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Machinery solutions for

Thinner and Stronger Collation and Packaging Film


•What drives growth & innovation
•Packaging requirements
•Collation Shrink Films state of the art & beyond
• Multilayer evolution
• Downgauging development trends
• New resins developments in metallocene polyethylene
• Assessing 5-layer POD technology capabilities
• Boost 5-layer polyolefin-dedicated (POD) technology
with new 5-layer formulations , recent cases

> Turning 5-layer POD technology into a business reality


What Drives Growth & Innovation

We drink more
Increased per capita consumption
Population Growth

Increased level of sales through supermarkets


Higher demand for multi-packs
Brand recognition and point-of-sales advertising

Sustainability
Cardboard replacement, downgauging, ease of recycling,
waste reduction, energy reduction, total cost reduction, lower
carbon footprint
What Drives Growth & Innovation
SOFT DRINKS GLOBAL
700.000

600.000
Middle East - Africa
500.000
Asia Pacific
LITERS ( MM )

400.000
Eastern Europe

300.000 Latin America

200.000 Australasia

Western Europe
100.000

North America

00 01 002 03 004 6
05 00 00
7 08 09 010 011 012 013 14 015 16 0 50 100 150 200 250
20 20 2 20 2 20 2 2 20 20 2 2 2 2 20 2 20

A growing industry of 60 Billion liters  +33% in 10 years Off trade volume liters per capita

Data Source: Euromonitor


What Drives Growth & Innovation
Cardboard replacement
LCA / CO2 benefits available today results in significant costs
No Need for Corrugated Board and environmental savings!
+ Fewer Trucks
+ Lower CO2
Strong Trend to Reduce Corrugated board

Estimated Costs Eur / package


+ Less Energy = Improved LCA Resulting in lower costs & Lower LCA (Life CycleAssessment)
Example: 4 Pack of Cans Corrugate
89% GreenHouseGas (gCO2 Eq)
Saving 78% Process Energy (MJ)
Plus: 55% savings vs Open Side Boxes

Example: 6 Pack of Bottles Corrugate


93% GHG (gCO2 Eq) Saving
Saving 86% Process Energy (MJ) Saving
Plus: 45% savings vs Top Handle Boxes
Paperboard
Corrugated Tray Shrink Film
+ Shrink Film
What Drives Growth & Innovation

Total Market Size in EMEA: > 900.000 MT


Growth rate: +2% per year
Beverage represents > 50%
Middle East
End Application Western Europe Eastern Europe
& Africa

Beverage 51% 47% 50%

Food 26% 28% 30%

Healthcare 8% 9% 7%
Household (e.g. diapers, tissues, cosmetic, personal
10% 10% 11%
care products, small appliances)

Others 5% 6% 2%
Packaging Requirements

Performance

Sustainability

Costs

1920 2014
Packaging Requirements
Shrink Hoods & Industrial Shrink Generic Collation Shrink Premium Clarity Collation Shrink

Technology:
Technology:
Technology: 3 layer coex blown film
3 layer coex or monolayer blown film
monolayer blown film
Skins
Skins
rich in
LDPE 555E rich in
LDPE 555E
or DOWLEX™ 4056G (optics)
or LDPE 303E
LDPE 303E or
+ DOWLEX™ 4056G
+ DOWLEX™ NG 5066G
HDPE (stiffness)
Core + LDPE 320E
+ LDPE 555E
DOWLEX™ 2045G or LDPE 303E
or + HDPE
DOWLEX™ 2645G Core Layer(s)
Monolayer LDPE 555E*
LDPE 303E or
+ HDPE LDPE 535E
or LDPE 555E + / or
+ DOWLEX™ 4056G XUS 59999.18 NEW!
®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Collation Shrink Films TODAY
Dow’s Top Benchmark Benefits
COEX 3 layers
 Very High Gloss
 High Stiffness for Downgauging
 Superior tear & processing
+ HDPE 40-50 micron for 1.5L six-packs
Shrink (MD)
175 Competitive Solution
150
125 50 um 20/60/20 A/B/A; A: 95% Mlldpe (0.927; 1.3)+5%
100
Melt Pressure
75
Shrink Load (MD) LDPE (0.928; 0.5); B: 90% LDPE (0.928; 0.5) + 10%
50 HDPE (0.965; 2.5)
25
0 DOWLEXTM NG 5066G Solution
50 um 20/60/20 A/B/A; A: 80% DOWLEX™ NG 5066
Tear Resistance (CD) Gloss 45% +20% LDPE 320E; B: 80%LDPE 555E+20% HDPE

