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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
-
10,00
20,00
30,00
40,00
50,00
60,00
2009 2014
Middle East Blown Film ProductionWorldwide Blown Film Production
4,78%
5,30%
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
COST
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
EFFI
CIE
NC
Y
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
L1L2
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
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