Film&sheet Extrusion magazine(june/july 2011)

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june-july 20011 Film&sheet Extrusion magazine

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Film&sheet Extrusion magazine(june/july 2011)

  1. 1. June/July 2011WATER-COOLING CREATES CRYSTAL CLARITYBIAXIAL ORIENTATION FOR PA AND PETMORE GROWTH IN GLOBAL STRETCH FILMADDING VALUE WITH HIGH SPEED PRINTING
  2. 2. Shaping the futureShaping the futurewith plasticswith plasticsFrom simple everyday products that make lifeeasier to step-changing technologicaldevelopments, Borouge is leading the way.lifeFrom simple everyday products that makeWe are committed to addressing globaleasier to step-changing technologicalchallenges responsibly with innovative plasticsdevelopments, Borouge is leading the way.solutions in infrastructure, automotives,We are committed to addressing global andadvanced packaging. with innovative plasticschallenges responsiblysolutions in infrastructure, automotives, andBorouge’spackaging. plastics solutions contributeadvanced innovativetowards addressing major global challenges suchas climate innovative plastics solutions contributeBorouge’s change, food protection, water,energy, communication and healthcare.towards addressing major global challenges suchas climate change, food protection, water,Combining the most advanced technologies withenergy, communication and healthcare.world-class innovation, Borouge, part of theADNOC and Borealis advancedcompanies, is withCombining the most group of technologiesmaking a difference to everyday life. of theworld-class innovation, Borouge, partADNOC and Borealis group of companies, ismaking a difference to everyday life.Visit us at Chinaplas 201117-20 May 2011 l Guangzhou, PR ChinaVisit us at ChinaplasHall 10.2 l Stand J41 201117-20 May 2011 l Guangzhou, PR ChinaHall 10.2 l Stand J41www.borouge.comwww.borouge.com
  3. 3. contents 04 Industry news european Commission considers plastic bag ban; inteplast boosts stretch filmpAge 4 capacity; Nordenia lifts production; Dow recovers energy from recycled film; Ami adds consultants 09 Pallet wrap stretches its horizons Global demand for pallet stretch film is expected to grow by more than 25% over the next four years, with Asia leading the charge. John Campin reportspAge 9 15 Stretching beyond polyolefins Biaxial orientation is most commonly used with polypropylene, but other, more sophisticated, polymers can also benefit from the technique. lou Reade reportspAge 15 23 Clear winner if polyolefin film is cooled rapidly, the resulting high clarity can take it into new applications. lou Reade reports 29 Surface effects lou Reade reports on some of the latest printing systems that are helping converterspAge 2 to add value to their products COveR phOtO: hilDe vANstRAeleN/www.BiewOef.Be 35 Technology: Materials 36 Technology: MachinerypAge 29 40 Extruder of the month 42 Dates for your diarycoming next issueBioplastics ❙ Barrier film materials ❙ Control instrumentation ❙ Applications in photovoltaics ➤ Click here to make sure you get your copycontact us Applied Market Information Ltd Head of business publishing: Andy Beevers e-mail: abe@amiplastics.com Ami house, 45-47 stokes Croft, Editor: lou Reade e-mail: lou@filmandsheet.com Bristol, Bs1 3Qp, United Kingdom Designer: Nicola Atkins tel:+44 (0)117 924 9442 fax:+44 (0)117 989 2128 Advertisement manager: Claire Bishop e-mail: claire@amimagazines.com www.amiplastics.com Direct tel: +44 (0)20 8686 8139© Copyright Applied Market Information. No part may be reproduced without the prior written permission of the publisher.www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON
  4. 4. newsinteplast plans increase Nordenia lifts production into stretch film capacity GermanyUs-based inteplast is to tonnes) annually. the two new lines will be Nordenia international is toincrease stretch film capacity Amtopp’s stretch film operational in the second half expand production inin its Amtopp division by operation produces conven- of 2012. Germany, with a three-layeradding two cast film extrusion tional and engineered hand film At the same time, it will co-extrusion facility due tolines at its lolita, texas plant. and machine wraps including increase output at its acquired come onstream in July.the lines will be the ninth and the loadstar series. the new facility in hazleton, Pennsylva- the site, which mainlytenth cast stretch film high-speed machines will nia – with plans to add five produces films for foodextrusion lines at the facility. produce ultra-light gauge pallet stretch film lines there. packaging that is sold acrossthe expansion will take wrap products and increase together, the two initiatives europe, is investing E3Amtopp’s stretch film production of loadstar will extend its service in the million in its Osterburkennameplate capacity to 260 products – further reducing north eastern United states. site.million pounds (120,000 their manufacturing cost. ❙ www.inteplast.com in a new production building, which will measure 522 sq m, the site’s thirteenthBilcare adds machine will lift production from 22,000 to 26,000 tonnes/Pet film to year. the move is also expected to take the numberportfolio of employees from 90 to 93. “With the continuedBilcare solutions has extended expansion of our productionits portfolio with a PetG film capacities, we will be able toline in staufen, Germany. meet the requirements of our the combination of a new customers all over europe,”Pet extruder with an existing said managing directorstenter line will lead to Andreas Paul.optimum manufacturing the plant focuses onefficiency, says the company. making blown films using “the capacity extension monoextrusion and coextru-enables us to serve the fast sion. sabic boosts opticalgrowing market of shrink film end uses can range fromfor sleeve applications even coffee or soup packaging, upbetter than before,” said heinz to films for light-sensitiveGärtner, chairman of BilcareResearch. film output in China products and form fill and seal (ffs) packaging. the combination of a new sabic innovative Plastics has boosted capacity of its lexan l taghleef industries hasPet extruder with an existing polycarbonate resins and film in China – including an extrusion installed a biorientedstenter line will lead to line for its optical quality (OQ) film in Nansha. polypropylene (BOPP) line atoptimum manufacturing the new line uses class 1,000 cleanroom technology to make its plant near Cairo in egypt,efficiency, says the company. custom textured materials and surface polished lexan OQ films. which will cover growing the company makes rigid more capacity additions in Asia are planned for 2012-2014. demand from Africa andfilm from PVC and PVC-Pe, this expansion addresses rising demand for speciality film europe.and includes the finishing of materials for applications in the consumer electronics, automo- the new line is scheduledfilms in the form of coating, tive and security sectors. the materials are widely used in to come on stream at the endstentering, laminating and applications such as automotive navigational display units, of 2012.metallising. notebook PCs and monitors. ❙ www.nordenia.com❙ www.bilcaresolutions.com ❙ www.sabic-ip.com ❙ www.ti-films.com film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com