DOWLEXTM 4056G Solution


2% Secant Modulus
(CD)
(CD) 50 um 20/60/20 A/B/A; A: 80% DOWLEX™ 4056G+
20% HDPE; B: 80%LDPE 555E+30% HDPE
®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Collation Shrink Films TOMORROW
Dow’s Top Benchmark Benefits
COEX 3 layers
 Very High Clarity
 Boosted Puncture Resistance
 Superior Toughness

NEW XUS 59999.18 + < 40 micron for 1.5L six-packs

Puncture resistance
Dow Incumbent Solution
200
NEW 150 NEW: Dow Next Generation Solution
shrinkable C8-MDPE resin
XUS 59999.18 100
DDI Toughness (MD)
0.935 / 0.5 50

2% Secant modulus
Clarity
®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow (MD)
Collation Shrink Films BEYOND TOMORROW
NEW CONCEPT Benefits
COEX 5 layers COEXTRUSION VS. BLENDING
• Improved Stiffness
• Boosted Toughness
• Increased Tear Resistance
< 35 micron for 1.5L six-packs
Patent pending XUS 59999.18
Toughness (MD)
150 NEW: Dow Next Gen 5 Layer Solution

125
Dow 3 Layer Solution
100

75

MORE dedicated functional layers 50

COEXTRUSION
VERSUS Avg Elmendorf Tear
2% Avg Secant modulus
(MD/CD)
BLENDING
®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
5 Layer System Solution – How Can You Benefit Today?
Incumbent solution

20% film downgauging


= Dow Next Generation solution
=
25% more product packed
which also means

20% LESS TRUCKS LOWER CO2 EMISSIONS SAVED


due to higher pack yield per
NEEDED 1 kg of polymer ENERGY
to transport the film to plants thinner film = faster shrink
Cardboard

Incumbent
collation shrink

®™Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow


Functional evolution of barrier films , driven by performances and cost reduction

THREE layer : basic film


FIVE layer films:
barrier features

SEVEN layer films: triple barrier +


asymmetric PA external layer
NINE layer films: triple barrier +
asymmetric PA external layer + cost
optimised skins

ELEVEN layer films: triple barrier +


asymmetric structure + functionalised
skins
(peel / reclosable)
Functional evolution of packaging films , driven as well by performances and cost reduction

Monolayer/ single resin

Monolayer/ polymer blends


Coextruded
THREE layer
1- 2- 1 structures Medium gauge core & sub-skin
concept technology for sealing
and optical properties. Limited
downgauging

Coextruded
THREE layer Thick core , extensive polymer
1- 4-1 structures blending for performances &
thin skin concept technology for
sealing and optical properties.
Good downgauging possibility

Coextruded structures functional evolution NON BARRIER films


PROBLEM Coextruded THREE layer 1 - 4 -1 and extreme skin structures
Machine design flexibility severely limited.
Specially on high output system the selection of
the extruders and the die design open to the risk
of making “One-Off” machines, totally opposite
to market requirements fostering flexibility and
versatility. The Coex3 has nothing more to offer.

SOLUTION Thick core or extreme skins obtained by running the extruder “in parallel”.
THE “POD” concept Extensive polymer blending for performances & thin skin concept technology no longer
necessary. Maximised benefits by using pure resins in defined layers addressing to
optical, sealing, stiffness. Extreme downgauging possibilities. Total flexibility in film design
and relevant manufacture
Rising the bar of line capacity thanks to use of layers made of high melt strenght polymers.

Coextruded
FIVE layer
1 - 1 - 6 -1 - 1
1- 2 - 4 - 2 -1 structures
20% 10% 10% 12.5% 15%
25%
30% 10%
20%
25% 15%

40% 50% 60% OLD NEW 60% 40% 25% 40%

20% 25% 15%


30% 10%
25%
20% 10% 10% 15%
12.5%

Using pure resins in defined layers improve optical, sealing, stiffness.


