EVOLUTION Technology

for 7- and 9-Layer Blown Film

Our Solutions - Your Success
EVOLUTION Technology for 7- and 9-Layer Blown Film
PE or PP or Surlyn (Ionomers):
Our Solutions - Your Success is a synonym for our enthusiasm,
experience and technical leadership which has been proven with the
EVOLUTION generation of blown film systems. Barrier film suppliers
with EVOLUTION systems are now recognized by their customers
as reliable high quality flexible barrier film packaging specialists.
Continuous research and development together with the experience
gained jointly with our customers has enabled Reifenhuser Kiefel
Extrusion to help our customers become successful players in the
global barrier film packaging industry.
Over the past few years the flexible packaging industry has
experienced dramatic changes. End users have increasingly
demanded multilayer barrier films with unique properties,
functionality and added value. Flexible multilayer barrier films are
today an integral part of our daily life, something we often do not
realize.
Reifenhuser Kiefel Extrusion heard the message from the world
markets and launched the modular EVOLUTION generation of
blown film systems. These systems enable film producers today
to grow existing markets, find new markets, and meet the changing
demands of the global flexible packaging industry.
Let us introduce you to the world of EVOLUTION technology for
the production of economic, high quality multilayer barrier films
consisting of 7 or 9 layers.
* = Barrier properties dependent on moisture level
** =Pasteurization: 82 - 85 C Sterilization: 121 - 125 C
EVOH (Ethylene Vinyl Alcohol):
PA or CoPA:
Why 7 or 9 layer?
Good odor barrier
Very good thermoforming properties
Good pasteurization properties
High mechanical strength
(puncture resistance)
Carrier layers (PE or PP)
Moderate O
2
barrier in dry environment*
Insufficient WVTR
No natural adhesion to polar polymers such
as PA, CoPA, EVOH, etc
Good water vapor barrier (PP or PE)
Good sealing properties
(mLLDPE blends, LLDPE or Surlyn)
High mechanical strength (puncture resistance)
Carrier layers (PE or PP)
Moderate O
2
barrier in dry environment*
High thermal stability for pasteurization
(PE) / sterilization (PP)**

Good odor barrier

Limited use for sterilization
High O
2
barrier in dry environment*
Insufficient WVTR

Protection of food, medical or other sensitive goods against penetration of oxygen, or other ambient
influences.
The required application properties can be achieved by combining different polymers.

EVOLUTION Extruders
Highest flexibility and widest output range with
our Ultra Range of extruders, i.e. depending on
the application requirements, extruders are
selected based on the polymers to be processed,
and all are equipped with a unique screw design.
A wide variety of polymers and blends, such
as LDPE, LLDPE, Metallocene, EVA, Ionomers,
MDPE, HDPE, PP, Adhesives, Copolyamide,
PA6, blends of Polyamide, EVOH, COC, PETG,
PS,K-Resin, etc. can be processed, enabling
a wide range of layer thicknesses and ratios
while ensuring perfect homogenization.
30 L/D Ultra Range Extruders

EXTRUDERS & DIE HEADS

High specific screw output with short residence time and
low melt temperature which avoids melt degradation and thus
improves film quality
Universal screw geometry designed for low melt temperatures,
perfect homogeneity at all output rates
Special heating-cooling combination on grooved feed section
allowing the widest range of polymers to be processed
The direct drive system along with the slim frame design allows
for compact installation without sacrificing operator requirements.
EVOLUTION Ultra Range Die Heads
The Reifenhuser Kiefel Extrusion philosophy from the beginning
has been to manufacture all key components in-house using state-
of-the-art CAD/CAM design in conjunction with CNC tooling
machines. The selection of the proper type of steel, along with
stress relieving steps are a further important quality factor. The
mirror appearance of each die head part is achieved by superlative
surface coating and experienced polishing department.
All EVOLUTION Ultra Range die heads are manufactured and
designed to achieve the requirements for continuous successful
production of barrier blown films. Key characteristics are:
very compact design, short melt flow channels
highest flexibility for resin and output ranges
superior individual layer thickness
very broad processing window for different film structures
no dead zones, low residence times
perfect self cleaning, short purging times
low pressure drop

