Innovations in extrusion systems target greater efficiency and sustainability

The Reifenhäuser Group, a leading specialist for extrusion systems and components, will be exhibiting at K 2025 in Düsseldorf from October 8 to 15. Under the motto “Boost Your Performance”, it will demonstrate how “Automated Extrusion”, “Smart Data” and “Innovative Training” ensure performance increases and make manufacturers less dependent on highly qualified personnel. Marcel Perrevort, CSO of the Reifenhäuser Group, shares some of the highlights of the Group’s presence at this world-renowned exhibition.

Marcel Perrevort, CSO, Reifenhäuser Group

How would you describe Reifenhäuser Group’s exhibit at K 2025?

Mr. Perrevort:   Success is closely linked to continuous improvement. However, in times of shortage of skilled workers, it is becoming a challenge for many manufacturers to achieve higher performance, better quality, greater efficiency or sustainability. We will therefore be presenting innovative technologies that give producers the extra boost they need right now. Automation, data and AI play a decisive role here.

As usual, the Reifenhäuser main booth with over 1,200 square metres will be located in hall 17, booth C 22, where the Reifenhäuser Blown Film, Cast Sheet Coating and Reicofil business units will present their line technologies for film and nonwovens applications. For the first time, the barrel and screw unit Reiloy as well as the subsidiary Kdesign - specialist also be represented at the main stand. The Reifenhäuser Extrusion Systems component unit will be exhibiting in Hall 1, Stand D91. The initiative R-Cycle, co-founded by Reifenhäuser to establish an open tracing standard for plastic packaging, can be found in Hall 7 in the Start-Up Zone.

What specific exhibit will put emphasis on Reifenhäuser’s sustainability focus?

Mr. Perrevort:   The circular economy and CO₂ reduction will also remain key topics for the entire industry at this K. Reifenhäuser will be presenting how the required recyclable products and products made from recyclate can be manufactured profitably. This is crucial for the future competitiveness of manufacturers, especially in view of the recently published PPWR (Packaging and Packaging Waste Regulation) in Europe.

We entered the cast MDO market at an early stage, which means that, in addition to the hardware, we have a firm knowledge of the process. Together with partners, we develop high-performance end products such as Cast All-PE stand-up pouches. As a line manufacturer, we always pursue one goal: to develop technology for recyclable films that are both functional and economical to produce. We will be showcasing the successful results at K 2025.

What benefits would Reifenhäuser’s MDO technologies bring to packaging producers?

Mr. Perrevort:  As we have noted, producing a fully recyclable pouch is no longer the challenge. Making it profitable and competitive with conventional solutions is now the order of the day. Reifenhäuser shows technologies and film structures that enable producers to build a functioning business model around sustainability.

The Reifenhäuser Blown Film and Cast Sheet Coating units will be presenting the latest MDO (Machine Direction Orientation) technologies, which enable recyclable mono-material packaging by film stretching. Thanks to ever thinner film structures (downgauging) and clever technology features, Reifenhäuser systems reduce production costs to the same level as conventional products. Both business units focus in particular on barrier applications for the food, medical and hygiene sectors.

Reifenhäuser Blown Film has succeeded in producing the world's first process-stable 18µm MDO PE film with further downgauging potential. The technology behind it is called EVO Ultra Stretch - a patented MDO unit that is positioned directly in the haul-off of the blown film line, that stretches the film from the first heat. This makes the process particularly stable, which is otherwise often the limiting factor for material reduction. Ultra Stretch provides additional added value when using EVOH for barrier films. The barrier effect of the expensive raw material is enhanced by the stretching process, meaning that less of it needs to be used.

How would MDO enable cost-saving especially in the production of film for barrier packaging?

Mr. Perrevort:  With MDO stretch units from Reifenhäuser, producers improve the mechanical film properties due to the orientation of the polymer chains in the stretch direction. This means that PET films, which usually ensure stability in film laminates, can be replaced in order to produce a recyclable mono-film composite. Mono-PE is the most common application for blown films in this regard. Stretching also makes the film thinner, which reduces material consumption. The standard thickness of MDO PE film is between 20 and 25 µm. The downgauging achieved in this way saves production costs and, therefore increases profitability.

Manufacturers who produce film for barrier packaging save material costs with MDO technology simply by stretching, because the process reinforces the EVOH barrier effect. The EVOH content can thus be reduced to less than five percent of the total weight of the packaging, which is a prerequisite for its recyclability and saves costs.

Reifenhäuser cast systems also offer a further option for significantly reducing production costs: a particularly clever edge encapsulation process that eliminates the EVOH content in the film waste - without the need to invest in an additional extruder, which is necessary with other solutions. The encapsulation of the barrier layer is carried out directly in the coextrusion adapter. The result: the film edges and the resulting edge trim contain only low-cost raw material. This allows producers to save up to 150,000 euros per year on average.

What automation solutions from Reifenhäuser will be presented at K 2025? 

Mr. Perrevort:  Reifenhäuser is presenting the latest generation of its unique automation solution for flat die extrusion lines at K 2025. With the new generation, the automation level of PAM (precise, autonomous, mechatronic) increases significantly. This makes producers even less dependent on highly qualified personnel and saves energy as well as raw materials at the same time.

The current PAM generation was first presented at K 2022.  PAM is also available for the Reifenhäuser Coextrusion Adapter Pro. This feedblock is the only coextrusion system on the market that allows the individual film layers to be profiled while the system is running. The second PAM generation will be even deeper integrated into the overall automation of the line.

We recognise the desire for more automation among our customers worldwide in order to ensure maximum system performance despite a shortage of skilled workers. With PAM, we offer a tried-and-tested solution whose range of functions will be significantly expanded again for K 2025. The new PAM generation (PAM 2.0) will set benchmarks in terms of automation and create clear competitive advantages for both experienced producers and industry newcomers. We are not yet giving any details about the new features, but users can look forward to a new level of automation that no one who has ever benefited from it will want to do without.