  5. 5. newseC considers total banon plastic bags in europethe european Commission has launcheda consultation into ways of reducing theuse of plastic carrier bags in europe. the public consultation will consider acomplete ban – as has already been carriedout in italy. it will also consider a ‘bag tax’,as well as ways to improve biodegradability. “fifty years ago, the single-use plasticbag was almost unheard of – now we usethem for a few minutes and they polluteour environment for decades,” said theeuropean Commissioner for environ-ment, Janez Potocnik. “there is a Potocnik: “We are looking at all thewidespread desire for change. that’s why options, including a Europe-wide ban onwe are looking at all the options, plastic carrier bags”including a europe-wide ban on plasticcarrier bags. We need the views of as the consultation will also gather viewsmany people as possible to complement on the adequacy of current requirementsour scientific analyses.” on compostability and biodegradability in some eU member states have already the eU Packaging Directive. the Directivetaken action to reduce the use of plastic does not clearly distinguish betweencarrier bags through pricing measures, biodegradable products – which shouldagreements with the retail sector or bans biodegrade naturally in the environmenton certain types of bags, but no specific – and compostable products, which onlymeasures exist at the eU level. biodegrade in industrial composting every year, the average eU citizen facilities. the consultation runs until 9uses around 500 plastic carrier bags. the August 2011.total volume of bags produced in europe ❙ http://ec.europa.eu/environment/in 2008 was 3.4m tonnes. consultations/plasticbags_en.htmUAe: bags phased out by 2013the United Arab emirates (UAe) is to director general of esmA, said: “All thephase out conventional plastic bags by plastic bags used in the UAe must be We maximize2013, and replace them with biodegrad- biodegradable from 2013 so the peopleable alternatives. using them should be made aware of this film producers profitability According to a report in Gulf News, all regulation and practise it.” Tailor-made project consultingproviders and suppliers of oxo-biode- About 95% of the plastic bags used in Reliable commissioninggradable additives — ingredients that the UAe are manufactured in the country. German workmanshiphelp plastic bags to degrade quickly — it is estimated that there are more than Flexible and efficient lineswill need to be verified and approved by 100 manufacturers and suppliers of bio- Comprehensive servicethe emirates Authority for standardisa- or oxo-biodegradable additives in the Individual financing solutionstion and metrology (esmA) before they UAe. three suppliers of these additivescan deal with plastic manufacturers and have been approved by esmA: Wellstraders. Plastics, symphony environmental and www.brueckner.com mohammad saleh Badri, acting Bin hilal enterprises.www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON
  6. 6. newsDow trial shows benefits ofenergy recovery from plasticDow has carried out a pilot test equivalent to 11.1m BtUs of of energy and ultimately help ing, such as flexible films andto show that recycled plastic natural gas, was used to fuel reduce our need for natural containers made from afilm can successfully be used an incinerator during the test. gas or other fossil fuels,” said combination of materials.to generate energy. linear low-density Jeff Wooster, plastics sustain- “energy recovery and the trial showed that polyethylene (llDPe) scrap ability leader for Dow’s North chemical transformation doplastic at the end of its life film from one of Dow’s American plastics business. not replace traditionalcould be used as a fuel rather extrusion laboratories was “the results demonstrate that recycling – they extend andthan being sent to landfill: Dow used in the test. this type of almost all of the available complement it,” Wooster said.found that 96% of available film is commonly used for energy stored in used plastic “Recovering embedded energyenergy was recovered after packaging food and consumer can be captured and reused.” in recycled plastic is used inincinerating 578lbs (263kg) of products. While many thermoplastics europe and other regions. Ourused plastic in a kiln at one of “the purpose of the test can be reprocessed, there are next step is to help find a wayits waste treatment facilities. was to show that used plastic limited end-of-life options for to scale this up in the Us.”the energy recovered, can provide a valuable source some types of plastic packag- ❙ www.dow.comAmi adds new consultants and an editorApplied market information industry knowledge and(Ami) has expanded its experience that will help us toconsulting team with two new continue with the rapid growthappointments that increase of our digital magazinesthe group’s expertise in business, as well as contribut-plastics processing, packaging ing to Ami’s successfuland recycling, as well as bring- conference activities anding valuable knowledge of Zimakiewicz, Tonkin and Smith bring new expertise consulting services”.consumer markets. smith will take over the Dr Jeremy tonkin has martyna Zimakiewicz has experienced plastics industry editorship of injection Worldjoined the company as a been appointed packaging journalist and editor. magazine from the June issuetechnical consultant. he has consultant at Ami. she joins smith has a degree in and will also be working on aheld a number of technology the company from Zenith materials science and worked number of new publishingmanagement posts at blow international where she was a in the polymer industry for projects.moulding, plastics packaging senior consultant focusing on several years before moving Compounding World willand automotive components a variety of dairy and beverage into magazine publishing. for continue to be edited by Andyplants. more recently, he was a markets. this work included the past 20 years he has been Beevers who has a degree inpackaging technologist with coordinating global databases writing about plastics technol- Chemical engineering andthe UK retailer, marks and covering the bottled water and ogy including stints as technol- more than 25 years experiencespencer, and european soft drinks sectors. ogy