Innovative Solutions for Film Producer s Challenging Market

Transcription

1 Innovative Solutions for Film Producer s Challenging Market Markus Gschwandtner Brückner Group 1 Contents Current BOPP Market Situation Industry Trends Our Innovative Solutions 2 AMI BOPP Film

2 . Before We Get Started. Dubai - our host city Sheikh Zayed Rd in 1990: Brückner leading BO supplier Siegsdorf in and today:.. and today: 3 Two New Members of the Brückner 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 4 AMI BOPP Film

3 Brückner Group Your Benefits Brückner 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 5 Contents Current BOPP Market Situation Industry Trends Our Innovative Solutions 6 AMI BOPP Film

4 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 7 Additional sold BOPP Capacity 2006 in [tpa] based on Name Plate Capacity (NPC) * Europe & CIS Greater China Americas PP Middle East & India PP PP PP Total market share % 14 % * Source: Reference lists and market information of sold and effective equipment (04/2007) 8 AMI BOPP Film

5 Additional sold BOPP Capacity 2006 and 2007 in [tpa] based on Name Plate Capacity (NPC) * Greater China Europe & CIS Americas PP Middle East & India PP Asia Pacific PP PP Total market share PP % 10 % * Source: Reference lists and market information of sold and effective equipment (04/2007) 9 Contents Current BOPP Market Situation What are the Industry Trends Our Innovative Solutions 10 AMI BOPP Film

6 Outlook New BOPP Resin Capacities 2005 Capacity (kton/yr) 2015 Capacity (kton/yr) A.a.g.r. % Middle East Africa % India Sub Continent % North East Asia incl. China % South East Asia % Europe incl. C&E Europe, Turkey % North America % South America ,5 % Source: Borealis A/S, KIWEB and other sources 11 Outlook - World BOPP Film Market Growth by Demand Area Western Europe Eastern Europe North America Central and South America Japan China Other Asia Pacific Middle East and Africa AVGR % 9.8% 5.3% 7.4% 3.5% 14.3% 11.4% 6.7% AVGR % 8.4% 3.4% 6.5% 2.0% 9.6% 5.9% 5.9% Source: AMI and PCI 12 AMI BOPP Film

7 Outlook - World BOPP Film Market Growth by Type Film type Transparent , , ,189 AVGR ,7% Metallised (excl. capacitors) ,0% White/opaque/matt ,0% Total world demand 2,801 4,285 5,772 6,1% Source: AMI and PCI 13 Outlook BOPP World: Demand / Production Tons Demand Actual: CAGR of 10,2% p.a. Demand Projection on CAGR 8,3 % p.a. Demand Projection on CAGR 6,8 % p.a. Demand Projection on CAGR 5,4 % p.a. Production AMI BOPP Film

8 Supply Chain View from the End User / Consumer Machine Supplier Resin supplier Supply Chain Film Producer Converting Packaging Easy to open Package size single household Re-closeable Microwaveability Design information, decoration, quality Environmental issue, i.e. Wal Mart does not approve PVC anymore Sustainability End User 15 Supply Chain View from the Food Industry Machine Supplier Resin supplier Supply Chain Film Producer Converting Machine runability FDA and EU directive approved Extended shelf life time Cost saving packaging Improved properties Environmental issues Sustainability Packaging End User 16 AMI BOPP Film

9 Supply Chain View from a Converter Machine Supplier Resin supplier Supply Chain Film Producer Converting Reduced lead times Printability High speed packing Constant film quality performance Modified & improved barrier properties Cost optimized laminates Packaging End User 17 Supply Chain View from a Film Producer Machine Supplier Resin supplier Supply Chain Film Producer Converting Smaller lots Just in time production Stronger competition from other markets in commodities Increased demand for specialty products Low energy consumption Short product changing time Low production costs Packaging End User 18 AMI BOPP Film

10 Supply Chain View from a Resin Supplier Machine Supplier Resin supplier Supply Chain Film Producer Converting Higher stiffness Low SIT materials Higher gloss Better flow properties Seal strength and integrity Cop with increasing oil price Packaging End User 19 Supply Chain View from a Machine Supplier Machine Supplier Resin supplier Supply Chain Film Producer Converting Packaging Commodity products Highly efficient lines Low energy consumption Highly automated Specialty products Flexibility Multipurpose Multilayer New products New technology Extended R&D End User 20 AMI BOPP Film

11 Film Producer s Challenging Markets Machine Supplier Need to provide: utmost flexibility, highest efficiency, low energy consumption, highest quality Film Producer Efficiency & diversification, value added film types Supply Chain Converting Appropriate converting steps & costs / multi-functional films Packaging Cost efficient and intelligent packaging End User Multifunctional flexible packaging, environment-friendly, easy use 21 Contents Current BOPP Market Situation Industry Trends What are Our Innovative Solutions? 22 AMI BOPP Film

12 Dubai Experts in Managing Challenges Brückner Office in Dubai, UAE 23 Our Innovative Solutions For The Production Line AMI BOPP Film

13 Our Innovative Solution Increased Uptime i Topic: Increased Uptime > 7,500 h/yr Uptime i Challenge: Constant Production Maintenance Unforeseen Stops Film Breaks i Solution: High End Equipment High Quality Equipment Latest Technology Automation i Benefit: Higher Productivity Up from 7,500 to 8,300 h/yr gives + 4,000 5 to/h ~ 8 Mio. USD / yr additional turnover 25 Increased Uptime Direct Drives without Gears 26 AMI BOPP Film

