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Markus Gschwandtner, Brckner

Innovative Solutions for


Film Producers
Challenging Market
Markus Gschwandtner
Br
Brckner Group

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Contents

Current BOPP Market Situation


Industry Trends
Our Innovative Solutions

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AMI BOPP Film 2007 1


Markus Gschwandtner, Brckner

. Before We Get Started .

Dubai - our host city Brckner leading BO supplier


Sheikh Zayed Rd in 1990: Siegsdorf in 1963

.. and today: .. and today:

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Two New Members of the Brckner Group

Production and special-purpose machines for


plastics processing

Automotive
Medical
Packaging industry and technical parts

Advanced blown film extrusion lines


Machine direction orientation (MDO)
Winding
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AMI BOPP Film 2007 2


Markus Gschwandtner, Brckner

Brckner Group Your Benefits

Brckner is a strong, sound partner ongoing


100% family-owned
Comprehensive solutions from one reliable
source by combining product programs
We offer an all-embracing partnership within your
area of expertise: plastics processing

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Contents

Current BOPP Market Situation


Industry Trends
Our Innovative Solutions

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AMI BOPP Film 2007 3


Markus Gschwandtner, Brckner

Current Situation - Production Lines

Existing Lines
Not many plants stopped but modified
More and more upgrading to multilayer structure
(5 to 7 layers)
i.e. Vibac or Radici
Upgraded lines are used for in-house R&D

New Lines
Higher speed - production speeds above 400
m/min
More output 4,000 5,000 6,000 kg/h
and more
Multilayer structure
Value added films barrier films, optical films,
opaque films

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Additional sold BOPP Capacity 2006


in [tpa] based on Name Plate Capacity (NPC) *

Europe & CIS Greater China

Americas

PP 66.000

PP 131.000
Middle East & India

PP 162.500 PP 48.000
Total market share

86 %

14 %

* Source: Reference lists and market information of sold and effective equipment (04/2007) 8 Brckner

AMI BOPP Film 2007 4


Markus Gschwandtner, Brckner

Additional sold BOPP Capacity 2006 and 2007


Greater China
in [tpa] based on Name Plate Capacity (NPC) *

Europe & CIS

Americas

PP 66.000

Middle East & India


PP 237.000

Asia Pacific

PP 162.500 PP 85.000
Total market share
PP 37.000
90 %

10 %

* Source: Reference lists and market information of sold and effective equipment (04/2007) 9 Brckner

Contents

Current BOPP Market Situation


What are the Industry Trends
Our Innovative Solutions

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AMI BOPP Film 2007 5


Markus Gschwandtner, Brckner

Outlook New BOPP Resin Capacities

2005 Capacity 2015 Capacity A.a.g.r. %


(kton/yr) (kton/yr)
Middle East Africa 160 660 30 %

India Sub Continent 240 620 16 %

North East Asia incl. China 1.730 2.945 7%

South East Asia 410 815 10 %

Europe 1.150 1.490 3%


incl. C&E Europe, Turkey
North America 2.010 2.700 3%

South America 460 720 4,5 %

Source: Borealis A/S, KIWEB and other sources 11 Brckner

Outlook - World BOPP Film Market Growth by Demand

Area AVGR AVGR


00 05 05 10

Western Europe 5.2% 2.7%

Eastern Europe 9.8% 8.4%

North America 5.3% 3.4%

Central and South America 7.4% 6.5%

Japan 3.5% 2.0%

China 14.3% 9.6%

Other Asia Pacific 11.4% 5.9%

Middle East and Africa 6.7% 5.9%


Source: AMI and PCI 12 Brckner

AMI BOPP Film 2007 6


Markus Gschwandtner, Brckner

Outlook - World BOPP Film Market Growth by Type

Film type 2000 2005 2010 AVGR


05 10
Transparent 1,959 3,033 4,189 6,7%

Metallised (excl. capacitors) 297 497 664 6,0%

White/opaque/matt 545 755 919 4,0%

Total world demand 2,801 4,285 5,772 6,1%


Source: AMI and PCI

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Outlook BOPP World: Demand / Production