editor on Plastics of writing, editing and publish-technical manager with A Polish national who Rubber Weekly and most ing magazines for the plasticsBraiform, a leading manufac- graduated in english language recently as editor of european industry.turer of garment hangars. he and translation, she has also Plastics News at Crain lou Reade will continue tograduated in materials science developed a close understand- Communications. edit film and sheet extrusionand engineering at the ing of the drinks markets of Andy Beevers, head of and Pipe and Profile extrusion.University of surrey and central and eastern europe. business publishing at Ami, he has a degree in Chemistryobtained a diploma in manage- l the Ami magazines team is said: “We are delighted to add and more than 20 years ofment science and a doctorate expanding with the appoint- Chris smith to our team. he technical journalism experience.in plastics recycling at Umist. ment of Chris smith, a highly brings a huge wealth of ❙ www.amiplastics.com film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com
  7. 7. Converting customer ideas into successful products.ust how Green is Davis-Standard, LLC? So green that were growing Sheetnew technology for energy and material savings all the time, while planting theseeds for more. Recycle, Reclaim CompoundingOur Green market expertise includes: Pipe Profile Capabilities for coreless, recycling, and  Equipment used to manufacture key Extrusion Coating Laminating down gauging of film and sheet products. components for advanced batteries . Cast Film Innovation to process fluoropolymers and  Technology for processing bioresins other resins used in solar panel encapsulation such as PLA or PHA for film and sheet technology. products used in flexible and rigid Blown Film packaging. Liquid Coating LaminatingIf you want to reduce your carbon footprint while improving efficiency,let us help you put a little green into your operation. Unwinding Winding Start at: www.davis-standard.com | www.bc-egan.com www.er-we-pa.de | www.davis-standard.com.cn
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  9. 9. Global stretch film | markets feature Global demand for pallet stretch films is expected to grow by more than 25% over the next four years, with Asia leading the charge, says Ami’s John Campin Pallet wrap stretches its horizonsOf all the major sub-divisions of the polyethylene film films. Back in the early 1980s, stretch films were Demand forindustry, the global pallet stretch film market has been produced using low density polyethylene (lDPe), but pallet stretchone of the strongest growing sectors for many years. development of stretch films really took off in the mid- film, such asDeveloped on a commercial scale during the mid 1980s, 1980s following the introduction of linear low density this one basedit rapidly began to penetrate more traditional methods polyethylene (llDPe). stretch films, both blown and on BASF’sof pallet stabilisation from the 1990s: it replaced shrink cast, are primarily manufactured using llDPe, the Styroflexhoods and either replaced, or was used in conjunction major varieties of which are those made with butene, material, iswith, strapping. hexene and octene copolymers, plus the later develop- growing in all Pallet stretch films are produced by either the blown ment of resins using metallocene single site catalysis geographicor cast film process – with the latter predominating, (known as mllDPe resins). marketsaccounting for 65% of global production. the advan- Pallet stretch films are usually supplied as a 400-tages of cast film include its superior appearance – 500mm wide single wound sheet that is then wrappedparticularly high clarity and surface gloss – increased around a palletised load in a spiral manner. the productfilm stiffness compared with blown films and its can be further divided into machine stretch and handrelatively low noise on unwind: this latter attribute is stretch. the advantages of machine stretch include:mainly a function of the means of achieving the cling efficient use of film compared with a hand-wrappingproperties in the two types of film. Blown film is operation; higher output rates; uniformly wrappedgenerally less transparent and less glossy than cast pallets; and less risk of any back strain injury to thefilm, but generally has superior puncture resistance operator performing the wrapping operation. A degreeand force-to-load holding power. Because many blown of capital investment is required to carry out machinefilms contain polyisobutene (PiB) to enhance the cling wrapping, but this depends very much on the level of sproperties, they tend to be noisier on unwind than cast sophistication of the packaging machine chosen.www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON
  10. 10. markets feature | Global stretch film PRODUCTION OF PALLET STRETCH FILM BY REGION Wrapping machinery mies. the market is now facing major questions: the Common wrapping machinery types are: turntable, demand for pallet stretch film is continuing to advance where the film carriage moves up and down as the in all regions of the world, although the more estab- pallet load rotates; rotary arm, where the pallet is lished countries are seeing a degree of maturity stationary as the arm rotates around it and the film resulting in a slowdown in the rate of increase in carriage goes up and down a mast; and ring machines, tonnage terms largely due to more efficient use of these which operate in a similar manner to rotary arm films and downgauging by the film producers. however, machines, where the load to be wrapped is stationary. developing nations are continuing to experience major these machines enable up to 150 pallets/hour to be investment and growth in the use of pallet stretch films. wrapped. At the other end of the scale is hand wrap, where the operator secures the end of the film to the Increased competition base of a stationary pallet and walks around the loaded With the increased competitive dynamic in the global pallet unwinding and stretching the film. hand wrapping marketplace, we are seeing capacity for production of has the clear advantage of no initial capital and the pallet stretch films expanding rapidly in some geo- choice of where in the factory the wrapping operation graphical areas in a way that could influence the takes place. the disadvantages are fairly obvious: the development of the market. more export-oriented process is labour-intensive and laborious, the amount plants are being commissioned in certain regions of the by which the film is stretched is variable and often world and this will lead to an increase in inter-regional insignificant (particularly towards the end of an trade that will have an increasing influence on the operator’s shift), the