june-july 20011 Film&sheet Extrusion magazine

1. June/July 2011
WATER-COOLING CREATES CRYSTAL CLARITY
BIAXIAL ORIENTATION FOR PA AND PET
MORE GROWTH IN GLOBAL STRETCH FILM
ADDING VALUE WITH HIGH SPEED PRINTING

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3. contents
04 Industry news
european Commission considers plastic bag ban; inteplast boosts stretch film
pAge 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 reports
pAge 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 reports
pAge 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 converters
pAge 2
to add value to their products COveR phOtO: hilDe vANstRAeleN/www.BiewOef.Be
35 Technology: Materials
36 Technology: Machinery
pAge 29
40 Extruder of the month
42 Dates for your diary
coming next issue
Bioplastics ❙ Barrier film materials ❙ Control instrumentation ❙ Applications in photovoltaics
➤ Click here to make sure you get your copy
contact 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. news
inteplast plans increase Nordenia lifts
production in
to stretch film capacity Germany
Us-based inteplast is to tonnes) annually. the two new lines will be Nordenia international is to
increase stretch film capacity Amtopp’s stretch film operational in the second half expand production in
in its Amtopp division by operation produces conven- of 2012. Germany, with a three-layer
adding two cast film extrusion tional and engineered hand film At the same time, it will co-extrusion facility due to
lines 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 mainly
tenth cast stretch film high-speed machines will nia – with plans to add five produces films for food
extrusion lines at the facility. produce ultra-light gauge pallet stretch film lines there. packaging that is sold across
the expansion will take wrap products and increase together, the two initiatives europe, is investing E3
Amtopp’s stretch film production of loadstar will extend its service in the million in its Osterburken
nameplate 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 thirteenth
Bilcare adds machine will lift production
from 22,000 to 26,000 tonnes/
Pet film to year. the move is also
expected to take the number
portfolio of employees from 90 to 93.
“With the continued
Bilcare solutions has extended expansion of our production
its portfolio with a PetG film capacities, we will be able to
line in staufen, Germany. meet the requirements of our
the combination of a new customers all over europe,”
Pet extruder with an existing said managing director
stenter line will lead to Andreas Paul.
optimum manufacturing the plant focuses on
efficiency, says the company. making blown films using
“the capacity extension monoextrusion and coextru-
enables us to serve the fast sion.
sabic boosts optical
growing market of shrink film end uses can range from
for sleeve applications even coffee or soup packaging, up
better than before,” said heinz to films for light-sensitive
Gärtner, chairman of Bilcare
Research.
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 has
Pet extruder with an existing polycarbonate resins and film in China – including an extrusion installed a bioriented
stenter line will lead to line for its optical quality (OQ) film in Nansha. polypropylene (BOPP) line at
optimum 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 and
film 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 scheduled
films in the form of coating, tive and security sectors. the materials are widely used in to come on stream at the end
stentering, 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. news
eC considers total ban
on plastic bags in europe
the european Commission has launched
a consultation into ways of reducing the
use of plastic carrier bags in europe.
the public consultation will consider a
complete ban – as has already been carried
out in italy. it will also consider a ‘bag tax’,
as well as ways to improve biodegradability.
“fifty years ago, the single-use plastic
bag was almost unheard of – now we use
them for a few minutes and they pollute
our environment for decades,” said the
european Commissioner for environ-
ment, Janez Potocnik. “there is a Potocnik: “We are looking at all the
widespread desire for change. that’s why options, including a Europe-wide ban on
we are looking at all the options, plastic carrier bags”
including a europe-wide ban on plastic
carrier bags. We need the views of as the consultation will also gather views
many people as possible to complement on the adequacy of current requirements
our scientific analyses.” on compostability and biodegradability in
some eU member states have already the eU Packaging Directive. the Directive
taken action to reduce the use of plastic does not clearly distinguish between
carrier bags through pricing measures, biodegradable products – which should
agreements with the retail sector or bans biodegrade naturally in the environment
on certain types of bags, but no specific – and compostable products, which only
measures exist at the eU level. biodegrade in industrial composting
every year, the average eU citizen facilities. the consultation runs until 9
uses 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.htm
UAe: bags phased out by 2013
the United Arab emirates (UAe) is to director general of esmA, said: “All the
phase out conventional plastic bags by plastic bags used in the UAe must be
We maximize
2013, and replace them with biodegrad- biodegradable from 2013 so the people
able alternatives. using them should be made aware of this
film producer's profitability
According to a report in Gulf News, all regulation and practise it.” Tailor-made project consulting
providers and suppliers of oxo-biode- About 95% of the plastic bags used in Reliable commissioning
gradable additives — ingredients that the UAe are manufactured in the country. German workmanship
help plastic bags to degrade quickly — it is estimated that there are more than Flexible and efficient lines
will need to be verified and approved by 100 manufacturers and suppliers of bio- Comprehensive service
the emirates Authority for standardisa- or oxo-biodegradable additives in the Individual financing solutions
tion and metrology (esmA) before they UAe. three suppliers of these additives
can deal with plastic manufacturers and have been approved by esmA: Wells
traders. Plastics, symphony environmental and www.brueckner.com
mohammad saleh Badri, acting Bin hilal enterprises.
www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON

