Hall 17, Stand A59
World Record Output
W&H exhibits new VAREX 5-layer blown film line for Polyolefin with 1000 kg/hr
New MAXICONE P die
At the K 2010, German machinery manufacturer, Windmöller & Hölscher, will present a
new 5-layer VAREX blown film line along with the new 5-layer 400 mm MAXICONE P die,
which was developed specifically for innovative polyolefin-based film structures. The die
allows for extremely high outputs of 1000 kg/hr. This sets a new world record! The film
produced at the K 2010 is a 40 µm tissue film, that up until now has been produced with
3-layers. Recognizing a need in the market, W&H worked with resin manufacturer Exxon
Mobil Chemical, one of the world's leading manufacturers of metallocene polyethylene
(mPE) and brands such as Exceed™ and Enable™ metallocene polyethylenes, to create
a new generation of 5-layer films using a polyolefin base. The results are improved film
properties as well as thinner films (downgauged) compared to conventional 3-layer films
on the market. The new films achieve a substantial reduction of raw materials, a priority for
W&H under their „greenovation“ philosophy.
Studies have shown that improvements in 3-layer structures will eventually reach their limits.
Using functional „interlayers“ makes it possible to improve performance efficiency. This led
to the development of innovative polyolefin-based film structures. For the manufacturing
of these new films in 5 layer configuration, W&H optimized the VAREX blown film line and
developed the new MAXICONE P die.
The show line has 5 VAREX extruders (70/70/105/70/70) with high-performance,
low-temperature screws specifically for polyolefin, and a layflat width of 2,200 mm. The
layer configuration, as opposed to most 5-layer barrier films lines, utilizes the largest
extruder for the middle layer. The new MAXICONE P was designed specifically with this
in mind. The extremely compact design and special layout of the spiral melt distributor
minimizes residence time, pressure drop and wetted surface areas, while delivering
great flexibility and very high outputs.
The new OPTICOOL air ring, successor to the well-known double air ring MULTICOOL D, is
key to the high output achieved by this line. Thanks to an improved air flow control, which avoids pressure drops of intake air, the OPTICOOL has a very high cooling capacity and enables the
blown film line to reach higher outputs than dual air rings do. The line is also equipped with
the MULTINIP oscillating haul-off with direct driven turning bars and the VARIOCAGE calibration
unit. The multifunctional FILMATIC S winder finishes the process with perfectly wound films.
The range of VAREX blown film lines from W&H is widely-known for producing the best film
quality. Demonstration runs at the K 2010 will again be performed without the need for edge trimming, even at output levels of 1000 kg/hr. That translates into substantial reductions of
waste, adding to the line's overall efficiency. The EASY-Family modules, EASY-CHANGE and PROFILE BOOSTER, contribute to the high performance. While EASY-CHANGE completely
takes over size changes, PROILE BOOSTER quickly narrows down film thickness tolerances, reducing both time needed to reach full production levels and waste by 60%.
After the K 2010, the VAREX show line will be modified from 5- to 7-layers and shipped to
Danafilms, Inc., for production in their Kentucky (USA) plant.
Windmöller & Hölscher is an international leader in the design, manufacturing and
distribution of machinery for the flexible packaging industry and is based in Lengerich,
Germany. The product range includes flexographic and gravure printing presses, blown
and cast film extrusion systems, multiwall equipment, plastic sack and bag making
machines, as well as form-fill-seal machinery.