quality of wrap is variable and market. frequently, the development of production in a there is always a risk of back injury. even so, some 52% new global region is accompanied by significant of all stretch wrapped pallets in the world are wrapped advantages in raw material availability and price, low in this way and this proportion is forecast to increase to energy costs, low transport costs and low labour costs 54% by the year 2015 as China and other developing compared with those experienced in the more mature countries adopt the use of pallet stretch film. economies of europe and North America. strong demand from a wide range of industries, it is estimated that in 2004 the global demand for combined with a real competitive advantage against pallet stretch films was 2.3 million tonnes and that other forms of pallet stabilisation, has led to sustained currently demand is running at 3.3m tonnes per year – growth in mature markets and accelerating growth in an increase of 1m tonnes per year over the seven years other regions. in the early years the market was to 2011. Of this increased demand, some 350,000 primarily located in the developed economies of North tonnes came from Asia and 250,000 tonnes from America and Western europe: more recently there has europe, driven by growth in Central and eastern been substantial growth – both in production volume europe. Ami forecasts that, by 2015, demand for pallet and demand – in several of the world’s emerging econo- stretch film will have grown by a further 800,000 tonnes.10 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com
  11. 11. markets feature | Global stretch film the forecast shifts in import/export activity in Nafta and latin America are more modest. Up to now the majority of exports from europe have been destined for countries within the middle east Africa region and the indian subcontinent, in addition to some exports to latin America and Central America. the future increased level of production in the middle east is the main reason why european net exports will all but disappear. Within the overall figure for the middle east Africa region, saudi Arabia will show the most dramatic increase in exports to 2015. total exports from saudi Arabia, including those to countries within the meA region, have already grown from virtually zero to a current level of 100,000 tonnes in only six or seven years. looking into the future, it is forecast that exports GLOBAL PALLET STRETCH FILM TRADING BALANCE BY REGION from saudi Arabia will grow a further 100,000 tonnes to reach over 200,000 tonnes by 2015 – in addition to Of this, 360,000 tonnes will be in Asia, (45% of the volume supplied to the domestic market. increase), 160,000 tonnes in europe (20% of the so why are producers in saudi Arabia able to increase) and 120,000 tonnes in the middle east produce and export so much pallet stretch film? firstly, Africa region (15% of the increase). looking at produc- resin prices are significantly lower in saudi Arabia tion growth during the four years to 2015 by global compared with those in europe and other regions of the region, Ami forecasts that of the total 800,000 tonnes world and – although this differential varies depending per year, 350,000 tonnes will be in Asia, in line with the on the price of resin and prevailing exchange rates – the demand forecast, while 160,000 tonnes (20% of the cost advantage of resin procurement in saudi Arabia is production increase) will be in the middle east Africa always going to be substantial. Other advantages and 125,000 tonnes (15% of the production increase) include the fact that power costs are lower there than in will be in europe. Although increase in demand and many other world regions and the cost of transport increase in production are virtually in line for Asia, we from saudi Arabia to, say, northern europe, is no more see that europe and the middle east Africa regions than that experienced in shipping by road from italy to have effectively swapped positions – with europe the same destination. increasing production by only 15% of the global total What we have already seen – and what we are while demand increases by 20% and the reverse is true forecasting for the middle east to 2015 – is only the start in the meA region. of the changes that will take place in the pallet stretch film market. in subsequent years there is no reason Net exporter why production of pallet stretch films will not increase europe has been a net exporter of pallet stretch film even more dramatically in saudi Arabia, the United Arab since before 2001. forecast capacity and production emirates (UAe) and other parts of the middle east, increases mean that it will remain so beyond 2011, but taking advantage of the significant cost savings will become a net importer by 2015. Asia has also been mentioned earlier, and leading to a much higher level of a net exporter since 2001 and the level of net exports is global trading towards the end of the present decade. forecast to remain at similar levels as today through to 2015: the dramatic demand growth that we are More information currently seeing in China is absorbing much of the the multi-client study, the Global market for Pallet increased capacity going into the region and restraining stretch films, published in may 2011, is now available the level of exports from Asia. the most dramatic shift from Ami Consulting. it provides the latest information to date has been the reduction of imports to the middle on the pallet stretch film market globally, including east Africa from 50,000 tonnes to 5,000 tonnes in detailed demand and production forecasts by region and 2011, followed by a forecast of 45,000 tonnes net by country. for more details, contact John Campin exports from the region by 2015 driven clearly by (jjc@amiplastics.com) on +44 (0)117 924 9442. investments in the middle east. ❙ www.amiplastics.com12 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com
  12. 12. Handrollex ® www.handrollex.com handrollex. The best choice to have many choices.* The revolutionary system for producing stretch film with the best cost/benefit ratio of the investment. HANDROLLEX® The hanDrolleX® line offers the widest range of revolutionary, compact and inexpensive cast stretch possible stretch film productions: Manual, automatic film line for the production of manual, automatic and and Jumbo. jumbo rolls in formats ranging from 1000 to 4000 mm ProDucTion range web width, with coextrusion up to 50 layers and many on 2 or 3 cores/format and subformat productions others optional parts available. 500 mm 150 mm after sale service 365/24h and always available spare 450 mm 125 mm parts for immediate delivery. 250 mm 100 mm * More than 40 lines sold. Machinery range Width version 1000 or 2000 or 3000 or 4000 mm (39 or 78or 118” or 157) EXTRUSION LINEScoLineS® S.p.a (azzate Factory) - hanDrolleX® Division - Via 1° Maggio - 21022 azzate (Va) - italy Ph. +39 0332 456401 - Fax +39 0332 456410 - info@colines.it