Increase the line capacity thanks to use of layers made of high melt strenght polymers.
Total flexibility in film design and relevant manufacture
Standard / Multipurpose - MS design -
multipurpose – MS design -

Highcapacity
high Capacity– -MB
“LOW temperature”
design - – MB design -

EVA // plastomers
EVA Plastomers –-CFC
CFCdesign
design-- (NOT for PP)

HD / long chain polymers - “LOW temperature” – GX design -


Choice of air or watercooled extruder motors

SIEMENS 1PH8 high efficiency (Ie2 / NEMA Premium) extruder motors


MACCHI’s COEXFLEX DIE DESIGN
-Pat. 2001-

TIME and FIELD PROVEN WINNING CONCEPT


3 - 11 layers design
 Extended Range of coex 5 IBC dies
4 new die blocks – all POD coex 5
TE 554 – die diameter range 200 – 400 mm 
TE 553 – die diameter range 350 – 550 mm 
TE556 – die diameter range 500 – 600 mm 
TE 555 – die diameter range 600 – 800 mm 

  
Typical setup

Plastification capacity
1350 kgh
Ø 65
Output rate with
Ø 80
40 my 1-2-4-2-1 structure
using
Ø 105 Die Ø 500 mm DOW’s collation shrink formula
< 1000 > kgh
Ø 80

Ø 65
Macchi CR-K3 air ring
The new design of this carbon
fiber body ring
features 8 tangential air-ports with
improved intake geometry
ADDITIONAL VENTURI COLLAR

Extra wide air ring collar

The schematic shows the actual


geometries involved .

This is the “ key“ to achieve a


wider heat exchange surface
TRIPLE LIP CR-K3 COOLING RING

SEQUENTIAL IBC PANCAKE


This extra long pipe stack
provides for cold air blowing
on the top in the tubular
collapsing area, as well as in
the lower section (IBC
pancake)

Additionally to high end


applications,
the antiblocking IBC may be
beneficial for production of films
with inner layers of
VLDPE/ULDPE/Surlyn (® DuPont)
WEB FLATNESS
Non Flatness / bagginess in most
cases comes from collapsing and
bands of uneven gauge that stretch
differently during the manufacturing .

During extrusion it may be a sure


source for wrinkles, especially with
thinner and stiffer films, which are
much more wrinkle-prone than thick
ones. Non flatness also originates
slack edges in multiple roll
production, with troubles in post-
production.

WEB FLATNESS has nothing to


share with transverse gauge profile
Bubble Collapsing Geometries and film FLATNESS

LF = web layflat [mm] 2500


Phi = bubble diameter 1591
R = bubble radius 795.5
D = distance nip roll center/collapsing frame
contact point 8000

RESULTING COLLAPSING ANGLE = 11.36

E = EDGE length = 8012 mm


C = Length at CENTER board = 8039 mm

STRESS-Strain (E < C) 0.34 %

…for the LEAST geometry-oriented  : the SMALLER the collapsing angle, the LESS the stressing.

RISE YOUR TOWER AND MAKE THE COLLAPSING BOARD AS LONG AS YOU CAN
Remedies ?
COLD STRETCH

WATER BATH

DIRECT HEATING
STEAM-BOX

LONG STRETCH
M.D.O.
SHORT STRETCH
M.D.O.

Web Tension Annealing involves


temperature and mechanical forces
MACCHI Roller annealer

The function of the roller annealer is primarily to achieve a thermal


stabilization of coextruded structures
It could be also recommended as film flattening device, resulting from a controlled OPEN threading ) CLOSED ( work )
light stretching in the machine direction, whilst preserving the film tensile
properties and orientation characteristic, otherwise significantly modified by an
high degree of orientation, typically made with the conventional MDO
Typical setup

5 extruders/5 layer
POD cofiguration
TE 556 coex IBC die
Downstream rollface 2600mm

Line sizes:
Length 18 mts
Width 8.5 mts
Height 16.5 mts
Fast turn-around of the higher initial investment for a POD line

source:
ExxonMobil estimates
October 2012
New lines purchase evolution
5-layer POD technology is expected to be the new industry standard

100 100

Coex 3
80 80
% of line sales

60 60

40 40
Monolayer Coex 5

20 20

source:
0 0 ExxonMobil estimates
October 2012
1990 2000 2010 2020 2030

2014
Cost saving
Improved productivity
New Line Converter Simplified operations

resins capabilities
Source reduction
End User more productive operations
Increased revenues

Film formulations Consumer Environmental friendly


Re-use Reduce Recycle

Sinergetic Delivered Benefits


to
springboard the recovery
We want to thank Dow for the precious cooperation

Thank you

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