BLOWN FILM COEXTRUSION LINES

Transcription

1 BLOWN FILM COEXTRUSION LINES

2 The origins of a solid forward thinking company Ever since its establishment in 1947 by Luigi Bandera, it has proved to be a dynamic company focussed on innovation the perfect ingredients for a pioneer of the extrusion line sector in Italy and worldwide. Today, Bandera designs and manufactures a complete range of extrusion lines based on two major applications: blown film, and sheet and foil with flat die technology. Bandera Brand Value EXPERIENCE & INNOVATION R&D ongoing investments RELIABILITY Sturdy and heavy-duty equipment TOP PERFORMANCE Enhanced productivity and tolerances CUSTOMER ORIENTED A customer service oriented company COMPETITIVENESS AND COST EFFECTIVENESS Consolidated standard production processes Over the years Bandera has earned a sound reputation worldwide thanks to its integrity and top quality standards RELIABILITY AND ORGANISATION A family business, managed by skilled managers IN-DEPTH KNOWLEDGE OF EXTRUSION PROCESS Over 66 years of in-house production and design expertise CUSTOMISED DESIGN FLEXIBILITY Turnkey customized complete extrusion lines PROVEN PERFORMANCES FullY fledged proven technologies APPLIED INNOVATION Preferred suppliers in the long term 2

3 Bandera Excellence in Extrusion Bandera s mission is to become the major European centre for excellence in extrusion. Focussed on manufacturing cutting-edge technological lines for plastics processing in blown film, sheet & foil and pipe extrusion, Bandera is pursuing to confirm its leading position for the future. Willing to enhance its international market position, Bandera s corporate strategy concentrates on converging innovative extrusion line designing, engineering, manufacturing commissioning in its Italian headquarters, together with its customer service centre. BANDERA IS FOCUSSED ON ESSENTIAL HIGH-TECH ASPECTS Ensure minimised power consumption. Design safe and reliable top performing extrusion lines compliant with the strictest safety standards. Manufacture extrusion lines dedicated to finished products from latest innovative thermoplastics, thus favouring the use of recycled and/or biodegradable materials. Promote technologies and processes aimed at consistent packaging weight reduction. 3

4 Bandera production range - Blown film extrusion Adhering to strict compliance with accredited procedures and accuracy in selecting reliable and skilled European part suppliers, Bandera is focused on exclusive in-house manufacture of the basic equipment for its blown film extrusion lines - a reason for the company excellence in the field. Bandera is ranked among the few European and world manufacturers of extrusion machinery whose technological assets feature a knowhow combining synergies of rigid and flexible packaging fields with the experience acquired in direct production of blown film extrusion heads in small, medium and large sizes. BANDERA PRODUCTION RAnGE INCLUDES: Single-layer, three-layer and five-layer film coextrusion lines for technical packaging solutions Five-, seven- and nine-layer coextrusion lines for barrier film Three, - five and seven layer coextrusion lines for the finest-quality agrifilm, up to 24m wide, processed with tailor-made coextrusion heads, of higher diameter than 2300mm. Bandera s leadership in the field is acknowledged worldwide. Extrusion lines of the latest generation hybrid flex, capable of processing all biodegradable resins and HDPE to produce singleand three-layer biodegradable film Three-layer film coextrusion lines for heavy duty sacks (FFS- HDB) Three-layer coextrusion lines for high-thickness geomembrane, for industrial and engineering waterproofing applications Bandera has recently enhanced the project Smartflex plus, aimed at manufacturiongf state-of-the-art film lines for competitive investment level, whilst maintaining high quality standard. Lines of the series Smartflex plus are astonishingly cost-effective, extremely reliable and ensure utmost versatility at reduced power consumption. After sale technical assistance is well supported and prompt. 4

5 Blown film extrusion lines for flexible packaging, converting and laminating The brand new 3-layer series Undoubtedly, film coextrusion represents the most consolidated technology for the production of standard multipurpose packaging solutions. Today, the three-layer coextrusion lines are the preferred option. The standard configuration comprises a mid high-capacity extruder, arranged with two smaller extruders intended for the outer layers. Bandera three-layer coextrusion lines combine top quality and quantity standards. Building on strong customisation, Bandera extrusion lines are characterised by production need orientation, top versatility and safety, combined with minimised power consumption. 5

