

EVOLUTION Ultra Range Take-off Systems .

g.34 % length difference . e.Enhancement of Film Quality Camber Camber of film is caused mainly by different length in the collapsing frame L1  L2 L1 > L2 Different length depends on collapsing angle . for a collapsing angle 11°: 0.

when cutting into stripes Slightly stretching of the film optimizes film flatness .Enhancement of Film Quality Flatness Bagginess in the film are mainly caused by length and temperature variations Bagginess in the film Bagginess leads to different lengths of the film.

EVOLUTION ULTRA FLAT Take-off Enhancement of Film Quality THE KEY FOR SUPERIOR FILM PRODUCTION Enhancing film quality through integrated flattening package  Customer benefits  Improved film flatness  Reduced film camber  Reduced film bagginess  Reduced waste      Superior post processing performance Improved printing speed Improved register accuracy Improved product quality Superior energy efficiency through use of “first heat” 28 10 April. 2013 .

EVOLUTION ULTRA FLAT Take-off Bullet Points  Highest film quality concerning flatness and camber → superior converting processabilities High energy-efficient process No negative influence on the thickness profile due to minimal stretching   .

EVOLUTION C Automation .

more profitable production  Higher line availability for production .Job Change Assistant  Secure product change without operator errors  Faster than operators can manually do  Parallel actions  Less scrap. less costs.

Stretching the limits .Conclusions The day after tomorrow        Continuous Improvements on raw materials Use of different raw materials. replacing traditional structures Simplyfying structures Improvement of barrier properties Increase of output Using more Layers with reduced resin cost Further down gauging .

Magic Triangle of Extrusion Goals of Extrusion More innovative solutions will be demonstrated at K’2013 .