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Enhance the Productivity and Availability of Older Extrusion lines with Retrofit Solutions

Enhance the Productivity and Availability of Older Extrusion lines with Retrofit Solutions

Extrusion technology is constantly developing. Innovation cycles are becoming shorter and shorter as a consequence of increasing digitalization. At the same time, the market is getting more difficult - reducing material costs while increasing quality are essential in order to remain competitive. However, purchasing an entirely new system is not always the most effective way to improve production. Retrofit solutions are one option for combining progress with cost efficiency. Windmöller & Hölscher offers modular retrofit solutions for both its own blown and cast film extrusion lines and systems from other manufacturers. The result: blown film extrusion lines can achieve up to 50% more output while delivering the same or even better quality.

W&H offers modular retrofit solutions for all machine sections from  material supply to extruder and die as well as unwinder and film winder. The machine is specifically modernized to achieve the greatest possible performance enhancement. In the process, the W&H team always focuses on the system as a whole. “We examine the individual factors such as output, film quality, system availability, flexibility along with waste minimization, spare parts availability and material savings,” explains Hendrik Steen, the Head of Extrusion-Retrofitting at W&H. The retrofitted machines are not only upgraded to state-of-the-art technology, they are also modified to match the customer’s specific market requirements.

Consultation with in-depth knowledge and process expertise

“High-quality retrofit modules form the foundation for our services. Yet the consulting is even more important,” explains Steen. W&H has been active in the extrusion retrofitting business for 10 years and has successfully completed more than 2,000 retrofit projects worldwide. This business profits from the company’s more than 50 years of market leadership with new machines. “Our services draw on in-depth practical knowledge and process expertise. This enables us to advise customers about the ideal combination of raw materials, recipes and machine applications to achieve the best results,” says Steen.

The installation and support is provided by the worldwide W&H Sales and Service network. Over 350 experienced service technicians from the 12 service centers work worldwide. This enables comprehensive support from the offer to the on-site commissioning – always with the goal of putting the system back into production as rapidly as possible and minimizing downtimes. “The increased productivity and quality generally return the costs of the retrofit solution for our customers in a very short period of time,” says Steen. “Customers often place further orders and that is the best praise they can give.”

Before: W&H line with air ring from other manufacturer, die diameter 500 mm, output 480 kg/h
After: W&H line with new MULTICOOL dual lip air ring, gauge profile controller OPTIFIL P2K, and increased output of 630 kg/h.