6 Technical film The 5-layer series APPLICATIONS The 5-layer configuration is perfect for customers needing high production flexibility to process PE film as well as barrier film. The 5-layer Techno Flex plus extrusion line has been designed for the production of technical film with outstanding top quality mechanical properties. The 5-layer Techno Flex plus series production range is definitely wide, and comprises, among others: Film used in top performing converting lines Film with specific characteristics intended for industrial applications Barrier film intended for food as well as medical and pharmaceutical applications. 5-layer PE film recipes an example 5-LAYER PE Functional layer PE Functional layer PE 5-layer barrier film recipes an example 5-LAYER PE TIE PA/EVOH TIE PE Major advantages Reduction of the thickness of the film Major flexibility Hourly production increased Ennobling of the formulations High quality film at competitive cost 6

7 The brand new 7/9-layer series The 7/9-layer coextrusion lines are intended for customers manufacturing top-notch high-barrier technical film for food, medical, pharmaceutical and several mechanical (e.g. automotive) applications. APPLICATIONS The 7/9-layer films have a double and triple barrier, respectively, with an EVOH central layer combined with PA middle layers, thus offering a high performing barrier against gases and water vapour. Also, Bandera offers extrusion lines capable of ensuring minimised curling effect in cases of asymmetric film structures. 7-9-layer simmetrical recipes - an esample 7-LAYER PE TIE PA EVOH PA TIE PE 9-LAYER LLDPE LDPE TIE PA EVOH PA TIE LDPE LLDPE 7

8 Blown film extrusion lines for FFS industrial bags PROCESS MATERIALS HDPE LDPE LLDPE Mldpe PP HDB FLEX the new series Industrial bag market growth is remarkable. Initial focussed on offering extrusion lines pursuing excellent mechanical characteristics, weldability, processability and printability, today the market trends require minimised film thickness aimed at maximising production capacity. Bandera has taken on this new challenge finding specific solutions to meet its customers needs, thus confirming once again its outstanding customer satisfaction orientation. Specifically, innovative solutions have been applied in each and every extrusion line section. The most outstanding ones are: Triple-flow cooling ring, which offers a strongly enhanced production capacity when combined with Bandera design extrusion heads Specific haul-off units with cutting-edge film cooling system for a better crease free film surface a solution setting the pace of innovation in HDB film field Integrated thickness control Fully-automated winding station, either by contact or by axial winding 8

9 Blown film extrusion lines for retail and industrial applications The brand new HYBRID FLEX series The brand new Hybrid flex range comprises single-layer extrusion lines and coextrusion lines for the production of HDPE and biodegradable/compostable resin blown film. Pursuing on its commitment for environmental protection and power saving, and conforming with the latest European laws about retail materials, Bandera has designed a multi-material extrusion line. The brand new Hybrid flex extrusion lines can process: Compostable materials Biodegradable polymers HDPE LDPE The brand new Hybrid flex extrusion lines have been designed to ensure top performance regardless of extruded products. A standard Hybrid flex extrusion line configuration comprises the following: Dosing system for 4 materials Extruders with bimetallic barrel and no-wear coated screw Fixed extrusion head arranged with IBC system and high efficiency cooling ring Rotating haul-off unit, flatteners equipped with either hard wooden slats or aluminium rolls; rollers specifically designed for thin film processing Automatic single- or double-station winding unit, by contact Each extrusion line can be customised to meet the customer s needs. Thanks to the consolidated partnership with the largest Italian bioresin and compostable resin producer, Bandera three-layer extrusion lines are accurately tested with different products. MAJOR ADVANTAGES Unrivalled flexibility in HDPE and bioresin film production Cost effectiveness Made in Italy - Made in Bandera User-friendly line management Sturdiness and performance 9

10 Multi-purpose extrusion lines for converting and flexible packaging film The new series MAJOR ADVANTAGES Excellent mid- and long-term yield Optimised production regardless of process type Excellent cost effectiveness Made in Italy - Made in Bandera Unrivalled user-friendly line management Over the past two years, Bandera has launched its Smartflex project. Aimed at designing fully customer-need-oriented PANTONE 2935 C MACTAC extrusion lines at PANTONE 431 C MACTAC a competitive price, the series pursues: Quality Flexibility Top performance Reliability Low power consumption Low environmental impact The achieved cost savings do not come from component quality reduction indeed from series production. All general costs are split into a large number of lines thus generating an economy of scale at procurement stage. Winding unit series W 400, by contact 10

