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Keywords of this article:  extrusion 
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From standard to very specific high-tech film products, Hosokawa Alpine offers tailor-made solutions with maximum flexibility.
From standard to very specific high-tech film products, Hosokawa Alpine offers tailor-made solutions with maximum flexibility.

High-barrier films are in demand around the globe as they prevent the permeation of oxygen, nitrogen, carbon dioxide and water vapor. Typically, layers of EVOH and/or with their adhesives and layers of polyolefins are combined to reach the required film properties.

Produce on 9-layer lines became state-of-the art for such applications within the last few years. Ultra-thin layers of only 1 μm need to be guaranteed under production conditions, tolerances are low and quality standards are extremely high. Highest flexibility is also requested.

Hosokawa Alpine’s 11-layer line focusses on flexibility in usage of raw materials and its throughput in the single layers. It brings clear benefits to the film producer, with the capability of producing high quality barrier films with 5-9 layers as well as creating new film structures with two more functional layers.

As said, less flexible very thin or very thick layers from the 9-layer-concept give way to flexible, more uniform layer thicknesses in the 11-layer line. By using 11 layers of equal thickness, the line opens up completely new avenues to unprecedented diversity of film structures.

Hosokawa Alpine puts every effort in continuous innovation of blown film processing, from standard 3-layer film to very specific high-tech film products with 11 functional layers. In its lab the extrusion line is shown in practice, and is available for interested customers.

MDO technology with patented TRIO system
The MDO technology of Hosokawa Alpine guarantees less trim waste and improved film flatness.
Hosokawa Alpine is also a technology leader in mono-axial film orientation, with a great number of Machine Direction Orientation (MDO) film stretching lines installed worldwide.

When comes to produce oriented diaper back sheets, laminating films or twist films, the MDO inline stretching process at Hosokawa Alpine achieves less trim waste and improved film flatness.

MDO technology improves film optics, increases mechanical values and can additionally lead to specific properties, such as breathability. In addition to niche markets, the technology is used now to produce standard products.

Hosokawa Alpine was granted a patent for their Trim Reduction for Inline Orientation (TRIO) system, which optimizes the film thickness profile inline. The result is minimum thickness variation across the entire layflat width, guaranteeing premium film quality after orientation for converting. The edge trim is also reduced by up to 50%.

According to the company, for the trend product breathable diaper film thicknesses of 12-25 g/m² are customary market standards and are commonly produced with film width of 2.500 mm. Specialized on low thicknesses in the range of 12-15 g/m², its blown film line with MDO inline prevails over previously used cast technology, with excellent breathability and improved mechanical properties.

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