Plastics News - Show Daily - October 20, 2022 - 16

16 * Plastics News, October 20, 2022
SHOW DAILY
Innovative oriented fi lm solutions
from Brückner Maschinenbau, Servtec
By David Vink
Plastics News Correspondent
Michael Baumeister, chief operating
offi cer, technology and logistics,
at Siegsdorf, Germany-based
bioriented fi lm machinery producer
Brückner
Maschinenbau
GmbH informed Plastics News in
June about a number of K 2022
development highlights that contribute
to higher productivity and
reduced
Pouch examples of full
BOPE monomaterial
packaging substituting
conventional multimaterial
solutions. Brückner Group photo
larly, existing BOPET lines need to
be able to run bioriented polylactide
fi lm (BOPLA) while retaining
BOPET capability.
Inline
ultrathin water-based
energy consumption.
This includes new " economy of
scale " line concepts that increase
biaxially oriented polypropylene,
PET and nylon (BOPP, BOPET
and BOPA) line speed speeds and
widths.
Baumeister showed charts in
which BOPA fi lm productivity increases
by more than 75 percent
as line speed increases from 220
meters per minute to 350 meters
per minute, along with width increasing
from 6.6 to 7.4 meters.
Using a patented technique to
take BOPP/BOPET line speed beyond
600-700 meters per minute
and running at 10.5 meters in
width has potential to increase
BOPP/BOPET fi lm productivity
by more than 15 percent in the future,
Baumeister said.
Increasing BPF battery separation
fi lm and capacitor fi lm line
width from 5.5 meters to 6 meters
and raising speed from below 50
to slightly above 50 meters per
minute will increase output by
more than 20 percent. Brückner
also continues to improve capacitor
fi lm yield and properties with
a focus on 2-micrometer fi lms.
Brückner lines have previously
fed waste material, arising from
starting up and stopping lines,
edge trim and product changeover,
into a waste fi lm grinder. The
5-8 percent " fl uff " form ground
material was fed back into the
extruder, the rest passed to an inBRÜCKNER
MASCHINENBAU
GMBH
Hall 3, Booth C90
house granulator, from which the
ground granulate material was
also fed into the extruder, together
with virgin granulate.
That has changed now, as all of
the 20-25 percent waste arising is
now fed as " fl uff " to the extruder
together with virgin granulate.
This eliminates in-house granulation
in what Brückner calls a " direct
fl uffi ng " approach that saves
material and reduces energy consumption.
Around
200 kilowatts per year
lower energy consumption is now
achieved with a patented intelligent
oven control system that no
longer needs heat exchangers for
heat recovery. Baumeister said
this involves combining exhaust
air at 140°C with outside air and
feeding the combined air back to
the fi rst oven on Brückner bioriented
fi lm lines.
A patented system for aerodynamic
hot air fl ow to each of the
pre-heating and stretching (both
100°C), annealing (230°C) and
cooling zones (35-70°C) also cuts
energy consumption and reduces
waste, resulting in higher, more
uniform fi lm quality across the
working width. The system also
contributes to higher line speed.
Brückner Servtec
Markus Gschwandtner, CEO at
Brückner Servtec GmbH (Hall 3,
Booth C90), stressed the importance
of sustainability and digitalization
for Servtec, which deals
with service, maintenance and
upgrading of Brückner bioriented
fi lm lines. He illustrated this by
citing statements by four leading
international consumer products
brand owners: Mondelez, Unilever,
Nestlé and PepsiCo, which
have all fully committed to particular
sustainability aims by 2025.
With slight differences on the
choice and extent among these
brand owners, all of these statements
relate to varying degrees
of recyclability, reusability, biodegradability
or compostability.
For Servtec, this involves adaptation
of bioriented fi lm lines
with its latest line transformation
conversion packages, so that
they can move away from multiBaumeister
Gschwandtner
layer
fi lm structures with different
polymers in some of the layers,
to monomaterial solutions.
These could involve just BOPE
fi lm, with low, high and linear low
density polyethylene versions
for multilayer fi lm construction.
Barrier properties would be obtained
by ILC inline coating medium
or HDPE with AlOx and/
or SiOx. The aim here is to ease
sorting and recycling.
For Servtec, this means assisting
customers to shift from BOPP
to BOPE production on existing
BOPP lines, in order to obtain " full
BOPE monomaterial packaging, "
under the slogan " Be innovative,
be BOPE. " It is also associated
with opportunities for cast fi lm
extrusion-based BOPE to replace
blown PE fi lm. Conversion should
be made while still retaining
BOPP production capability. Simichemical
coating AlOx/SiOx nanolayers
between orientation stages
provide barrier properties, dispensing
with the need for polymer
barrier layers.
Gschwandtner also referred to
how overall energy effi ciency may
be improved by upgrading lines
to direct drive for extruders and
winders, eliminating maintenance
otherwise needed for gearboxes,
belts and pulleys. This also comes
with better fi lm quality through
more accurate torque and speed
control.
A " Smart Swivel Roll " system
used in the cast fi lm production
section of BO lines optimizes cast
fi lm cooling time and reduces the
amount of heating needed in the
subsequent
machine
direction
orientation (MDO) part of the
stretching process. The system
achieved this by intelligently lowering
the fi lm in the chill-roll bath
only to such an extent that heating
in the MDO process is no longer
necessary.
Servtec has installed its digital
service package, available in silver,
gold and platinum levels, to
more than 359 lines worldwide,
representing 50 percent of the
total installed base of Brückner
BO lines. This enables Brückner
to operate in a " glocal way,
being global but acting local, "
Gschwandtner said.
Maximum line availability is ensured
with a digital maintenance
plan assistant system based on
sensors and algorithms. This
provides automatic system notifi
cation on whether service is
due or necessary on a particular
line component, or even on downstream
equipment.
Hall 14
Booth C03
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Plastics News - Show Daily - October 20, 2022

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