Reifenhäuser highlights productivity, sustainability and digitalization at NPE

Under its motto “The Time is Now”, Reifenhäuser presents plastic films solution focusing on three major topics of the industry – sustainability, digitalization and productivity – at NPE 2024, from May 6 to 10 in Orlando, Florida, the US.

The highlights range from production systems for fully recyclable barrier films, EFSA/FDA-compliant food contact films made from 100% recyclate to performance-enhancing components and digitalization solutions.

On productivity

As a special highlight, Reifenhäuser exhibits Kdesign technologies for blown film at NPE for the first time. At the booth, the KARAT air ring, which is well known for maximum output, narrowest film tolerances and easy handling, and the CENTRO-Freeze secondary cooling unit are showcased.

CENTRO-Freeze secondary cooling increases the blown film output and saves anti-block additives.

Another highlight is the new Coextrusion Adapter Flex for the extrusion of cast, sheet and coating applications, which is also presented to the public for the first time. This new “mid-range model” enables high flexibility in production with quick changes to the film profiling on the system using adjustable profiling inserts.

The Reifenhäuser coextrusion portfolio Fix, Flex and Pro (from left to right).

Reifenhäuser also exhibits its latest automation option PAM (precise, autonomous, mechatronic) for flat film extrusion lines. PAM calibrates coextrusion adapters and dies automatically for best comfort, quality, and productivity.

On sustainability

Reifenhäuser’s patented EVO Ultra Stretch stretching unit enables the production of all-PE mono-film, such as for barrier food pouches. The patented technology increases the barrier effect of the EVOH, leading to the necessary barrier effect is achieved with an EVOH content of less than 5%, and thus meets all the requirements for complete recycling.

With EVO Fusion technology, Reifenhäuser can turn any recycling content as well as production scrap such as PET/PE film into sellable blown film. Using twin-screw technology, the line reconnects PET and PE after melting despite chemical incompatibility. EVO Fusion also masters degassing from printing ink. Twin-screw extruders offer a significantly larger free surface in the outgassing zone than single-screw extruders.

EVO Fusion enables the use of readily available, cost-effective film waste and even printed laminates directly as raw material.

For flat films, EFSA/FDA approved PET sheet line enables PET recyclate to be processed directly into food-safe films without pre-drying. The process uses a co-rotating twin-screw extruder and a specially developed high-performance vacuum system that enables producers to process PET recycling material directly.

Reifenhäuser’s PET Sheet lines produce sustainable PET film from up to 100% PET bottle flake for direct food contact.

On digitalization

The core of the Reifenhäuser’s digital solution is the so-called c.Hub, a middleware that ensures the secure exchange of data between different IT systems, applications, extrusion machines and line controls.

Another digital solution is the associated ExtrusionOS software provides user-friendly applications and dashboards that help monitor, manage, store and analyze all production data.

Both c.Hub and Extrusion OS is developed by RE: GmbH, a tech start-up of the Reifenhäuser Group, specialized in digital solutions for the plastics extrusion and packaging industry.