7.500.000

7.000.000

6.500.000

6.000.000
Demand Actual: CAGR
5.500.000 1998-2004 of 10,2% p.a.

5.000.000
Demand Projection on
CAGR 8,3 % p.a.
4.500.000

4.000.000
Tons

Demand Projection on
CAGR 6,8 % p.a.
3.500.000

3.000.000 Demand Projection on


CAGR 5,4 % p.a.
2.500.000
Production
2.000.000

1.500.000

1.000.000

500.000

0
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

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AMI BOPP Film 2007 7


Markus Gschwandtner, Brckner

Supply Chain View from the End User / Consumer

Machine Supplier Resin supplier Easy to open


Package size single household
Re-closeable
Film Producer Microwaveability
Design information, decoration,
Su

quality
Environmental issue, i.e. Wal
pp

Converting
Mart does not approve PVC
anymore
ly C

Sustainability
Packaging
hai

End User
n

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Supply Chain View from the Food Industry

Machine Supplier Resin supplier

Machine runability
FDA and EU directive approved
Film Producer Extended shelf life time
Cost saving packaging
Su

Improved properties

pp

Converting Environmental issues


Sustainability
ly C

Packaging
hai

End User
n

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Supply Chain View from a Converter

Machine Supplier Resin supplier Reduced lead times


Printability
High speed packing
Film Producer Constant film quality
performance
Su

Modified & improved barrier


properties
pp

Converting
Cost optimized laminates
ly C

Packaging
hai

End User
n

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Supply Chain View from a Film Producer

Machine Supplier Resin supplier

Smaller lots
Just in time production
Film Producer Stronger competition from other
markets in commodities
Su

Increased demand for specialty


products

pp

Converting Low energy consumption


Short product changing time

ly C

Low production costs

Packaging
hai

End User
n

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AMI BOPP Film 2007 9


Markus Gschwandtner, Brckner

Supply Chain View from a Resin Supplier

Machine Supplier Resin supplier

Higher stiffness
Low SIT materials
Film Producer Higher gloss
Better flow properties
Su

Seal strength and integrity


Cop with increasing oil price
pp

Converting
ly C

Packaging
hai

End User
n

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Supply Chain View from a Machine Supplier

Machine Supplier Resin supplier

Commodity products
Highly efficient lines
Film Producer Low energy consumption
Highly automated
Su

Specialty products
Flexibility
pp

Converting
Multipurpose
Multilayer
ly C

New products
Packaging
New technology
Extended R&D
hai

End User
n

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AMI BOPP Film 2007 10


Markus Gschwandtner, Brckner

Film Producers Challenging Markets

Machine Supplier Need to provide: utmost flexibility, highest efficiency,


low energy consumption, highest quality

Film Producer
Efficiency & diversification,
Su

value added film types


pp

Converting Appropriate converting steps & costs /


multi-functional films
ly C

Packaging
Cost efficient and intelligent packaging
hai

End User
Multifunctional flexible packaging,
n

environment-friendly, easy use


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Contents

Current BOPP Market Situation


Industry Trends
What are Our Innovative Solutions?

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Dubai Experts in Managing Challenges

Brckner Office in Dubai, UAE

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Our Innovative Solutions


For The Production Line

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Markus Gschwandtner, Brckner

Our Innovative Solution Increased Uptime

Topic: Challenge:
i Increased Uptime i Constant Production
> 7,500 h/yr Uptime Maintenance
Unforeseen Stops
Film Breaks

Solution: Benefit:
i High End Equipment i Higher Productivity
High Quality Equipment Up from 7,500 to 8,300 h/yr gives
Latest Technology + 4,000 tpa @ 5 to/h
Automation ~ 8 Mio. USD / yr
additional turnover
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Increased Uptime Direct Drives without Gears

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Markus Gschwandtner, Brckner