  13. 13. The international conference and exhibition for the bi-oriented polypropylene film industry click here for detailsImages courtesy of: Treofan GmbH Co. KG and Innovia Films Platinum Sponsor 28 -30 June 2011 Austria Trend Savoyen Hotel, Vienna, Austria final reminder – book now! Organised by: Also Sponsored by: Media sponsor: Applied Market Information Ltd becky merriott – Conference manager rm@amiplastics.com Tel: +44(0)117 924 9442 fax: +44(0)117 311 1534
  14. 14. Biaxially oriented film | process feature Biaxial orientation is most commonly used with polypropylene, but other, more sophisticated, polymers can also benefit from the technique. Lou Reade reportsStretching beyond polyolefinsThe technique of stretching film in two directions – Lisim lines for optical film, which can deliver: better DSM’s lowknown as biaxial orientation – is widely used to improve yield of A-grade quality film; no scratches, due to non- oligomerthe barrier properties of film. The most commonly used contact stretching of film up to 400 microns thick; highly polyamidesubstrate is polypropylene (PP), but biaxial orientation transparent film; and very low MD-shrinkage due to (LOPA) can cutof other resins – notably PET and polyamide (PA) – is MD-relaxation. lactamimportant in a range of applications. Brueckner has also used its Lisim process to pollution Brueckner of Germany says that growing demand improve the optical properties of films in these during thefor flat panel displays, solar panels and flexible printed applications, by developing a simultaneous stretching/ production ofelectronics has led to increased demand for high end retarding process. BOPABOPET film. Alois Koerber, a development engineer at Brueck- The company has carried out a number of tests at its ner, says that stretching followed by relaxation is apilot line using its Lisim technology, which allows common way of enhancing film quality, and is usuallysimultaneous stretching of film. It has begun to offer done by uni-axial stretching between two rollers (in thewww.filmandsheet.com June/July 2011 | fILM ShEET EXTRUSION 15
  15. 15. process feature | Biaxially oriented film raw material. It can be used on amorphous raw materi- als such as cyclic-olefin-copolymers (COCs), cellulose triacetate (CTA), PMMA or polycarbonate, as well as semi-crystalline polymer films like PET, PP and PA. Higher dielectrics US researchers have found that biaxially oriented multi- layered films could have enhanced dielectric properties – making them potentially useful in high energy density film capacitors. The films, made of PET and a PVDF co-polymer, took advantage of the synergistic effects of microlayering and biaxial orientation, according to the researchers from the Center for Layered Polymeric Solutions at Case Western Reserve University in Cleveland, Ohio. Polymer film capacitors are attractive devices due to their low cost, simple construction, high operating voltages and long lifetimes. The major disadvantage of polymer film capacitors is their low energy density resulting from the low dielectric constant (K) of Lindauer machine direction) while it relaxes in the transverse polymers that are typically used as the insulating Dornier direction. This, he says, has several disadvantages: dielectric – usually PP or PET. recently maximum web width is limited by the lateral dimen- Multi-layer films were co-extruded using alternating supplied a film sions of the die and extruded melt; this is further layers of a PVDF-co-tetrafluoroethylene copolymer stretching line reduced by the lateral relaxation; and friction between (PVDF-TFE) and PET. Films with 32 layers were for BOPA film to the roller surfaces and film can lead to surface defects. produced in thicknesses of 5, 10 and 200 microns. local company The company’s Retard stretching method allows film Biaxial orientation was carried out using a Bruckner- MF-Folien to relax in the machine direction while being stretched type Karo IV laboratory film stretcher. Only the 200 in the transverse direction. This can be done by micron film was stretched: this resulted in a 20x decelerating the linear motor driven clips during reduction in thickness, making it comparable in transverse stretching. This leads to uni-axial molecular thickness to the two ‘unstretched’ samples. orientation (in the transverse direction). Compared to All compositions that were successfully biaxially the MD roller stretching method, Retard leads to oriented, including the PET control, had enhanced increased film web width. This means that compensa- breakdown properties compared to the unoriented tion films for large LCDs can be made easily and – in films. The optimum composition was 80/20 (PET/PVDF- producing compensation films for small LCDs – the TFE) and represented a 50% improvement in breakdown output can be increased because more film units can be properties compared to the unoriented microlayered cut from the film web along the transverse direction. films and controls. The addition of layers and layer The Retard process is not restricted to a particular interfaces into a dielectric structure provided an www.ndcextrusion.comFilm Sheet meaSurement appliCationS Control ■ Cast Film NIR, Non-nuclear, High ■ Battery Film Speed, High Resolution ■ Co-extrusions Measurements, for a ■ Stretch Film High Quality Flat Profile ■ Blown Film with Automatic Profile ■ Biax Control (APC) The Measure of Quality™NDC Infrared Engineering Ltd, Maldon, UK, CM9 5FA - Tel: +44 1621 852244 - Email: enquiries@ndcinfrared.com - Web: www.ndcinfrared.com
  16. 16. Proven technology – enhanced service. ervice Top s proved and im logy by o techn ITZ Biax AND R y lit W bi or a l d w i d e re l iANDRITZ Biax offers a com- project management experience. either sequential or simultaneousplete package of technology and No matter the material (BOPP, stretching technology.service for producers of biaxi- BOPET, BOPS, BOPA, PE, etc.),ally stretched films. Our package ANDRITZ Biax supplies produc- Learn how you can benefit from thecombines technical and process tion machinery and complete turn- new ANDRITZ Biax package – con-expertise with ANDRITZ’s financial key plants for all types of biaxi- tact us today: biax@andritz.com.strength, manufacturing depth, and ally stretched films. Our lines utilize www.andritz.com