DIE HEADS & TAKE-OFF

EVOLUTION Take-off
The take-off unit is an important intermediate station in
the blown film process. Its task is the wrinkle-free
collapsing of tubular film into a double layflat film, without
scratching sensitive film surfaces but still ensuring perfect
flatness. As multilayer barrier films are often very stiff
(as a result of the total film thickness and the selected
polymers such as PP, COC, CoPA and EVOH), the take-
off must be constructed in a very robust design.
All EVOLUTION take-off units fulfil the above
requirements and, in conjunction with a number of special
features, set the market standard.
Film flatness is significantly improved by the length of
the collapsing frames and side guides.
Reifenhuser Kiefel Extrusion can offer these parts in a
segmented design to run barrier film even with a higher
BUR due to the more exact guiding of the collapsed film.
This is achieved by utilising a combination of the binary
pre-distributor divison principle together with axial spi-
ral mandrels or plate design dies, depending on specific
customer and recipe requirements. The heart of a mo-
dern barrier blown film system is the die head and we
are proud to be able to offer both proven technologies
to our customers.
A further advantage of all EVOLUTION die heads is
that the assembly and disassembly can be easily
achieved without any problem at the customers facility.
Flexibility today is important, such that the extruder
and the die should not present any limitations.
All EVOLUTION extrusion systems are known for the
highest flexibility and the widest output ranges. Our
die heads support this philosophy. The ultimate
challenge with barrier films is to run thin individual layers
while ensuring perfect individual layer thickness
tolerances.
The binary pre-distributor division principle in conjunction with either axial spiral mandrels or plate design
dies results in a short residence time and homogeneous temperature profile. This allows our customers to
run layers with expensive polymers as thin as possible whilst maintaining barrier properties.
Unique and exclusively available from Reifenhuser Kiefel Extrusion are brush rolls, which are mounted on the
collapsing frame, and side guide rolls.
The diagonal brush rolls, which are fitted in front of the nip rolls, ensure perfectly flat film. Homogeneous cooling
of the film over the entire layflat width and compensation of the relative different speeds of the film as it travels
up the rotating collapsing frames are two further key advantages of these hairy companions
The microporous slats which are installed just prior to the nip rolls and the microporous air turning bar system
finally ensure that a wrinkle- and scratch-free film will be delivered to the winder.
Clean edges, perfect roll geometry, constant winding
tension from the first to the last meter, overlap free
splices, etc., these are the roll criteria which barrier
film suppliers have to meet in their daily business.
This is especially true for films which are rigid, have
an asymmetric structure or have a tacky inside layer.
These requirements put the highest possible
demands on all film winders. All winder types offered
by Reifenhuser Kiefel Extrusion are designed to
meet the above criteria regardless of whether it is a
contact winder or a center/surface/gap winder.
Unique features such as constant lay-on pressure,
reverse winding, flap-free web splicing, vacuum
contact drum, tapeless splicing, different devices
for web cooling and web slitting, special driven
spreader rollers, semi- or automatic shaft handling
systems, etc. enable us to achieve these
requirements.
WINDERS & AUTOMATION
EVOLUTION Winders
Making film is one thing, but its all wasted effort
without perfect winding!
EVOLUTION Automation
The key to economic and consistent high quality
producti on of mul ti l ayer barri er fi l ms are
automated machine control systems, which
simplify work for operators. The EVOLUTION
automation system enables operators to easily
enter control functions resulting in a considerable
reduction of start-up and change-over waste.
Due to the diversity of barrier film formulations,
each extruder can have different temperature
settings as well as blends with up to seven
components per layer. It is therefore necessary
that the automation system assists the operator
and that the accuracy and the adjustment speed
of the system from the start to the end of an order
is fast, easy, and reliable.
The system is characterized by the following
factors:
Central operation and control of the entire blown
film system from a single operator-friendly intui-
tive 24 touch screen panel which includes: raw
material supply, gravimetric dosing, temperature
settings, screw speed, throughput of extruders
and die, blower settings, profile control, width
control, winder settings, etc. in a smartphone like
presentation

Possible applications
Whether films with low, middle or high barrier properties are required, the Reifenhuser Kiefel Extrusion
production program will enable you to meet these requirements.
AUTOMATION & APPLICATIONS
Typical 9-layer film structures
Recipe memory for exact repeat orders
Online service diagnostics
Detailed reporting for quality and order control
Data export capability to Excel, Access, SQL, etc
Job change assistant to minimize polymer loss and speed
up changeover
Integration of treaters and other optional equipment
Easy handling, operation and maintenance
Modular design - enables us to easily enhance the system
at any time
Films which require even more precise thickness tolerances are possible due to the high resolution
measurement technology and the ingenious control algorithms of our various profile control systems. This
also creates perfect roll geometry, simplifies and enhances further processing steps.

10/2010 Proprietary information

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Reifenhuser Kiefel Extrusion GmbH
Cornelius-Heyl-Strasse 49 D-67547 Worms Germany Phone: +49 (0)6241 902-0 Fax: +49 (0)6241 902 100
[email protected] www.reifenhauser-kiefel.com