Flexible Packaging Vietnam 2009 - HCMC Latest Film Extrusion Technology Bandera - Company introduction: With more than 60 years of successful and glorious history in the plastics machineries, Bandera from Italy is a company well known for its rich experiences and deep know-how in extrusion machinery design, manufacturing, installing and with several world wide state-of-the-art reference lines running. All those activities are under the strict control of ISO 9001 Quality Certificate. 1
Bandera - Company introduction: Having a group of skilled engineers staff for the R&D activities, Bandera also keeps close relationships with raw materials suppliers, Universities and Research Institutes to match the ever increasing demanding market requirements. In addition, within its 100,000 square meters production facilities, several large openhouse-exhibition-hall for the real on-siteoperations of various extrusion lines are available. Thus make Bandera in the leading position for the R&D of new extrusion technology in accordance to most demanding customers production requirements. Co-Extruded Blown Films Co-extruded Blown film is diversified in terms of either the way of processing or application for packaging industry. The blown film lines Bandera can produce 3-5-7 and also up to 9 layer of co-extruded film or produce the stretch film and shrink film, FFS bag film and other co-extruded blown films. 2
Latest Blown Film Co-Extrusion Technology on the market requirement to the following films: Packaging Films Film for converting Film for hoods Stretch Films Shrink Films Adhesive Films (Tacky Films) Lamination Films Barrier Films Co-Extruded Blown Films 3 Layer Technical blown Films Which are the applications? Stretch Hoods (Stretch films) Heavy Duty Bags (FFS Bags) Masking and protective films Film for printing and lamination Shrink Hoods (Shrink films) Film for general packaging 3
3 Layer Technical blown Films What is new? Modern and Innovative line with high output, for the extrusion of shrink film, lamination film and film for elastic hoods (stretch hood film) 3 layers coextrusion line for the production of shrink film and for general packing: Layflat 1600mm Thickness 70 µm 2 sigma ± 1,9 % Metallocene based formulation with over 500 kg/hrs output. Line composition: 3 Layer Technical blown Films One TR 100 AFS extruder in the middle layer, L/D ratio=30, A.C. ABB motor 160 kw Two side extruders TR 65 AFS, L/D ratio=30, A.C. ABB motor 75 kw 3-layer side-feeding coextrusion head, Mod. EXPH 400, with IBC internal cooling N 3 ultrasound sensors Ø 350 mm die Air cooling ring Mod. Karat 3.2 Com 3 (K-Design) ST 139/2000 oscillating take-off E+L Web center guide Mod. DR 313 ESR 9000 TW 1800 double station winder with Safe Load mandrel loading device 4
3 Layer Technical blown Films NEW SINGLE MULTI LIPS AIR RING: Air cooling ring Mod. Karat 3.2 Com 3, presented by Bandera in cooperation with K-Design as the latest innovation. 3 Layer Technical blown Films NEW SINGLE MULTI LIPS AIR RING - FEATURES: Adjustable in height with remote control, the cooling ring built-in also the 60 segments Vario Cool thickness control system, with modulation of the air quantity through high-precision step-by-step motors. It is equipped with multiple inserts specially designed to perfectly adjust the incidence of the air flux on the bubble. 5
3 Layer Technical blown Films Stretch Hoods Advantage of Stretch Hoods: Lower material cost No additional heating -lower energy costs No risk of fire or explosion Pallet load is not exposed to any source of heat Faster packaging speed Retain products which settle during transportation Higher vertical holding force No risk of fusion between packaging goods and film 3 Layer Technical blown Films Stretch Hoods Benefits of Stretch Hoods: Lower cost with a thinner film Lower cost with a smaller tube One tube size in storage Faster cycle time for pallet packaging Irregular load sizes using the same line and film Higher visibility into the pallet Higher load stability Marketing surface for printing 6
3 Layer Technical blown Films HDB & FFS Films Heavy Duty sack are used to transport bulky baggage from one place to another. Depending on the applications and market demands the classification can be split in two categories Consumer sack Heavy Duty sack 3 Layer Technical blown Films HDB & FFS Films Consumer Sack: Are mainly used to carry products less than 10 kg with a thickness around 10 80 µm Heavy Duty sack these sacks are used to carry products with more than 10 kg. Typically with a thickness of 80 200 µm 7
3 Layer Technical blown Films HDB & FFS Films Market overview demand for plastic heavy duty sacks 7000 6000 5000 4000 3000 2000 1000 Year 2000 2004 2006 2010 Million [ ] 3.227 4.280 4.825 6.000 0 2000 2004 2006 2010 Significant grove of the trend index forecast: 5 % Year 3 Layer Technical blown Films HDB & FFS Films Market overview thickness of plastic Heavy duty sacks 180 160 140 120 100 80 60 40 20 0 2000 2004 2006 2010 Year 2000 2004 2006 2010 Thickness [µm] 180 160 140 100 (80) With the same mechanical proprieties European standard HDB Trend of the reduction of thickness for the next 4 years: From 10 % to 12 % 8
3 Layer Technical blown Films HDB & FFS Demand Europe 27% Asia 36% Others 13% South America 6% North America 18% TOTAL market size: 35 milion tons 3 Layer Technical blown Films HDB & FFS Films Bandera last technology: DOUBLE AIR RING HIGH OUTPUT LINE 9