  17. 17. process feature | Biaxially oriented filmSetting a BOPET benchmark Chinese BOPET film producer Jiangsu Suqian Color Plastic Packing recently installed an 8.7m wide line from Brückner set another benchmark in BOPET film production. The extrusion system is equipped with twin screw technology, which eliminates energy-intensive raw material pre-drying. It also features direct flake processing, which further boosts energy savings by feeding the edge trim flakes directly to the twin screw main extruder. The high melt quality and two gap stretching process allowed the company to produce A-grade quality immediately after start-up. The line has an output of 4250kg/h. additional barrier to breakdown and charge migration For polyester condenser film, plants are available for through the film thickness. final thicknesses of just 1 micron and a trimmed width The films showed breakdown fields as high as of 5.5m. For thick film application plants are available 1000kV/mm and energy densities up to 16.2J/cc – which for a maximum thickness of 400 microns and widths up was a 50-100% improvement compared to the unori- to 7m. For packaging, lines are available with a ented films. thickness range of 8-50 microns, a trimmed width of “These films combine the synergistic effects of 8700mm and speeds up to 500m/min. microlayering and biaxial orientation, which exhibit For polypropylene application the lines are designed enhanced dielectric breakdown properties – enabling for a thickness of 10-50 microns, a trimmed width of higher applied electric fields and subsequent higher 8700mm and production speeds of 500m/min. energy densities,” said the researchers. For polyester film production, it supplies lines equipped with extruders. But it also offers lines where Polyamide stretching the melt is provided from a polymerisation unit. Thick Lindauer Dornier, which makes film stretching lines, film applications are currently booming, says the showed a range of its products at the recent Chinaplas company, especially for optical grade film used for LCD exhibition. displays. Its equipment can handle a range of materials – The company has also supplied a film stretching line including polyester, polypropylene, PVC, PEN, PA and for biaxially oriented polyamide (BOPA) film to a local PS – to make film in a range of thicknesses. company – which is not common, as almost all of its Flexible Maag screen changer in extrusion The new flat slide screen changer by Maag combines the advan- tages of the well-proven FSC and HSC Series. Screen changing can be carried out either manually, hydraulically or electrically. The compact and economical execution ensures secure melt filtration and reliable sealing. The user can find the most optimum solution based on application and cost basis. a brand of maag group Maag Pump Systems AG | 8154 Oberglatt | Switzerland | welcome@maag.com www.maag.com
  18. 18. Quality Productivity!High performance slitting rewinding solutions World Leader in Slitter Rewinders for Plastic Film Atlas is one of the world’s largest manufacturers of slitter rewinders for plastic film, labelstock, paper board, providing solutions for customers on all 5 continents. Atlas has designed the world’s largest fastest slitting machines for plastic film. It has installed more than 200 primary film slitters worldwide exceeding 6m in width, including several at 10 metres wide. For some types of film, running speeds can be as high as 1500 m/min. The company also has a broad range of secondary slitter rewinders, processing both plain and metallized film in narrower widths up to approx. 4 metres. Fully automated and integrated roll handling systems can also be supplied to meet specific production requirements. Atlas Converting Equipment Ltd., Bedford MK42 7XT, UK sales.atlas@atlasconverting.com www.atlasconverting.com
  19. 19. PolyolefinAdditives2011 International conference on enhanced polyolefin additives and compounding clicK Here for DeTailS 18-20 October 2011 Maritim Hotel, Cologne, Germany * + 19% German VAT Special offer Save €100* if you register before 12th September 2011 SPECIAL OFFER::Save €100* if you register before 12th September 2011Organised by:by: Organised Sponsored by: Sponsored by: Media sponsor: Media sponsor: Applied MarketApplied Market Information Ltd.Information Ltd. rocio Martinez – conference organiser rmm@amiplastics.com ph: +44 117 924 9442 fax: +44(0)117 311 1534
  20. 20. Biaxially oriented film | process feature products are sold abroad. internal (cyclic) amides. These evaporate and condense The company, MF-Folien, is a European leader in PA as a fine, white powder that sticks to equipment, and film production and has made PA cast film for many can be transported through the air and inhaled by years. Its main market is the food industry, and this is workers. The cause of this evaporation is high C1 its second Dornier film line. With the new line, the film (caprolactam) content in the PA6. is stretched to a width of 5300mm, resulting in a final BOPA film is used for flexible packaging, particularly film thickness of 12-25 microns. The plant, which is food packaging, because it provides protection from 100m long, can produce about 5500 tonnes of PA film deterioration. A typical BOPA film line can produce up to per year. On the line, the cast film is cooled, stretched – 15 tonnes of lactams per year, which requires frequent first in longitudinal direction and then in transverse cleaning of stretching ovens and the overall facility. It direction – and finally wound to rolls on coils. may also pose a health risk to workers. BOPA convert- For the application in food packaging the PA film is ers see lactams as unavoidable, but DSM believes it has adhesively bonded with a PE film. The combination of solved the problem with its new material. the two materials allows humidity to escape but keeps Trials showed a marked reduction in lactam flavour in. pollution: compared to conventional PA6 at a viscosity of RSV 3.0, which has a C1 monomer level of about 0.18%, Cutting pollution LOPA has a level of about 0.10%. Meanwhile, DSM Engineering Plastics has developed a way to cut a common source of pollution during the Click on the links for more information: production of BOPA, with a low oligomer polyamide ❙ www.brueckner.com (LOPA). ❙ http://clips.case.edu/clipsresearch.html Production of BOPA film using conventional PA6 ❙ www.lindauerdornier.com resins can lead to pollution by lactams, which are ❙ www.dsmep.comWho can: help improveyour operating profits byproviding a complete lineof material handling andfeeding systems solutions?K-Tron can. Jay Coventry Engineering Manager Dean Li President BoltaronThe World’s Most Reliable and Accurate ProcessesStart with K-Tron.Companies around the globe turn to us for material handling and feeding solutionsbecause they know we can deliver. From machinery to maintenance, consulting toconcrete cost-savings, we’re the partner they rely on for success every step of the way.Find out how K-Tron can solve your material handling and feedingchallenges. Visit us at www.ktroncan.com.
