SML came with a world debut in stretch film manufacturing to K 2022: a patented triple turret winder for the PowerCast XL stretch film line. The W4000-4S-3T is the first winder in the market for manufacturing 2” stretch film hand rolls on a 4.5 m wide line.

The company's new “three-turrets-in-one-frame” concept enables significantly higher production speeds for maximum output quantities – especially at the lighter 2” rolls.

“The PowerCast XL with the new turret winder W4000-4S-3T has yet to meet its match. The possibility to manufacture also 2” rolls on that 4.5 m wide increases the product diversity and productivity of our PowerCast stretch film line significantly,” introduced Thomas Rauscher, SML Product Manager.

Until now, it was only possible to run 2” hand rolls on lines up to 3 m width, thus the new development boosts the output of hand rolls by about 50 %. As before, 3” hand rolls, machine rolls and jumbo rolls an also be manufactured, with ease, with this new solution.

SML presents its PowerCast XL stretch film line with a patented, brand-new triple turret winder at K 2022.

The technical basis of the new winder W4000-4S-3T is the patented "three turrets-in-one-frame concept". Compared to other winders for wider lines, the three winding shafts with 1.5 m each are relatively short. This guarantees very stable production processes and allows significantly higher production speeds, especially at hand rolls.

The new turret winder W4000-4S-3T can be equipped with a range of cutting-edge winding technologies for stretch film production:

• Thin Core Technology
  This well-proven concept allows to run thinner and therefore lighter paper cores on specific winding shafts. A reduction of the core weight of approx. 50 % minimises the raw-material consumption in the core production – and with it the CO2 emissions in the same way.

• Coreless Winding
  Even better than winding on thinner paper cores, is to use no cores at all. SML’s Coreless Technology was developed for the coreless production of hand and machine rolls. Beside considerable sustainability effects, this winding method has also a significant impact on production costs.

• Modified Edges
  ME is a patented SML technology to reinforce the edges of stretch film, making them nearly indestructible. The whole process is very efficient as it completely takes place in-line. Higher residual stretchability and puncture resistance are the key-characteristics of stretch film with modified edges.

The 4.5 m wide PowerCast XL in combination with the winder W4000-4S-3T is the latest step forward in SML’s PowerCast series, successfully uniting maximum output volumes of up to 3.400 kg/h net with highest flexibility in production. 

Like all stretch film lines from SML, the PowerCast XL is able to process up to 80 percent post-consumer recyclate, i.e. from LLDPE/LPDE.

Film production Braskem’s PCR for the first time

Also, Braskem and SML presented to the market a solution that combines SML's technology in film processing and Braskem's post-consumer recycled resin (PCR). They demonstrated this innovation in a large machine on the exhibition grounds.

Braskem and SML stated that it was a challenge to show the stretch film solution with 30% PCR without compromising product quality or performance, as stretch film used for unitization of loads and protection in transport must be able to withstand great stress and need to be very resistant.

SML uses Braskem’s PCR for film production for the first time.

There, films produced with recycled material on the SML machine can achieve high performance in stretching and mechanical properties.

Braskem's Wenew DL085C resin made it possible to bring to the market the film transparency suitable for this segment, as well as to meet the requirements of mechanical strength and elongation for automatic application in the beverage industry.

"The stretch film developed together with SML shows how far Braskem has already increased PCR quality and what is already feasible today. Combining Wenew product with Braskem's portfolio, we can achieve a film with extremely high-quality and thus helping to open completely new perspectives for the use of recycled materials in a wide range of applications," commented Carlos André Silva, Subject Matter Expert at Braskem.

Heat-resistant C-PET light cup combining transparency and recyclability

Furthermore, SML has joined forces with its partners Sukano AG and Kiefel Packaging B.V. The result of their common R&D is a C-PET light cup that combines transparency and recyclability as well as suitability for thermoformed hot-filling or microweavable products.

The heat-resistant C-PET light cup.

Other advantages include short cycle times during thermoforming and a high stiffness. The newly developed C-PET light can thus be a reasonable option for manufacturers looking for an economic and easy-to-recycle alternative to PP and PS.

“Because easy recyclability is becoming increasingly important, we opted for a transparent C-PET solution at an early stage of our joint research and development work,” said Max-Phillip Lutz, Product Manager at SML.

Compared with other colored PET or PP and PS products, the recycling process of C-PET light is considerably easier. C-PET light film can be smoothly reprocessed in existing facilities together with other post-consumer or post-industrial PET materials.

In general, C-PET is temperature resistant up to 220°C. However, this is not necessary for many applications and limits the output in thermoforming. In contrast, C-PET light was developed to withstand a maximum temperature of 100°C.

The new C-PET light enables the manufacturing of transparent thermoforming products for hot-fill applications up to 100°C at output volumes comparable to those of conventional A-PET processes. Especially the shorter cycle times during thermoforming are an economic advantage compared with conventional C-PET.