Increased Uptime LIWEB for Reduced Clipping Errors

TDO Inlet

Linear Motor

Ultra Sonic Sensor


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Our Innovative Solution Faster Product Change

Topic: Problem:
i Product Change i Off-Grade Film
More flexibility in product Changeover time > 1 h
management
Off-Grade film

Solution: Benefit:
i Controlled Changeover i Higher Productivity
Automatic changeover Reduced changeover time: 0.5h
@ 2 x per day, 4 to/h
Recipe management
~ 2,5 Mio. USD / yr
additional turnover
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Faster Product Change Recipe Management

Automatic changeover
function with ramping and
gauge adjustment
Preempting of storage and
dosing system
Accurate material tracking
Recipe management with
reliable time stamp function

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Faster Product Change MDO Gap Position Selection

Utmost flexibility in stretching


gap selection

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Our Innovative Solution Increased Production Speed

Topic: Challenge:
i Increased Speed i Yield
Low Margins Film Breaks
Thinner Film Lower Film Quality
Resin Properties

Solution: Benefit:
i High Quality Equipment i Higher Productivity
Advanced Technology Speed increase by 50 m/min @
25 m, 7,500 h/yr, 8.2 m
Reliable Components
~ 8,4 Mio. USD / yr
Proven Design
additional turnover
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Increased Production Speed Optimum Film Quality


TDO Top and Bottom Fans for Excellent Air Balancing

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Increased Production Speed Optimum Film Quality


TDO Fresh Air System with Heat Recovery Unit

Your Benefits
Energy saving > 200 kWh
Condensate reduction
Reduction of exhaust air
Easy handling and cleaning
Less pollution

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Increased Production Speed Output Increase


8,2 m 500 m/m BOPP Line
Brckner High Speed
Production Lines
3000

2500
Additional Output [kg/h]

30m BOPP Film

2000 25m BOPP Film

1500 20m BOPP film

15m BOPP Film


1000
12m BOPP Film
500
10m BOPP Film
0
350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500

Line Speed [mpm]

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Our Innovative Solutions


For The Production Plant

Our Innovative Solution - Turnkey BOPP Plant

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Our Innovative Solution - Turnkey BOPP Plant

Oct 1

July 12

March 1 Nov 1

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Our Innovative Solution - Turnkey BOPP Plant

Consulting and engineering

Plant design and construction

Plant utilities with all necessary


infrastructure

Stretching line

Slitters

Mill roll and slit roll handling

Coaters, laminators, metallizers

Turnkey supervision and installation

Training

All in-time and in-budget !!


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Our Innovative Solutions


For Product Development

Our Innovative Solution BOPP Specialty Films

Film Price

Raw Material Price

ng
agi Film
l e Film ab el P ack wra
p
e nk wi t
h
ilm alab ink
L
p eed FS O ver p aqu l Film Shri F ilm
e r O r r
eF at S Sh h S HF ink ite abe rrie rrie
Tap He MD Hig for Shr Wh ink L Ba Ba O H
Film r
Film Film Sh EV
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Our Innovative Solution Brckner Technology Centre


Sequential and Simultaneous Operation

Lab Stretcher Pilot Line

Film Laboratory Life Time Tests

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Our Innovative Solution - LISIM or Sequential Pilot Line

Extrusion Casting MDO TDO / LISIM Pullroll Winder


7 layers

The most flexible line worldwide

Multi-Layer up to 7 Layers
Multi-Polymers i.e. PP, PET, PEN,
PS, PA, PE, COC or PVC
Sequential or Simultaneous

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Our Innovative Solution BOPP Film Developments

Seal Integrity

Advantages
Applications VFFS High Sealing Strength

Features
Hot Tack
HFFS Low SIT Stiffness
High Sealing Strength Downgaging

7 Layer with EVOH


Transparent
Barrier 7 Layer with PA

Metallized Replacement
Ultra High Barrier
BOPP Barrier of Aluminium
Films
MD Shrink Alternative to
Shrink Label Sleeves
TD Shrink