  21. 21. NEW LOOK bookshelf MORE BOOKS We’ve improved the Plastics Information Direct online bookshop - please take a look today rECommEnDED rEADInGOur selection of the latest titles and essential reference works for the film sheet industryBloWn FIlm ExtrusIon BIoPolymErs: nEW mAtErIAls HEAt sEAlInG tECHnoloGy AnD For sustAInABlE FIlms AnD EnGInEErInG For PACkAGInG: CoAtInGs PrInCIPlEs AnD APPlICAtIons2011, by Cantor, 2011, by Plackett, 2009, by Hishinuma,E90.00 or £75.00 or $120.00 E100.00 or £85.00 or $135.00 E140.00 or £115.00 or $175.00Brand new Up-to-date A practical andedition, look at non- well-illustratedcombining petroleum guide. Essentialtheory and materials reading.practice. for practicalIncludes Blown applications.Film ExtrusionSimulator CD.For further information, or to order your copy For further information, or to order your copy For further information, or to order your copytoday, please click here today, please click here today, please click hereBAsICs oF trouBlEsHootInG PolymErs In PHotovoltAICs vACuum DEPosItIon ontoIn PlAstICs ProCEssInG: An 2011 ConFErEnCE ProCEEDInGs WEBs, FIlms, AnD FoIlsIntroDuCtory PrACtICAl GuIDE2011, by subramanian, 2011, 19 papers and CD, 2007, by Bishop,E115.00 or £95.00 or $140.00 E335.00 or £280.00 or $420.00 E155.00 or £130.00 or $195.00Another brand Discover the Practicalnew work latest polymer guidancedesigned for uses in back and to improvethe plastics front sheets, efficiency andprocessor. sealants and performance, encapsulants. from an industry expert.For further information, or to order your copy For further information, or to order your copy For further information, or to order your copytoday, please click here today, please click here today, please click hereAll prices are correct at the time of publication but may be subject to change. Please check the Plastics Information Direct website for current prices and shipping charges. WWW.PIDBOOKS.COM PLASTICS INFORMATION DIRECT Secure online ordering is available for credit card customers, or we are happy to deal with orders and enquiries by telephone, fax or email. Please contact: Matt Wherlock, Plastics Information Direct Bookstore - tel: +44 (0)117 924 9442 fax: +44 (0)117 989 2128 email: mjw@amiplastics.com web: www.pidbooks.com
  22. 22. Water-cooled blown film | process feature if polyolefin film is cooled rapidly, the resulting high clarity can take it into new applications. Lou Reade reports Clear winnerWater, with its high heat capacity, is a far more effective freezing of the melt minimises the build-up of crystal- High clarity PPcoolant than air. Of course, air-cooled machinery is usu- lites in the plastic, creating an amorphous structure film couldally cheaper – but there can be specific advantages to with excellent optical properties. At the same time, the replace PVC ineffective and rapid cooling using water. effect of biaxial stretching, which can only be achieved infusion bags, Blown film production is one area that is beginning with the blown film process, is maintained. it produces which must beto see huge benefits from this. Although water-cooled films with completely new properties that can be used transparentblown film has been available for some time, combining for a variety of applications.the method with the latest generation of materials is During K2010, Wh hosted an in-house event at itshelping some converters to replace materials like PVC headquarters in lengerich, where Aquarex was shownwith polyolefins. running a three-layer, 200 micron, high-clarity PP film Windmöller Hölscher has expanded its blown film for the production of infusion bags. the high clarity,product range to include the Aquarex line – which blows achieved through ‘shock cooling’ of the melt, isfilm downwards and uses water, rather than air, to especially important for the production of infusion bags.quench the bubble. traditionally, these are made of PVC. many product Wh says it has taken technology that is known for developers expect PP to replace the PVC, which onlyits use with smaller, special lines, and tailored it to becomes soft and pliable after mixing with plasticisers.meet the needs of the flexible packaging industry. high clarity PP films can be a good substitute. the company says that Aquarex opens up opportuni- Aside from the improved optical properties, theties for blown film manufacturers to create new packag- water quenching process can also boost mechanicaling products reaching beyond medical applications. properties such as puncture resistance. the highly Quenching the bubble with water rather than air amorphous micro structure also improves sealability, sdecreases the cooling time by a factor of 30. the sudden says the company.www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON 23
  23. 23. process feature | Water-cooled blown film eration of microcrystals – both reasons for haze – is restricted,” said the company. it also claims that the process can be used to make improved vacuum bags and thermoforming film, saying that conventional methods of cast and blown film have their downsides. While cast film techniques have quite good cooling, high producitivity and good tolerances, they can also have disadvantages, including: edge trims, high investment, restriction to axial orientation, high resin cost and curl. While blown film techniques can solve some of these – notably by cutting out edge trim and cutting invest- ment – they also have shortcomings: bad cooling, low productivity, radial orientation and low transparency are just a few. Plamex says that its iC technique combines the advantages of the two processes. “the film stays highly transparent and can be thermoformed to deep trays with rectangular shape and small loss of thickness in the lower edges,” says the company. Because different resins freeze at different tempera- tures, a curl in the direction of the resin that freezes at lower temperatures often occurs in asymmetrical layer combinations (such as PA/Pe). Using intensive cooling, as on the iC line, this process can be eliminated or even reversed – so that it curls towards the outer PA layer. this can help to make the bags easier to open. in principle the iC process is blown film extrusion modified by water cooling, which can banish edge cuts. the company claims that throughputs of up to 500kg/ hour are possible.The Aquarex PVC replacement Seven-layer productsline blows film One company, Melitek, has teamed up with Wh to Dr Collin of Germany also offers water-cooled blowndownwards and develop products. its meliflex range of polyolefin resins, film machinery, and has developed lines to make three-,quenches it based on tPe and tPO, was specifically developed for five- and seven-layer products that can compete withwith water pharmaceutical packaging and medical devices. it is plasticised PVC.instead of air ideal for medical applications as it is produced from the main application of its Bl 185/400 and Bl chemically inert raw materials. its film grades, meliflex 185/600 is within the medical field, for either infusion Xf, can be processed using either cast or blown film bags or secondary packaging. the lines can produce extrusion. heavy-walled bubbles up to 300 microns thick. layflat PP-based grades of the material, specially devel- widths of 30-500mm have been achieved to date, says oped for infusion bags, have been run on Wh’s the company. Aquarex blown film line. several elevated extruders feed a blown film die, the materials feature high softness and low whose die gap points downwards. the film bubble is flexibility, superior optical properties (with a clarity then guided down into a water-cooling ring, collapsed above 99% and a haze below 1%), high gloss and high and dried. it is then treated by a film gauge equalising heat sealing properties. unit (if required), or simply cut off and wound onto rolls. similarly, the iC system (standing for ‘instant Water calibration is a critical element: a flow Cooling’) from Plamex Maschinenbau ensures that the adjustment system helps to ensure that homogeneous melt is frozen in its amorphous state. cooling takes place, even at high take-off speeds. “the creation of macrospherulites and the agglom- Cooling water must be clean – and the system is24 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com