11 L. BANDERA ±0.0 The Smartflex range comprises two configurations: Smartflex 16 Smartflex 22 Useful width 1600 mm 2200 mm Extruder configuration 1 x 65 ø mm 2 x 50 ø mm 1 x 75 ø mm 2 x 65 ø mm Extrusion head range mm mm Haul-off unit Winding unit Oscillating 1800 mm By contact Open width: 1800 Oscillating 2400 mm By contact Open width: 2400 Bandera Smartflex projects include standardised extrusion lines fully arranged to be implemented according to customers requirements. Smartflex extrusion line production includes: Packaging film (food and non-food film) Thermoretractable film Lamination film Stretch hood film PROCESS MATERIALS LDPE LLDPE mldpe EVA MDPE HDPE PP Standard Smartflex 22 layout FORNIRE FOTO SEZ.2 SEZ

12 New extrusion lines for the production of agrifilm Bandera is a pace setter in agrifilm extrusion lines. AGRIFILM APPLICATIONS Greenhouse film Thermal film Diffusive film Photoselective film Fumigation film Mini tunnel film Silo film Mulching film Solar film Today, agrifilm production is predominantly obtained by multi-layer coextrusion lines while single-layer film application is increasingly intended for a limited and low target market. Nowadays, three-layer coextrusion lines are preferred as they satisfy the current requirements for agrifilm. Nonetheless, future trends are toward 5-layer line configuration ( with the possibilities to have 7-layer configuration). The multi-layer film ensures an enhanced management of raw process materials and optimised additive distribution in every layer, thus increasing film physical and mechanical properties as well as light and heat transmission: as a consequence, the film life cycle is increased. Bandera agrifilm coextrusion line flexibility and versatility is increasingly appreciated by customers, considering that, generally, agrifilm is a seasonal product. With the same coextrusion head and minimised set-up times, Bandera coextrusion lines can produce agrifilm as well as thicker film (e.g. waterproofing geomembrane): a valuable chance to have an all-yearround profitable coextrusion line, regardless of agrifilm seasonality. 12

13 The classical configuration of agricultural systems are: Coextrusion line Extrusion head Open width 3-layer Up to 2300mm Up to 24m 5-layer Up to 2200 mm Up to 22m 7-layer Up to 2000 mm Up to 18/20 mt Bandera coextrusion lines are equipped with cutting-edge peripheral and ancillary systems, whose control and display functions are integrated into the Bandera line supervision system in order to ensure automated line operation: Haul-off units, up to 8500mm open width Power-driven gusseting units C- and V- folders for easy reel stocking and handling Winders up to 5500mm, available in gap winding mode 13

14 Complete extrusion lines for geomembrane WATERPROOFING GEOMEMBRANE INTENDED FOR Landfills Tunnels Collection tanks Water basins Irrigation channels Extraction mines Motorways Strengthening works at river and marine water flows Dam protections Fish farming THICKNESS RANGE Min thickness: 0.5 mm Max thickness: 3 mm USEFUL WIDTH Useful width: from 6 8 m PROCESS MATERIALS HDPE Black(carbon black)/white Masterbatch Geomembrane is the most peculiar product in the tubular blown film sector, with unique characteristics. Geomembrane target market growth is ongoing, especially in emerging economies where rapid development has increased the demand for geomembrane. Bandera offer comprises complete extrusion lines with up to 1200kg/h production capacity, with film thickness up to 3 mm. 3-LAYER GEOMEMBRANE EXTRUSION LINE STANDARD CONFIGURATION Dosing system The standard configuration comprises a high-capacity extruder for the inner layer and two smaller extruders intended for the outer layers, arranged with bimetallic barrels and no-wear coated screws Coextrusion head (die up to 2300mm) equipped with internal bubble cooling system (IBC) Fixed haul-off unit, suitably designed for production needs Fully-automated winders, 8m width, with automatic shaft extraction and reel downloading Geomembrane can be textured on one or both sides; a plain strip can be obtained to ease welding. This product can also be processed with 5 layer extrusion head for the production of Agrifilm. Bandera geomembrane extrusion lines can be customised according to Bandera customer s needs. 14

