On Reifenhäuser EVO blown film lines using the patented EVO Ultra Stretch MDO technology, Reifenhäuser Blown Film has produced the world's first MDO-PE film just 18 micrometers thick with superior mechanical properties, appearance, and further processing.

The new 18-micron film reduces the amount of material used by around 25% compared to previous film thicknesses of 25 microns. This makes the production of fully recyclable mono-material structures significantly more economical.

The film has been developed and tested for practical suitability in collaboration with raw material manufacturer LG Chem and printing specialist BOBST.

The printed and world's first 18 micrometer thin MDO-PE film developed by LG Chem, BOBST and Reifenhäuser. 

The industry has been pursuing the goal of not to use more material in fully recyclable all-PE solutions than in conventional PET-PE laminates. Technically, this is achieved due to the different densities of PET film and MDO-PE film by replacing the 12 μm PET film with a 16 to 17 μm MDO-PE film.

“With the reduction to 18 μm, we have taken a significant step in this direction - with further downgauging potential for the future," says Christoph Lettowsky, Senior Product Manager at Reifenhäuser Blown Film.

This leap in development was made possible by the combination of MDO Ultra Stretch technology with suitable raw materials. Thanks to the patented position of the Ultra Stretch unit directly in the system's haul-off, the film is stretched from the first heat. This makes the process particularly reliable and Reifenhäuser has produced the 18-micron MDO-PE film stably and reproducibly over many hours in the test runs.

The combination of suitable raw materials and Reifenhäuser’s MDO Ultra Stretch technology directly in the line's haul-off, where the film is stretched from the first heat, enables the 18-micron film.

Superior mechanical and optical properties

The 18-micron MDO-PE film achieves low thickness without compromising optical and mechanical properties. With a modulus of elasticity MD exceeding 1,400 MPa and a modulus of elasticity TD exceeding 1,100 MPa, the film meets the current market standard for stretched PE films.

Besides, with a haze of less than 5%, the film performs even better in terms of optical properties than the market standard, which is 6-7%.

Impressive print results

The 18-micron MDO-PE film also performed excellently in the converting process and exceeded all expectations of printing specialist BOBST.

BOBST has printed the film at high speeds of up to 500 m/min with excellent results in terms of printing quality and register performances. “But even more impressively, we were able to demonstrate the quality of our machine when printing in the BOBST oneECG process, achieving excellent print results at 300 m/min (and above),” says Davide Rossello, Head of Competence Center and Process Manager Gravure at BOBST.

Printed samples of the film are on display at the BOBST stand at drupa 2024 (28 May - 7 June) held in Dusseldorf, Germany.