K 2013: Hosokawa Alpine presented die head for 11-layer film

Dusseldorf - At K 2013, blown film equipment maker Hosokawa Alpine says its 'absolute' highlight was its X die head for 11-layer production.

The company says that where 7- and 9-layer composites reach their limits, Hosokawa Alpine's X die head for 11-layer production opens up completely new options.

"For processors operating with 11-layer technology, this high level of versatility presents a definite leading edge as the intelligent combination of different functional layers reduces production costs," the company said. "The highest savings, however, can be realized by replacing laminated structures with extruded composites."

The company says there is a particularly wide range of potential applications for 11-layer film in the food packaging segment.

5-layer blown film line

Hosokawa Alpine touts that when it presented a 5-layer co-extrusion line at K 2010, it was a sign of the times. Today, the trend is well under way and an ongoing number of processors are shifting from 3-layer lines to 5-layer lines. At this year's K, Hosokawa Alpine presented a reportedly advanced, versatile 5-layer blown film line with output rates of up to 1000 kg/h.

The extruders with Smartbox were driven by water-cooled asynchronous servo motors. The line is controlled via ExVis 2.0 with one-touch system. Both the patented FBF 16-40 X die head, which was equipped with a 400 mm die and the cooling system, were designed for high throughput rates.

MDO film orientation line with patented TRIO system

On five exhibition days of the trade show, the produced film was also oriented inline by an Alpine MDO 20/11 inline film orientation line with an operating width of 2000 mm, 11 rolls and an outlet line speed of ≤ 200 m/min. The orientation ratio of ≤ 10:1 could be infinitely adjusted.

On those days, visitors were able to view the newly developed and patented TRIO system in operation and saw how this unique profile control system reduced the process-related waste web scrap by up to 50% with excellent film flatness. At the end of this demonstration, the waste web scrap was compounded by a repelletizing extruder.

Range of films

At the Hosokawa Alpine stand, processors using blown film lines were presented with the live production of a range of film structures. During the demonstrations, the lines processed resins from Borealis, ExxonMobil, Sabicand Total.

Alpine's test center in Augsburg, Germany, comprehensively tested the film structure developed by ExxonMobil Chemical and Hosokawa Alpine. The tests demonstrated that thinner hygiene compression packaging films are possible without compromising critical end-use performance properties. 

"Working on advanced film formulations with a leading resin manufacturer like ExxonMobil has allowed us to showcase the full potential of our 5-layer film technology," said Holger Niemeier, operations director, film extrusion division, Hosokawa Alpine Aktiengesellschaft. "The potential for very high throughput rates, energy savings and the opportunity to produce packaging film that does more from less resin."