3 Layer Technical blown Films Protective Films Why use protective films: Protect surfaces Insure the quality of product while making manufacturing processes more efficient. Reduce the costs arising from rejected, defective and reworked products. Which applications? 3 Layer Technical blown Films Protective Films Metal Building Panels Decorative Architectural Panels Metal Plated Products Metals Extruders, Anodizers and Polishing Stainless Steel Coil Coaters Metals factories Trophy & Plaque manufactures Appliance manufactures Doors manufactures Refrigeration Equipment 10
3 Layer Technical blown Films Protective Films Also Protective film are used when customer needs: Excellent "lay-flat, no curling effect and excellent optical proprieties High clarity for inspection To peeled back for inspection and then re-laminated the film Easy handle during installation (for example into the display units) Barrier Blown Films Barrier films are used to extend shelf life of refrigerated products like meats, poultry, cheese, and fish and unrefrigerated foods like powdered milk, nuts, pet food, and wine. Besides barrier, flexibility is the most desired property, for everything from large shipping sacks and bag-in-box films to flexible thermoformed pouches with sealing lid. 11
5 Layer barrier blown Films WHAT IS 5 LAYERS FOR? Longer shelf life Preservation of freshness, taste and fragrance No corrosion No freezer burns No variation of package s atmosphere (Co 2, NO) Barrier proprieties: No penetration from atmosphere inside the package No migration of product s aroma outside the package 5 Layer barrier blown Films Why 5 Layers are needed? PE BARRIER PE PE TIE BARRIER TIE PE The barrier layer is PA (Nylon) or EVOH. They are not chemically compatible with PE. That s why a 3 layers structure is not possible To have adhesion between PE and the barrier layer, N 2 tie layers are necessary Note: PE LD LLD mlld - EVA and blends with MD, HD, PP 12
5 Layer barrier blown Films WHICH ARE THE APPLICATIONS? FOOD APPLICATIONS DRY (snacks, pet food, coffee...) PERISHABLE (fresh meat, cheese, prepared foods, fruit juices...) PROCESSED (processed meat, sauces, jam...) FROZEN (fish, meat, vegetables, soups...) 5 Layer barrier blown Films WHICH ARE THE APPLICATIONS? CHEMICALS & COSMETICS Detergents, soaps, toothpastes, creams... PHARMACEUTICALS Retortable film, blister packs, medical kit... 13
5 Layer barrier blown Films WHICH ARE THE APPLICATIONS? ELECTRONICS Antistatic film, electronics packaging AGRICULTURE VIF (Virtual Impermeable Film), TIF (Totally Impermeable Film) For soil sterilisation (fumigation) 5 Layer barrier blown Films WHICH ARE THE APPLICATIONS? INDUSTRIAL Fumigation LAMINATION with PET, PP, PS, (for sealable or peelable film) with paper, aluminium 14
7 Layer HIGH barrier blown Films PE TIE PA EVOH PA TIE PE BARRIER BLOCK 7 Layer HIGH barrier blown Films ADVANTAGES Improved bonding strength: Adhesion between PA and EVOH, two polar materials are irreversible tied (no delamination). Temperature resistance of the structure: As the EVOH layer is imbedded between two PA layers which shows better thermal and mechanical properties. -Better hot tack performance. -Better hot filling performance. -Higher temperature resistance in pasteurization or retorting process. 15
7 Layer HIGH barrier blown Films ADVANTAGES Improved mechanical properties like: - Tensile strength - Tear resistance - Puncture resistance (depending on the PA content of the structure) - Flex crack resistance Extended barrier properties: - Especially the dynamic barrier is improved, as the number of absorption - Migration - desorption processes are increased. - The outer block is protected against aggressive Medias as well as humidity from the product by the inner block, which is closer to the product. Vice versa the inner block is protected from ambient by the outer block. - Protecting the EVOH layer against water-, grease-, aroma- or solvent - migration is improving also the gas barrier. 7 Layer HIGH barrier blown Films ADVANTAGES Improvement of thermoforming: - Improved thermo-formability - Less problems when the temperature distribution of the heating station is unequal. - Improved rest thickness in corners - Improved puncture resistance - The use of 15-20% thinner film gauge is possible 16
Costr. Mecc. L. BANDERA S.p.A. What we can offer Costr. Mecc. L. BANDERA S.p.A. What we can offer Setting up own office: it shows that Bandera pays much attention to the customer and the resolution to service the market. It surely will provide better channel for the communication and timely service and support. 17
Costr. Mecc. L. BANDERA S.p.A. What we can offer The technical service team of Bandera knows local raw materials very well with humble and kind working manner and attitude to ensure the excellent communication with all the Customers. Costr. Mecc. L. BANDERA S.p.A. What we can offer Bandera has a strong technical R&D team and the strong capability in design and manufacturing in all key parts including (screw, barrel, die-head, air ring, winder, and take off unit ) to guarantee the quality control and the supply in the spare parts. 18
Costr. Mecc. L. BANDERA S.p.A. What we can offer Bandera assembles best brand products for the key electrical parts, as well top manufacturers for peripheral and ancillaries equipments. THANK YOU FOR YOUR KIND ATTENTION COSTRUZIONI MECCANICHE LUIGI BANDERA S.P.A. WEB SITE: www.lbandera.com Email: lbandera@lbandera.com Bandera Blown Film Line Dpt. Paolo Ceol Product & Business Manager phone: +39.(0)331.398.154, Mob.: +39 348 26.41.216, email: p.ceol@lbandera.com Diego Ferrari Sales Manager phone: +39.(0)331.398.179, Mob.: +39 335 87.56.102, email: d.ferrari@lbandera.com Luca Magni Sales Manager phone: +39.(0)331.398.120, Mob.: +39 348 76.75.598, email: l.magni@lbandera.com China & Far East Representative Office Mrs. Ida Tian phone: +86 10 65831285, +86 10 65831287, e-mail: ida.tian@gmail.com 19