Box Over Wrap MD Shrink Cigarette


Printing
High Surface PA Skin Layer Laminating
Tension Aroma/Flavour
PP / PE Replacement
Lidding
White Opaque Barrier of Coated Film
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Our Innovative Solution BOPP Low SIT Film

Structure Application

A: Copolymer / Corona
Treated Surface
B: PP
C: PP Core Layer
D: Copolymer
E: Very Low SIT
SEALANT

6
Advantages
Seal Strength [N/15mm]

5,5
5
5-Layer
High seal integrity 4,5
4
High packaging speed 3,5
3
3-Layer
2,5
2
1,5
1
0,5
0
90 95 100 105 110 115 120 125 130 135 140 145
Sealing Jaw Temperature [C]
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Our Innovative Solution BOPP Transparent Barrier Film

Structure Application
A: Skin
B: PP Blend
C: Tie Layer
D: Barrier Layer
E: Tie Layer
F: PP Blend
G: Skin

OTR Transparent
cm commercial films new development
Advantages mbar
1000
3-layer coex

Superior oxygen barrier < 2 cm/mbar


Excellent optics 100 7-layer with PA
Low temperature sealing PVDC coated
properties 10 SiOx coated

PVOH coated
7-layer with EVOH
1

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Our Innovative Solution BOPP Metallized UHB Film

Structure Application
Metallised Surface

A: High Surf.
Energy Polymer
B: Adhesive Layer
C: PP Core Layer
D: PP
E: Co-Polymer

OTR Metallized
cm commercial films new development
Advantages mbar
1000
Exceptional gas and aroma barrier
OTR: 0,15 [cm3/m2 d bar] @ 23C / 75% 100
standard metallized

WVTR: 0,2 [g/m2 d] @ 38C / 90% r.H. high barrier met.

10

ultra high barrier 5-layer HSE met.


0,1 46 Brckner

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Our Innovative Solutions


For Services

Service at a Glance Financing Support


Brckner Realized Financings of EUR 354 Mill. in 2000 - 2006

ECA covered buyers credit


195 Mill.

Short term financings


Leasing
up to 1 year
30 Mill.
129 Mill.

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Service at a Glance Financing Support


Sample: Project Financing Bank Loans / Direct Loan

Supply Contract
Seller Buyer

Audited balance sheets


(IFRS/IAS, US-GAAP)
Profit and loss accounts
ECA: Euler
Company profile
Hermes
Feasibility study
Hermes Financial sources
guarantee

Bank of seller
IFRS = Intern. Financial Reporting Standards
IAS = Intern. Accounting Standards
US-GAAP = Generally Accepted Accounting Principles
Loan agreement
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Service at a Glance Tele-Service Solutions


We see what you see
at Brckner at Your Site

... Wearing the


Mobile Service Assistant
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Markus Gschwandtner, Brckner

Service at a Glance Highlights in Upgradings

Speed upgrade: the worlds fastest BOPP line - 525 m/min


7-Layer film production with high barrier EVOH capability
Thickness measurement controlled infrared heaters in TDO
Fully integrated web scan systems for maximum quality control
Electrical and automation upgrades
TDO heat recovery and condensate absorption system
Line conversion to shrink film production (OPS or OPVC)
Winder contact roll system upgrade (LIWIND), ultra-fast response
and highest accuracy
Special MDO for optical film, 100% direct drive controlled and with
automatic roller cleaning

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Service and Sales at the Spot We are where You are

Germany Russia
Brckner Group OOO Brueckner

Slovakia
Brueckner Slovakia s.r.o.

China
Brueckner Machinery
Jiangyin Co., Ltd.
U.S.A.
Brueckner Inc.

Mexico China
Brueckner Mxico S.A. Brueckner Far East Ltd.
de C.V. Hong Kong

Indonesia
Brasil Brueckner Far East Ltd.
Coras do Brasil

Argentina UAE India


Coras Brueckner Middle East Brueckner India Pvt. Ltd.
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Markus Gschwandtner, Brckner

Thank You

AMI BOPP Film 2007 27