SML came with a world debut in stretch film manufacturing to K 2022: a patented triple turret winder for the PowerCast XL stretch film line. The W4000-4S-3T is the first winder in the market for manufacturing 2” stretch film hand rolls on a 4.5 m wide line.

The company's new “three-turrets-in-one-frame” concept enables significantly higher production speeds for maximum output quantities – especially at the lighter 2” rolls.

“The PowerCast XL with the new turret winder W4000-4S-3T has yet to meet its match. The possibility to manufacture also 2” rolls on that 4.5 m wide increases the product diversity and productivity of our PowerCast stretch film line significantly,” introduced Thomas Rauscher, SML Product Manager.

Until now, it was only possible to run 2” hand rolls on lines up to 3 m width, thus the new development boosts the output of hand rolls by about 50 %. As before, 3” hand rolls, machine rolls and jumbo rolls an also be manufactured, with ease, with this new solution.

SML presents its PowerCast XL stretch film line with a patented, brand-new triple turret winder at K 2022.

The technical basis of the new winder W4000-4S-3T is the patented "three turrets-in-one-frame concept". Compared to other winders for wider lines, the three winding shafts with 1.5 m each are relatively short. This guarantees very stable production processes and allows significantly higher production speeds, especially at hand rolls.

The new turret winder W4000-4S-3T can be equipped with a range of cutting-edge winding technologies for stretch film production:

• Thin Core Technology
  This well-proven concept allows to run thinner and therefore lighter paper cores on specific winding shafts. A reduction of the core weight of approx. 50 % minimises the raw-material consumption in the core production – and with it the CO2 emissions in the same way.

• Coreless Winding
  Even better than winding on thinner paper cores, is to use no cores at all. SML’s Coreless Technology was developed for the coreless production of hand and machine rolls. Beside considerable sustainability effects, this winding method has also a significant impact on production costs.

• Modified Edges
  ME is a patented SML technology to reinforce the edges of stretch film, making them nearly indestructible. The whole process is very efficient as it completely takes place in-line. Higher residual stretchability and puncture resistance are the key-characteristics of stretch film with modified edges.

The 4.5 m wide PowerCast XL in combination with the winder W4000-4S-3T is the latest step forward in SML’s PowerCast series, successfully uniting maximum output volumes of up to 3.400 kg/h net with highest flexibility in production. 

Like all stretch film lines from SML, the PowerCast XL is able to process up to 80 percent post-consumer recyclate, i.e. from LLDPE/LPDE.

Film production Braskem’s PCR for the first time

Also, Braskem and SML presented to the market a solution that combines SML's technology in film processing and Braskem's post-consumer recycled resin (PCR). They demonstrated this innovation in a large machine on the exhibition grounds.

Braskem and SML stated that it was a challenge to show the stretch film solution with 30% PCR without compromising product quality or performance, as stretch film used for unitization of loads and protection in transport must be able to withstand great stress and need to be very resistant.

SML uses Braskem’s PCR for film production for the first time.

There, films produced with recycled material on the SML machine can achieve high performance in stretching and mechanical properties.

Braskem's Wenew DL085C resin made it possible to bring to the market the film transparency suitable for this segment, as well as to meet the requirements of mechanical strength and elongation for automatic application in the beverage industry.

"The stretch film developed together with SML shows how far Braskem has already increased PCR quality and what is already feasible today. Combining Wenew product with Braskem's portfolio, we can achieve a film with extremely high-quality and thus helping to open completely new perspectives for the use of recycled materials in a wide range of applications," commented Carlos André Silva, Subject Matter Expert at Braskem.

Heat-resistant C-PET light cup combining transparency and recyclability

Furthermore, SML has joined forces with its partners Sukano AG and Kiefel Packaging B.V. The result of their common R&D is a C-PET light cup that combines transparency and recyclability as well as suitability for thermoformed hot-filling or microweavable products.

The heat-resistant C-PET light cup.

Other advantages include short cycle times during thermoforming and a high stiffness. The newly developed C-PET light can thus be a reasonable option for manufacturers looking for an economic and easy-to-recycle alternative to PP and PS.

“Because easy recyclability is becoming increasingly important, we opted for a transparent C-PET solution at an early stage of our joint research and development work,” said Max-Phillip Lutz, Product Manager at SML.

Compared with other colored PET or PP and PS products, the recycling process of C-PET light is considerably easier. C-PET light film can be smoothly reprocessed in existing facilities together with other post-consumer or post-industrial PET materials.

In general, C-PET is temperature resistant up to 220°C. However, this is not necessary for many applications and limits the output in thermoforming. In contrast, C-PET light was developed to withstand a maximum temperature of 100°C.

The new C-PET light enables the manufacturing of transparent thermoforming products for hot-fill applications up to 100°C at output volumes comparable to those of conventional A-PET processes. Especially the shorter cycle times during thermoforming are an economic advantage compared with conventional C-PET.