15 Automatic winding units Bandera winding units are definitely worth detailing. Fully automatic and equipped with safety devices. Winding cycle control by touch screen user interface connected with central PLC. Winders are offered in three operating modes: By contact (peripheral winding), single- and double-station configuration; film tension control by top sensitivity load cells By contact and with shaft axial control, single- and double-station configuration. Two winding modes are available: - by contact - by axial control on winding shaft axis, - a.c. servomotors Top quality winders featuring the following operation modes: - by contact - with axial control arranged on winding shaft axis by AC servomotor - with gap control - combined winding, with control arranged on winding shaft axis and by contact on the rubberized pressure roller - by counter-rotation - shaft accelerator. Larger pressure roller size allow for top-quality faultless reels, whose diameter can exceed 1500 mm. W 400 series: Contact mode Contact mode combined with axial control Top ESR 9000 series 15

16 Winding units for agricultural film and geomembrane As far as agrifilm is concerned, Bandera winding unit range comprises single- and double-station versions: Useful width from 2500 to 5000 mm Fully automated for jumbo reels Shaftless to wind agrifilm on cardboard and PVC cores Bandera offers geomembrane automatic winding units with automatic steel shaft extraction and reel download. Geomembrane automatic winding unit 16

17 Made in Bandera a synonym for quality In-house manufacture of the most critical and complex extrusion components: Screws: they are designed on the basis of process material rheological characteristics in collaboration with raw material producers. Extrusion heads: conceived with the support of the most up to date and precise design systems, taking into account customers process material rheological characteristics. Bandera offers its customers the widest range on the market, with dies from 30 to 2300 mm. Bandera extrusion heads ensure top quality products and minimised melt residence time inside the extrusion head, thus allowing accurate temperature control and offering the chance to process the most thermosensitive materials. Cooling rings: cutting-hedge double-flow cooling rings for extremely accurate bubble stability control and top performance with minimised thickness tolerances. They ensure trouble-free integration into top-quality automated thickness control systems. Cutting-edge haul-off units, either oscillating or fixed: designed and manufactured in compliance with product requirements and line production range. Useful widths comprised between 800 mm (for the production of industrial heavy bags) and a 8500 mm (for the production of agrifilm and geomembrane). 17

18 OVER 24-MONTH WARRANTY UPON REQUEST RECLAIMING OF EXISTING MACHINES AND REVAMPING OF COMPLETE EXTRUSION LINES CUSTOMIsED ON-SITE TRAINING FOR NEW APPLICATIONS EXPRESS CUSTOMER SERVICE SUPPORTED BY BANDERA STAFF UNRIVALLED EXPERTISE IN PROCESS MECHANICS/ ELECTRONICS 4 SERVICE CENTERS FOR A WORLDWIDE ASSISTANCE COST EFFECTIVE SPARE PARTS PACKAGES SCHEDULED INTERVENTIONS FOR EXTRAORDINARY MAINTENANCE Why choose Bandera as a technological partner? Over the past years Bandera has strengthened its leading position in its reference markets worldwide of packaging film, agrifilm and waterproofing geomembrane sectors. Among its customers Bandera lists major packaging item suppliers of food industries, and major agrifilm and geomembrane producers. Why choose Bandera? Unrivalled expertise in manufacturing complete blown film extrusion lines Worldwide appreciation Pace-setting know-how from the collaboration of leading packaging companies and expertise in small-, mediumand large-sized blown film extrusion heads manufacturing Wide extrusion head range, from 30mm to 2300mm Extended expertise in winding units Its rooted collaboration with tested reliable sub-suppliers Timely and efficient aftersales service ISO 9001:2000 certification 18

19 R&D A new Research & Development area is going to be fully operational by 2014 to test complete extrusion lines Facts & figures: latest turnovers Coming Soon 19

20 PLASTICS MACHINERY EXTRUSION TECHNOLOGY SINCE 1947 REV2/FILM/EN/09/13 briefinglab.com For details about Bandera technology, visit us at luigibandera.it FOIL SHEET EXTRUDERS PIPE COATING EXTRUDERS GRANULATION Visit our website and learn about our products Costruzioni Meccaniche Luigi Bandera SpA Corso Sempione, I Busto Arsizio (VA) Italy t f [email protected] - luigibandera.com You can download this document for your own mobile use and in the interest of the environment Technical specifications provided for illustrative purpose only and subject to change without prior notice.