6. news
Dow trial shows benefits of
energy recovery from plastic
Dow has carried out a pilot test equivalent to 11.1m BtUs of of energy and ultimately help ing, such as flexible films and
to show that recycled plastic natural gas, was used to fuel reduce our need for natural containers made from a
film 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 do
plastic at the end of its life film from one of Dow’s American plastics business. not replace traditional
could be used as a fuel rather extrusion laboratories was “the results demonstrate that recycling – they extend and
than 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 energy
energy was recovered after packaging food and consumer can be captured and reused.” in recycled plastic is used in
incinerating 578lbs (263kg) of products. While many thermoplastics europe and other regions. Our
used plastic in a kiln at one of “the purpose of the test can be reprocessed, there are next step is to help find a way
its 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.com
Ami adds new consultants and an editor
Applied market information industry knowledge and
(Ami) has expanded its experience that will help us to
consulting team with two new continue with the rapid growth
appointments that increase of our digital magazines
the group’s expertise in business, as well as contribut-
plastics processing, packaging ing to Ami’s successful
and recycling, as well as bring- conference activities and
ing 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 World
joined the company as a been appointed packaging journalist and editor. magazine from the June issue
technical consultant. he has consultant at Ami. she joins smith has a degree in and will also be working on a
held a number of technology the company from Zenith materials science and worked number of new publishing
management 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 will
and automotive components a variety of dairy and beverage into magazine publishing. for continue to be edited by Andy
plants. more recently, he was a markets. this work included the past 20 years he has been Beevers who has a degree in
packaging technologist with coordinating global databases writing about plastics technol- Chemical engineering and
the UK retailer, marks and covering the bottled water and ogy including stints as technol- more than 25 years experience
spencer, 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 plastics
Braiform, 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 to
graduated in materials science developed a close understand- Communications. edit film and sheet extrusion
and 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 Chemistry
obtained a diploma in manage- l the Ami magazines team is said: “We are delighted to add and more than 20 years of
ment 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

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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 horizons
Of all the major sub-divisions of the polyethylene film films. Back in the early 1980s, stretch films were Demand for
industry, the global pallet stretch film market has been produced using low density polyethylene (lDPe), but pallet stretch
one of the strongest growing sectors for many years. development of stretch films really took off in the mid- film, such as
Developed on a commercial scale during the mid 1980s, 1980s following the introduction of linear low density this one based
it rapidly began to penetrate more traditional methods polyethylene (llDPe). stretch films, both blown and on BASF’s
of pallet stabilisation from the 1990s: it replaced shrink cast, are primarily manufactured using llDPe, the Styroflex
hoods and either replaced, or was used in conjunction major varieties of which are those made with butene, material, is
with, 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 geographic
or cast film process – with the latter predominating, (known as mllDPe resins). markets
accounting 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 wrapped
particularly high clarity and surface gloss – increased around a palletised load in a spiral manner. the product
film stiffness compared with blown films and its can be further divided into machine stretch and hand
relatively 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-wrapping
properties in the two types of film. Blown film is operation; higher output rates; uniformly wrapped
generally less transparent and less glossy than cast pallets; and less risk of any back strain injury to the
film, but generally has superior puncture resistance operator performing the wrapping operation. A degree
and force-to-load holding power. Because many blown of capital investment is required to carry out machine
films contain polyisobutene (PiB) to enhance the cling wrapping, but this depends very much on the level of
s
properties, 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. 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

12. 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.com
12 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com

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14. The international conference and exhibition for
the bi-oriented polypropylene film industry
click here
for details
Images 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