  24. 24. EXTRUSION PRINTIN PRINTING T CONVER ING CONVERTING N ERT N BEST IN CLASS: A TRADITION THAT RUNS IN OUR FAMILY. Best in class. Its a claim we live up to by developing new ideas and exceptional technologies. Take our new OPTIMEX 3-layer blown film line as an example; its modern die technology and ease of operation put it ahead of the class in terms of output and film quality. Plus, the OPTIMEX gets top marks in economic efficiency. Excellent prerequisites for being best in class in packaging, carrier bags, laminations, as well as in shrink- and stretch-hoods. For more information, visit www.wuh-group.com.PASSION FOR INNOVATIONWindmöller Hölscher KG | Phone: +49 5481 14-0 | Fax: +49 5481 14-2649 | info@wuh-group.com | www.wuh-group.com
  25. 25. process feature | Water-cooled blown film suitable for use in clean rooms. the Alpha Glacier system, from Alpha Marathon, is a downward water-cooled blown film line. the film is Advantages of iC cooled rapidly: if it cools slowly, it is susceptible to stretching and tearing, says the company. process from Plamax “if either of these problems arise, these disruptions l high film transparency and thermoformability with become very costly,” it said. Rapid cooling helps to avoid standard resins (such as commodity PA instead of these problems, to maximise production time and boost expensive copolyamides) production capacity. l Defined, adjustable microcrystallinity for higher During this process, the film stretches very little – density, more tensile strength, better puncture which helps to maintain its material properties. Clarity resistance, stiffness and barrier properties and transparency increase while haze is reduced. l Balanced film, adjusted to requirement (isotropic At K2010, the company exhibited a nine-layer Alpha or unisotropic) Glacier water quench film die. this happened soon after l eliminated or defined (to outside) curl it had delivered a water-cooled blown film line to an l Very high throughputs unnamed producer of medical packaging film in Asia. Sustainable choice an air ring of iBC uses 50kWh of power, while an Brampton Engineering says that its Aquafrost water- Aquafrost pump uses just 8kWh. for a 22-hour day, and cooled system is a sustainable choice for making a cost of 10c per kWh, Brampton says that switching barrier packaging – as it saves raw materials, energy over could lead to monthly savings of $2770. and water. the process delivers other economic savings for the company says that water cooling is more energy barrier packaging. for example, nylon 6 can replace efficient than conventional air cooling. the heat transfer more expensive nylon 66 in thermoformable films, while rate is very high, making the polymer quenching almost also improving optical properties and thermoformability instantaneous. compared to conventional blown film. in other cases, PP “Only a small volume of water in the closed loop can replace nylon for outer layers.Brampton says system is active at any one time,” says Brampton. “in Cast metallocene or plastomer films could bethat its conventional blown film, a large volume of air is cooled replaced with water-cooled llDPe film – which willAquafrost and delivered to the bubble through the air ring and the offer comparable mechanical properties due to thesystem uses far iBC. the bulk of the cooling air stream dissipates into transverse direction orientation that can be incorpo-less power the surrounding atmosphere. the low heat transfer rate rated into the process.than a conven- extends the quenching time and uses more energy.” Brampton has now sold 14 Aquafrost lines world-tional air- As a consequence, films made this way require lower wide, including three – to repeat customers – in the firstcooled blown thermoforming temperatures. quarter of this year. these latest systems are 9-, 10-film line Brampton estimates that a conventional blower on and 11-layer lines, which were all supplied with a flexstack sCD blown film die. One leading user of the system is not a medical company – as is often the case with water-cooled blown film – but a food packaging company. Packall Packag- ing, which specialises in meat, cheese and seafood flexible packaging, was the first North American Aquafrost user. it uses a nine-layer line to produce high clarity co-extruded barrier film that is 71-279 microns thick and up to 1828mm wide. Click on the links for more information: ❙ www.wuh-group.com ❙ www.melitek.com ❙ www.plamex.de ❙ www.drcollin.de ❙ www.alphamarathon.com ❙ www.be-ca.com26 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com
  26. 26. STRETCH SHRINK FILM 2011 The business conference and exhibition for the stretch shrink film industry The business conference and exhibition for the stretch shrink film CliCk here for DetailS October 11-12, 2011 October 11-12, 2011 Images courtesy of: Hyatt Regency Atlanta,Images courtesy of: Hyatt Regency Atlanta, Dow Chemical Company Atlanta, Georgia, USADow Chemical Company Atlanta, Georgia, USA SpeCial offer: Save $190 ifif you register before August 31, 2011 SPECIAL OFFER: Save $190 you register before August 31, 2011 Sponsored by: Media sponsors: Sponsored by: Media sponsors:Organized by: Organized by:Applied Market Applied MarketInformation LLC. Information LLC. Jessie Martin – Conference Coordinator jm@amiplastics-na.com ph: +1 610 478 0800 fx: +1 610 478 0900
  27. 27. Printing and converting | machinery featuresurface effectsPrinting adds enormous value to film, so it’s littlewonder that major converters are willing to invest in thelatest systems – which can add photo-quality printing to Lou Reade reports on some offilm at high speed. As well as trying to be more the latest printing systems thateconomical – by saving ink or energy, for example –some of the latest models take into account the need to are helping converters to addcarry out shorter product runs. Windmöller Hölscher showed off its miraflex Am 8 value to their productsat K2010 in Düsseldorf – and an earlier generationmiraflex Cm 10 at a corresponding open house event. inthe two years since the Am 8 line of central impression printed at speeds up to 370m/min. The CL 850flexographic presses was launched, more than 100 have many Am and Cm components and features are the duplexbeen sold. the company says this is due to a combina- same – including print length and width, press frame laminator wastion of its print quality and its configuration concept, and colour decks. the press frame and drive technology seen laminatingwhich allows printers to tailor the press specifically to of both presses result in high print quality and perform- a 6.35 microntheir needs. ance. With minimal energy use, advanced safety aluminium the miraflex Am 8 completes the Wh flexographic features, noise reduction, lel control and an ergonomic substrate to apress range. the machine seen at K has been sold to operation concept. 12 micron PETBema Polytech, a vertically-integrated converting the line shown at K2010 was equipped with easy- film, atcompany located in elmhurst, illinois in the Us. the Col, a colour matching system that allows for on-press Rotomec’s in-machine is available with 8- or 10-colour decks and is colour correction and reduction of excess ink. With house eventdesigned for printing lengths up to 800mm and printing shortened job changeovers and the reduction of left-widths of 820-1450mm. it can be used for both large over ink and other waste, it helps to lower productionand small jobs. film, paper and laminates can be costs. At the same time, it provides key data for thewww.filmandsheet.com June/July 2011 | film sheet eXtRUsiON 29

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