First direct extrusion technology for multi-layer film production

EVOLUTION Ultra Fusion, the first direct extrusion technology for the production of multi-layer blown films boosts productivity and energy efficiency, reduces production costs and improves film properties. Tests conducted under production-oriented conditions in the Technology Center of Reifenh?user Kiefel Extrusion confirm the competitive advantages initially presented at K 2013 under the motto Rethinking Technology. Now, the technology will be further developed for commercial use.

The Evolution Ultra Fusion technology processes raw materials directly – without previous pre-drying and compounding. For this reason, the engineers came up with the concept of integrating a twin-screw extruder of the REItruder series directly in a blown film line. Compared with the processing of compounds and masterbaches, the direct extrusion technology can reduce the production costs for 3-layer blown films by more than 15 percent.

The technology shows its full savings potential particularly in the production of filled multi-layer films in which expensive raw materials like polyethylene, are replaced in part with lower-priced fillers such as calcium carbonate (CaCO3). The Evolution Ultra Fusion technology enables producers to process especially high filling amounts of up to 50 percent. This allows them to reduce their production costs by about 20 percent.

In addition to cost savings, the high filling amounts have a positive effect on the film properties: Film strength and film stiffness are increased while elongation is reduced. Furthermore, special properties can be obtained with this technology, for example those needed for the production of breathable films.

Together with a partner from the industry, Reifenh?user Kiefel Extrusion is developing products for industrial use to bring the technology to the market. Evolution Ultra Fusion can already be tested by customers in the world’s largest Technology Center for the production of nonwovens, films and wood polymer composites at the company’s site in Troisdorf.