15. 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 reports
Stretching beyond polyolefins
The technique of stretching film in two directions – Lisim lines for optical film, which can deliver: better DSM’s low
known as biaxial orientation – is widely used to improve yield of A-grade quality film; no scratches, due to non- oligomer
the barrier properties of film. The most commonly used contact stretching of film up to 400 microns thick; highly polyamide
substrate is polypropylene (PP), but biaxial orientation transparent film; and very low MD-shrinkage due to (LOPA) can cut
of other resins – notably PET and polyamide (PA) – is MD-relaxation. lactam
important 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 the
for flat panel displays, solar panels and flexible printed applications, by developing a simultaneous stretching/ production of
electronics has led to increased demand for high end retarding process. BOPA
BOPET 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 a
pilot line using its Lisim technology, which allows common way of enhancing film quality, and is usually
simultaneous stretching of film. It has begun to offer done by uni-axial stretching between two rollers (in the
www.filmandsheet.com June/July 2011 | fILM ShEET EXTRUSION 15

16. 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
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17. 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 i
ANDRITZ Biax offers a com- project management experience. either sequential or simultaneous
plete 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 the
combines 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

18. process feature | Biaxially oriented film
Setting 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

19. 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

20. 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 2011
Organised by:by:
Organised Sponsored by:
Sponsored by: Media sponsor:
Media sponsor:
Applied Market
Applied Market
Information Ltd.
Information Ltd.
rocio Martinez – conference organiser rmm@amiplastics.com ph: +44 117 924 9442 fax: +44(0)117 311 1534

21. 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.com
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concrete 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 feeding
challenges. Visit us at www.ktroncan.com.

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23. 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 winner
Water, with its high heat capacity, is a far more effective freezing of the melt minimises the build-up of crystal- High clarity PP
coolant than air. Of course, air-cooled machinery is usu- lites in the plastic, creating an amorphous structure film could
ally cheaper – but there can be specific advantages to with excellent optical properties. At the same time, the replace PVC in
effective 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 be
to see huge benefits from this. Although water-cooled films with completely new properties that can be used transparent
blown 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 its
helping some converters to replace materials like PVC headquarters in lengerich, where Aquarex was shown
with 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, is
film 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 only
its 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, the
ties for blown film manufacturers to create new packag- water quenching process can also boost mechanical
ing 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,
s
decreases the cooling time by a factor of 30. the sudden says the company.
www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON 23

24. 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 products
line blows film One company, Melitek, has teamed up with Wh to Dr Collin of Germany also offers water-cooled blown
downwards 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 with
with 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 is
24 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com

25. EXTRUSION PRINTIN
PRINTING
T CONVER ING
CONVERTING
N ERT N
BEST IN CLASS: A TRADITION THAT RUNS
IN OUR FAMILY.
Best in class. It's 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 INNOVATION
Windmöller Hölscher KG | Phone: +49 5481 14-0 | Fax: +49 5481 14-2649 | info@wuh-group.com | www.wuh-group.com

26. 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 be
that its conventional blown film, a large volume of air is cooled replaced with water-cooled llDPe film – which will
Aquafrost and delivered to the bubble through the air ring and the offer comparable mechanical properties due to the
system 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 first
cooled 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.com
26 film sheet eXtRUsiON | June/July 2011 www.filmandsheet.com

28. 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, USA
Dow 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 Market
Information LLC.
Information LLC.
Jessie Martin – Conference Coordinator jm@amiplastics-na.com ph: +1 610 478 0800 fx: +1 610 478 0900

29. Printing and converting | machinery feature
surface effects
Printing adds enormous value to film, so it’s little
wonder that major converters are willing to invest in the
latest systems – which can add photo-quality printing to
Lou Reade reports on some of
film at high speed. As well as trying to be more the latest printing systems that
economical – by saving ink or energy, for example –
some of the latest models take into account the need to are helping converters to add
carry out shorter product runs.
Windmöller Hölscher showed off its miraflex Am 8
value to their products
at K2010 in Düsseldorf – and an earlier generation
miraflex Cm 10 at a corresponding open house event. in
the two years since the Am 8 line of central impression printed at speeds up to 370m/min. The CL 850
flexographic presses was launched, more than 100 have many Am and Cm components and features are the duplex
been sold. the company says this is due to a combina- same – including print length and width, press frame laminator was
tion of its print quality and its configuration concept, and colour decks. the press frame and drive technology seen laminating
which allows printers to tailor the press specifically to of both presses result in high print quality and perform- a 6.35 micron
their 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 a
press range. the machine seen at K has been sold to operation concept. 12 micron PET
Bema Polytech, a vertically-integrated converting the line shown at K2010 was equipped with easy- film, at
company 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 event
designed 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 production
and small jobs. film, paper and laminates can be costs. At the same time, it provides key data for the
www.filmandsheet.com June/July 2011 | film sheet eXtRUsiON 29