K2025: Extrusion Machinery

Reifenhäuser proposes machinery with higher outputs

Extrusion machinery maker Reifenhäuser will show how film manufacturers can be less dependent on skilled workers and increase profitability by demonstrating automated extrusion, smart data, and innovative training.

Since circular economy and CO2 reduction will be key topics at K, Reifenhäuser will also be presenting how recyclable products and products made from recyclate can be manufactured profitably. Thus, highlights include the latest MDO technology for recyclable mono-material packaging by film stretching. The firm has succeeded in producing the world's first process-stable 18 micron MDO PE film with further downgauging potential, through its patented MDO unit, Ultra Stretch, which is positioned directly in the haul-off of the blown film line and stretches the film from the first heat.

Other highlights are the Centro Freeze 2 secondary cooling system boasting 25% more output in a compact design and Aqua Cool that doubles output without extra operating costs.

The German firm is also presenting further developments of its patented PAM system (precise, autonomous, mechatronic) for flat film lines, with a second generation to be presented for the first time at K.

Meanwhile, to further expand its commitment to digitalisation, it will bundle its digital and learning solutions under the Reifenhäuser Next brand. The new business unit will focus on the integration of Industrial AI and will launch at the K three product categories: Next. AI, Next.Learning, and Next. Data.

Next.Data will ensure customers have access to all the data generated by the machine and make this actionable. Next Learning will facilit a t e on-boarding and help keep a company’s expertise within the system, once experienced workers leave the workplace, while Next. AI will bring inexperienced and unskilled workers up to speed on machine operations quickly.

SML unveils TSE twin-screw extruder; Vertex multifilament spinning system and SmartCast stretch film line

Austrian firm SML is expanding its extruder portfolio with the introduction of a co-rotating twin-screw extruder (TSE), its answer to increasing demand for high-output capacities for polyolefins and polyesters. Compared to a large single-screw extruder with the same output capacity, the TSE has a shorter processing unit and, thus, a smaller footprint. Therefore, less heating power is required to maintain the barrel temperatures. Because of starve feeding the extruder drive operates at high torque over the entire output range, where it exhibits the maximum efficiency.

Additionally, the melt temperature can be controlled by adjusting the degree of filling. Extensive tests of the new TSE on a CPP line in SML’s technology centre have shown that the specific energy input (SEI) is 10-15% lower compared to a single-screw extruder. In terms of film quality, the gel count detected by a web inspection system could be reduced by up to 20% for a standard CPP film.

In combination with SML’s vacuum unit, the firm says it can offer a complete in-house extrusion solution for processing PET or PLA without pre-drying. Furthermore, the TSE enables high amounts of regrind or flakes to be processed as well as in-line compounding.

Meanwhile, in the field of spinning systems, SML is presenting its Vertex line to manufacture partially oriented yarn (POY) or fully drawn (FDY) yarn at low titres in higher volumes. Key characteristics are the optimisation for PET, the ability to manufacture a wide range of different yarn types, qualities and colours, as well as the line’s expandability. Beside PET, Vertex lines process PP and PA, too.

A clear strength of the Vertex series lies in the titre range between 50 to 1,200 den at an maximum output capacity of up to 270 kg/hour.

As well, two separate spinning heads enable the simultaneous manufacturing of two different products. Spinning positions can be adjusted flexibly. The Vertex line can be equipped with one or two extruders of different types and performance parameters, exactly tailored to the requirements of each individual customer. Thanks to its modular design, the line can be easily extended to increase capacity, scaling from 24 ends up to 32, 48, or even 64 ends as needed.

Another highlight at the SML stand will be the SmartCast stretch film line (6-up) that features a variety of equipment options for 2-inch hand rolls to high-quality machine rolls, 60 kg-jumbo rolls, and films with folded edges, among others.

Next to an overall face-lift, the new 3 m line concept boasts an ultra-compact footprint with newly arranged, parallel-oriented extruders. This arrangement places all motors, dosing units, and filters next to each other, facilitating faster and easier access for maintenance and service. Pre-assembled extruder modules further streamline the installation process. In addition, all small electrical components are now housed in an E-container, which eliminates connection boxes in the hot areas of the extruder.

The SmartCast is equipped with the largest chill roll, with a diameter of 1,800 mm and the latest chrome-plated Smart 3.0 surface. The surface finish significantly reduces cleaning efforts for paraffin and other deposits that occur during production. The extended contact area at the chill roll allows for gentle cooling, which results in the highest elongation combined with superior tear propagation. Despite its size, it still offers the fastest cooling for SuperStiff products.

With the new SmartCast design, SML has further developed its coreless winding technology not only to improve production economy but also to save resources and improve sustainability. It improves the winding quality on the inside of the stretch film roll at optimised production speeds. Post-production shrinkage is reduced. But most importantly, quick switches between coreless winding and winding on rigid cores are achieved at the touch of a button. This unique key feature reduces waste to zero during changeover and maximises production efficiency

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