Document1

EVOLUTION – Innovative Blown Film Technology

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

Agenda

Reifenhäuser Group in in Brief

Reifenhäuser Kiefel Extrusion in Brief

Market data – Trends and Drivers

Magic triangle of Extrusion

EVOLUTION Highlights

Conclusions

10. April 20134

Reifenhäuser Group – „The Extrusioneers“Focused on Extrusion

PET Strapping tape lines

1.200employees

Reifenhäuser Group we believe in entrepreneurship

5 10. April 2013

All corecomponents are

in-house developed

Reifenhäuser Group Focus on R&D

6 10. April 2013

Made in Germany

Reifenhäuser Group Competence in manufacturing

7 10. April 2013

10. April 20138

Reifenhäuser Kiefel Extrusion in Brief

Focus on blown film only More than 7.350 installed lines - worldwide Widest product range Extruder: 50 - 200 mm Die diameter: 120 - 2.500 mm Film width: 1.000 - 5.800 mm In-house design & manufacturing of core components Local service organizations

Market Data – Trends and Drivers

10 April, 20131010

Blown Film ProductionRegional Distribution Middle East

2009 2014

Middle East Blown Film ProductionWorldwide Blown Film Production

Mio Tons Source: AMI

Annual growthapprox. 7,7%

5,3% equals approx. 2,42 mio. tonns

Major drivers:- Turkey- Saudi Arabia

10 April, 20131111

Global Blown Film ProductionRegional Distribution

Western Europe16,31%

Eastern Europe5,89%

Middle East4,78%

India4,63%

China23,63%

Asia Pacific17,99%

North America15,33%

South America8,24%

Africa3,19%

Western Europe13,13%

Eastern Europe5,29%

Africa3,14%

Middle East5,30%

India5,28%

China27,28%

Asia Pacific16,97%

North America15,19%

South America8,43%

45,8 Mio. Tons35,1 Mio. Tons

2009 2014F

Source: AMI Plastics, UK

7,7% annual growth in Middle East

Blown Film Trends

Increasing number of multi-layer lines 5-, 7-, and 9-layer

Transfer of traditional 3-layer films to 5-layer structures

Increasing number of films with barrier properties

Since 2009

increasing number of 5-layer lines focus of 9-layer lines for high barrier applications

MAJOR APPLICATION: FOOD & PACKAGING FILMS

12 10. April 2013

Benefits of Multi-layer Films

Down gaugingUse of new resin grades

Film properties

Opening of newmarkets

Use of cheaperraw materials

Broader range oflayer distributions

Flexibility

Barrier properties

Benefits

10 April, 201313

Blown Film ProductionFilm Cost Factors

Source: AMI

14 10. April 2013

Global Requirements of Film Producers

Converter‘s Film RequirementsMajor Criteria

Printability/Register accuracy

quality

Printing speed

output

Type of films

flexibility

16 10 April, 2013

Picture: courtesy of Bobst Group

Converter‘s Film RequirementsImpacts on Film Producer

Quality surface tension optical properties tolerances skiing of film

Output tolerances film planarity waste

Flexibility range of film dimensions range of materials

17 10 April, 2013

Picture: courtesy of Comexi Group

Magic Triangle of ExtrusionGoals of Extrusion

Flexibility

1 : 01 : 0 ULTRA RANGE EXTRUDERS (22´)

FLEXIBILITY

2 : 0 EVOLUTION ULTRA COOL (48´)OUTPUT

3 : 0 EVOLUTION ULTRA FLAT (72´)QUALITY

2 : 03 : 0

Ultra Range Extruders processing all materials without screw change

Ultra Range Die Heads broad processing window low residence time fast purging properties

Ultra Range Winders for all film types (tacky, high slip content, stiff, etc.)

EVOLUTION C with Apps such as start up assistant job change assistant

Flexibility

Magic Triangle of ExtrusionFlexibility

EVOLUTION Ultra Range Extruders

Screw design for PE, PP, mLLDPE, Reclaim, CACO3, liquid PIB, as well asPA, EVOH, K-resin, PETG, COC, etc. = Flexibility and Quality

Low temperature screws, high efficiency mixer – High Output / Energy Saving. Grooved feed section with unique heating / cooling section

Ultra Range Screws providing low melt temperature

Ultra Range Die Heads providing less back pressure allowing high outputs

EVOLUTION Ultra Cool

Flexibility

Magic Triangle of ExtrusionOutput

10 April, 201322

Ultra Cool – Stable Bubble even at Highest Rates

Ultra Performance Cooling System EVOLUTION ULTRA COOL

Ultra Performance- High Output- High Quality

Ultra Flexibility- Wide Product Range

Ultra Handling- Fast start up & Fast

change overs

Ultra Range Screws providinghomogeneous melt

Ultra Range Die Heads providing perfect gauge variation

EVOLUTION Ultra Flat Take Off

EVOLUTION Ultra Stretch Take Off

EVOLUTION Ultra Range Winders for perfect roll quality

Magic Triangle of ExtrusionQuality

Flexibility

EVOLUTION Ultra Range Take-off Systems

Enhancement of Film QualityCamber

Camber of film is caused mainly by different length in the collapsing frame

Different length depends on collapsing angle ,e.g. for a collapsing angle 11°: 0.34 % length difference

L1 > L2

Enhancement of Film QualityFlatness

Bagginess in the film are mainly causedby length and temperature variations

Bagginess leads to different lengths of

the film, when cutting into stripes

Bagginess in the film

Slightly stretching of the film optimizes

film flatness

EVOLUTION ULTRA FLAT Take-offEnhancement of Film Quality

THE KEY FOR SUPERIOR FILM PRODUCTIONEnhancing film quality through integrated flattening package

Customer benefits Improved film flatness Reduced film camber Reduced film bagginess Reduced waste

Superior post processing performance Improved printing speed Improved register accuracy Improved product quality

Superior energy efficiency through use of “first heat”

28 10 April, 2013

EVOLUTION ULTRA FLAT Take-offBullet Points

Highest film quality concerning flatness and camber→ superior converting processabilities

High energy-efficient process

No negative influence on the thickness profile due to minimal stretching

EVOLUTION C Automation

Job Change Assistant

Secure product changewithout operator errors

Faster than operatorscan manually do

Parallel actions

Less scrap, less costs,more profitable pro-duction

Higher line availabilityfor production

ConclusionsThe day after tomorrow

Continuous Improvements on raw materials

Use of different raw materials, replacing traditional structures

Simplyfying structures

Improvement of barrier properties

Increase of output

Using more Layers with reduced resin cost

Further down gauging - Stretching the limits

Magic Triangle of ExtrusionGoals of Extrusion

More innovative solutions will be demonstrated at

K’2013

Document1

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