EXPO in Lengerich 28./29.10. + 01./02.11.2010

Focus on the Product
W&H Presents Innovations in Film Applications  

The flexible packaging market is dynamic and possesses tremendous growth potential.
According to a study from the US-based Freedonia Group, global demand for flexible
packaging will increase by 3.5% from 16 million tons in 2008 to nearly 19.5 million tons
in 2013. Innovations in film production, printing and manufacturing will need to meet the
increasing market demands. Solutions from Windmöller & Hölscher can be seen at the
company's in-house EXPO in Lengerich, Germany. In addition to two VAREX blown film
lines and a FILMEX cast film line, visitors will also see the recently introduced OPTIMEX
and AQUAREX blown film lines as well as the MDO (Machine Direction Orientation) line in
production. The EXPO will focus on demanding, innovative products, which may have the
potential to revolutionize the flexible packaging market. Printing presses, valve bottomers
for PP woven sacks and other equipment from W&H subsidiary, BSW (Bag Solutions
Worldwide) on display add to the scope of the EXPO.

VAREX blown film line for production of PP labeling
PE has traditionally been the preferred material for bottle labeling. For recycling purposes,
it makes sense for bottles made of PP to have labels also from PP, although it’s handling
can be more difficult. W&H will exhibit an ultra-smooth, stiff 65 µm three-layer film made at
outputs of 500 kg/hr. Because film smoothness is crucial to label stock and a prerequisite
for easy downstream processing, the 3-layer VAREX is equipped with an annealing unit.
The line also features the NOSTIC AIR CAGE to achieve an immaculate optical appeal
of the film and the new FILMATIC T winder for perfectly wound rolls.

VAREX Blown Film line for stretch-wrapping of hay
Hay bundles are frequently stored outdoors wrapped in 3-layer PE-based stretch films.
Farmers complain however that these films lack of an oxygen barrier, which can cause the
hay to mold. W&H is the first machinery manufacturer to show the production of a 25 µm
7-layer stretch barrier film that effectively prevents fungus growth. An example of this film
will be produced on a VAREX blown film line at an output of 360 kg/hr. A newly developed,
stretchable EVOH serves as barrier. To produce these films, a wider line is required
(2,200 mm) as well as a smaller die for a blow up ratio of 1:3.8. For this reason, the
VAREX is equipped with 350 mm MAXICONE 160/400 die. Also being shown for the first
time is the Module K-NDC rotary non-contact thickness gauge for barrier films.

OPTIMEX Blown film line for production of laminating films
The OPTIMEX, W&H’s newest blown film line, produces superior, high-clarity 3-layer
laminating film with a high metallocene content. After lamination with aluminium foil,
the composite can be used for many types of packaging, including those for coffee, tea
and cosmetics. The OPTIMEX was introduced at W&H’s in-house EXPO in 2009 and
is capable of producing outstanding films for multiple applications at an attractive price.
Outputs of 350 – 400 kg/hr prove that the OPTIMEX is not hiding in the VAREX’s shadow.

AQUAREX blown film line for the production of 3-layer PP infusion bags
Infusion bags must be extremely transparent. To date, PVC has been the primary material
used to produce them. The new AQUAREX „up-side-down-wet“ blown film line produces
films with high gloss and superior clarity and will show that PP can replace PVC for the
production of infusion bags. The AQUAREX blows the bubble downward and quenches it
with water, thereby achieving higher outputs than conventional blown film lines and delivering
better mechanical and optical film characteristics. The reason for this is the high cooling
speed of the melt. During the AQUAREX presentations, a 200 µm 3-layer film will be produced
at outputs of 250 – 300 kg/hr.

MDO (Machine Direction Orientation) for shrink sleeves for bottles
A look at the beverage aisle in the supermarket shows that more and more bottles are
being labeled with shrink sleeves. In order to reach the desired shrink characteristics for
the sleeves, the film is processed on an MDO line which orients it in machine direction. Visitors
to the EXPO will see this process live. A 3-layer COC film (cyclo-olefinic co-polymer), which was produced using TOPAS Advanced Polymers, will be oriented to a ratio of 1:3 (from 140 µm to
47 µm). COC is used for its particularly good stiffness and shrinkability. Unidirectional stretching permits a very specific tailoring of film properties to the desired needs. The COC film processed during the demonstrations features a high shrink in machine direction and no shrink at all in
cross direction. Such film characteristics cannot be attained by standard blown film stock without being stretched by an MDO unit. In general, films can achieve higher tensile strength and rigidity
as well as more gloss and transparency by the stretching process. The downgauging reduces
raw material usage and costs, especially with expensive barrier materials.

Cast film line FILMEX for co-extrusion of PET-barrier films
Coextruded barrier films continue to develop in the flexible packaging market. As thermoformed-, lidding stock- or bag films, barrier films guarantee the shelf life of packaged food. Laminated composites of polyamide (PA) and polyethylene (PE) films, which were used in the past for
these applications have been superseded by co-extrusion of PA/PE films. At the W&H in-house EXPO, a thermoformed shell from high clarity, high rigidity 250 µm PET/PE will be produced on
the FILMEX. Because the process bypasses lamination and permits production of thermoforming films in a gauge segment, which was never before thought possible, it offers substantial economic benefits. The FILMEX presentation will include a 17-layer, high-clarity nano-layer barrier film as a cover film for the thermoformed shell.

Windmöller & Hölscher is an international leader in the design, manufacturing and distribution of machinery for the flexible packaging industry and is based in Lengerich, Germany. The product range includes flexographic and gravure printing presses, blown and cast film extrusion systems, multiwall equipment, plastic sack and bag making machines, as well as form-fill-seal machinery.