Rigid Packaging in PET Products, Production & Critical Success Factors

Transcription

1 Rigid Packaging in PET Products, Production & Critical Success Factors Andreas Blin Sales and Product Manager CPP and PET-Sheet Brückner Maschinenbau GmbH & Co. KG

2 Brückner Group Members Brückner Maschinenbau Brückner Servtec Kiefel Brückner Biotec Breakthrough Solely dedicated to the Machines for joining and Innovative, profitable biogas technologies in film customers` service needs forming plastic film and plants stretching sheet Sophisticated cast and sheet extrusion lines Since 1960 Since 2006 Acquired in 2007 Since 2003 Automotive Medical Packaging Thermoforming

3 Brückner Maschinenbau Product Range Turnkey Plants Sequential Biaxial Stretching Lines Simultaneous Biaxial Stretching Lines Speciality Film Lines CPP Lines PET Sheet Lines, Cast PET Sheet Lines Monoaxial Stretching Lines Extrusion

4 Brückner is Dedicated to PET Brückner has 40 years experience in PET Produced its first PET line in 1967 Acquired Barmag Technology in 1998 PET is a strategic product for Brückner BOPET flexible packaging MOPET shrink sleeves PET sheet & Cast PET sheet rigid packaging

5 PET Abbreviations Amorphous PET APET, A-PET, PETE (US) Glycol modified PET PET-G Crystallised PET CPET Recycled PET R-PET PCR bottle flakes Post consumer Recycled bottle flakes CSD Carbonated Soft drinks Coextruded structures A / B / A; A / B / B G / A / G PET/PE for FFS - MAP PET sheet laminated with Polyethylene for Form Fill and Seal Modified Atmosphere Packaging

6 APET Properties and Applications Amorphous Rigid and stiff Highly transparent Good barrier against steam and gas Resistant against oils and fats APET can be employed in temperatures ranging from - 40 C to + 70 C

7 PETG Properties and Applications Non-crystallizing Crystal-clear at very high forming temperatures Allows very high forming sharpness Wide processing window Good sealing properties especially multi-layer films PETG-APET- PETG G-A-G PETG can be employed in temperatures ranging from - 40 C to + 70 C

8 CPET Properties and Applications Crystallized Non-transparent Equipped with nucleating agents crystallizes quickly during processing High temperature resistance CPET can be employed in temperatures ranging from - 20 C to C dual ovenable

9 APET Material Processing Options Raw material source PCR Raw material treatment Compacting Drying Extrusion system Single screw Industrial reclaim Flake Resin Twin screw Poly- Sheet condensation forming

10 APET Sheet Converting Options Inline process Inhouse process Sold product Sheet forming Winding PET roll stock PElamination Winding PE- lamination PET/PE roll stock Thermo- forming Thermoforming PET trays

11 Production of PET sheet Extrusion Forming and Cooling

12 PET Extrusion Single Screw vs. Twin Screw Single Screw Twin Screw Pre-drying resin Typical 150 C n/a Compacting of flakes Necessary n/a Pressure build-up 180 bar 60 bar Total energy consumption 0,55 kwh/kg 0,36 kwh/kg Output Ø 150mm Ø 169mm

13 Twin Screw Extruder Vacuum Pump Advantages of Twin screw extrusion Elimination of PET-perdrying Flexibility in raw material selection virgin, flakes Realisation of high outputs Low energy consumption up to 35% less than single screw Brückner s experience: First Twin screw in a film line in 1992 More than 30 Twin screws in PET-Sheet extrusion 18 BOPET lines with Twin screws

14 PET Sheet Production Sheet Forming Concepts Roll Stack Calendering Chill Roll Casting Output is limited by the cooling capacity of the main cooling roller Cooling roller diameter is limited by the geometry die has to be close enough to the nip! Output is limited by the cooling capacity of the main cooling roller Cooling roller diameter is not limited!

15 Comparison PET Roll Stack / Chill Roll Roll Stack Chill roll Production speed up to 50 m/min up to 120 m/min Cooling roll diameter max. 800 mm mm realised Output max kg/h kg/h realised Net film width Thickness range (125) (1.200) µm Optical properties Both sides polished One side polished Extrusion Single screw or twin screw Twin screw

16 Brückner Line Layout Cast PET Sheet

17 Brückner XL Chill Roll with Electrostatic Pinning

18 Brückner Line Layout Polished PET Film

19 Brückner XL 2.7 m Roll Stack Featuring JUBO Technology

20 Critical Success Factors

21 Production Cost for PET Sheet 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 1 Overhead Cost Specific Maintenance Cost Specific Space Cost Specific Labour Cost Specific Compressed Air Consumption Specific Water Consumption Specific Electrical Power Consumption Specific Capital Interest Specific Depreciation Resin

22 Critical Success Factors PET Sheet Production Resin cost Raw material accounts for 85% of product cost Utilization of Post Consumer Recycling Material Further reduction of raw material cost Reusability of edge trim Especially in PET/PE structure production Economy of Scale Reduce specific cost through larger output Productivity and yield Use state of the art tools to manage production Energy efficiency Take advantage of Twin Screw Extrusion

23 Brückner - An Important Step Ahead Polished PET XL Roll Stack Twin Screw Extrusion INNOVATION JUBO Roll PVSS II, RDH, MMS Cast-PET XL Chillroll Direct Drives

24 Thank You for Your Attention!