14 Increased Uptime LIWEB for Reduced Clipping Errors TDO Inlet Linear Motor Ultra Sonic Sensor 27 Our Innovative Solution Faster Product Change i Topic: Product Change More flexibility in product management i Problem: Off-Grade Film Changeover time > 1 h Off-Grade film i Solution: Controlled Changeover Automatic changeover Recipe management i Benefit: Higher Productivity Reduced changeover time: 2 x per day, 4 to/h ~ 2,5 Mio. USD / yr additional turnover 28 AMI BOPP Film

15 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 29 Faster Product Change MDO Gap Position Selection Utmost flexibility in stretching gap selection 30 AMI BOPP Film

16 Our Innovative Solution Increased Production Speed i Topic: Increased Speed Low Margins Thinner Film i Challenge: Yield Film Breaks Lower Film Quality Resin Properties i Solution: High Quality Equipment Advanced Technology Reliable Components Proven Design i Benefit: Higher Productivity Speed increase by µm, 7,500 h/yr, 8.2 m ~ 8,4 Mio. USD / yr additional turnover 31 Increased Production Speed Optimum Film Quality TDO Top and Bottom Fans for Excellent Air Balancing 32 AMI BOPP Film

17 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 33 Increased Production Speed Output Increase 8,2 m 500 m/m BOPP Line 3000 Brückner High Speed Production Lines Additional Output [kg/h] Line Speed [mpm] 30µm BOPP Film 25µm BOPP Film 20µm BOPP film 15µm BOPP Film 12µm BOPP Film 10µm BOPP Film 34 AMI BOPP Film

18 Our Innovative Solutions For The Production Plant Our Innovative Solution - Turnkey BOPP Plant 36 AMI BOPP Film

19 Our Innovative Solution - Turnkey BOPP Plant Oct 1 July 12 March 1 Nov 1 37 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!! 38 AMI BOPP Film

20 Our Innovative Solutions For Product Development Our Innovative Solution BOPP Specialty Films Film Price Raw Material Price Tape Film Heat Sealable Film MD Shrink Label Film High Speed Packaging Film for HFFS Shrink Overwrap Film White Opaque Shrink Label Film Barrier Shrink Film Barrier Film with EVOH 40 AMI BOPP Film

21 Our Innovative Solution Brückner Technology Centre Sequential and Simultaneous Operation Lab Stretcher Pilot Line Film Laboratory Life Time Tests 41 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 42 AMI BOPP Film

22 Our Innovative Solution BOPP Film Developments Applications VFFS HFFS Transparent Barrier High Sealing Strength Low SIT High Sealing Strength 7 Layer with EVOH 7 Layer with PA Features Seal Integrity Hot Tack Stiffness Downgaging Advantages BOPP Films Metallized Barrier Shrink Label Ultra High Barrier MD Shrink TD Shrink Replacement of Aluminium Alternative to Sleeves Box Over Wrap High Surface Tension Lidding MD Shrink Cigarette PA Skin Layer PP / PE White Opaque Barrier Printing Laminating Aroma/Flavour Replacement of Coated Film 43 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 Advantages High seal integrity High packaging speed Seal Strength [N/15mm] 6 5,5 5-Layer 5 4,5 4 3,5 3 3-Layer 2,5 2 1,5 1 0, Sealing Jaw Temperature [ C] 44 AMI BOPP Film

23 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 Advantages Superior oxygen barrier < 2 cm³/m²bar Excellent optics Low temperature sealing properties OTR cm³ m²bar Transparent commercial films new development 3-layer coex PVDC coated SiO x coated PVOH coated 7-layer with PA 7-layer with EVOH 45 Our Innovative Solution BOPP Metallized UHB Film Structure Metallised Surface Application A: High Surf. Energy Polymer B: Adhesive Layer C: PP Core Layer D: PP E: Co-Polymer Advantages Exceptional gas and aroma barrier OTR: 0,15 [cm3/m2 d 23 C / 75% WVTR: 0,2 [g/m2 38 C / 90% r.h. OTR cm³ m²bar Metallized commercial films new development standard metallized high barrier met. 1 0,1 ultra high barrier 5-layer HSE met. 46 AMI BOPP Film

24 Our Innovative Solutions For Services Service at a Glance Financing Support Brückner Realized Financings of EUR 354 Mill. in ECA covered buyer s credit 195 Mill. Leasing 30 Mill. Short term financings up to 1 year 129 Mill. 48 AMI BOPP Film

25 Service at a Glance Financing Support Sample: Project Financing Bank Loans / Direct Loan Seller Supply Contract Buyer Hermes guarantee ECA: Euler Hermes Bank of seller Audited balance sheets (IFRS/IAS, US-GAAP) Profit and loss accounts Company profile Feasibility study Financial sources Loan agreement IFRS = Intern. Financial Reporting Standards IAS = Intern. Accounting Standards US-GAAP = Generally Accepted Accounting Principles 49 Service at a Glance Tele-Service Solutions We see what you see at Brückner at Your Site... Wearing the Mobile Service Assistant 50 AMI BOPP Film

26 Service at a Glance Highlights in Upgradings Speed upgrade: the world s fastest BOPP line 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 51 Service and Sales at the Spot We are where You are Germany Brückner Group U.S.A. Brueckner Inc. Mexico Brueckner México S.A. de C.V. Brasil Coras do Brasil Russia OOO Brueckner Slovakia Brueckner Slovakia s.r.o. China Brueckner Machinery Jiangyin Co., Ltd. China Brueckner Far East Ltd. Hong Kong Indonesia Brueckner Far East Ltd. Argentina Coras UAE Brueckner Middle East India Brueckner India Pvt. Ltd. 52 AMI BOPP Film

27 Thank You AMI BOPP Film