Reifenhäuser to further develop twin-screw technology

The Evolution Ultra Fusion technology processes raw materials directly – without previous pre-drying and compounding. For this reason, engineers came up with the concept of integrating a twin-screw extruder of the Reitruder series directly in a blown film line. Compared with the processing of compounds and masterbatches, the direct extrusion technology can reduce the production costs for three-layer blown films by more than 15 percent.

It is the first direct extrusion technology for the production of multi-layer blown film, and is said to boost productivity and energy efficiency, reduce production costs and improve film properties. Potential applications include breathable film, bio films, packaging bags for flower soil and peat, and breathable and non-breathable diaper backsheets.

Tests were conducted under production-oriented conditions in the Technology Center of Reifenhäuser Kiefel Extrusion, and showed the full savings potential of the technology, particularly in the production of filled multi-layer films in which expensive raw materials like polyethylene are replaced in part with lower-priced fillers such as calcium carbonate (CaCO3). The Evolution Ultra Fusion enables producers to process especially high filling amounts of up to 50 percent, said Reifenhäuser Kiefel Extrusion, enabling them to reduce production costs by about 20 percent.

In addition to cost savings, the high filling amounts have a positive effect on film properties, with strength and stiffness increased while elongation is reduced. Furthermore, special properties can be obtained with this technology, for example those needed for the production of breathable films.

Now, the technology will be further developed for commercial use. Together with a partner from the industry, Reifenhäuser Kiefel Extrusion is developing products for industrial use to bring the technology to market. Evolution Ultra Fusion can already be tested by customers at the company’s site in Troisdorf.

Sascha Skora, Reifenhäuser Kiefel Extrusion senior sales manager, said: ‘Many customers are using the testing possibilities offered by our research and development center. The technology is widely accepted because of the high savings potential and the opportunity it offers for entering new markets demanding high-quality films. With Evolution Ultra Fusion, these high demands and special film properties can be realized, reliably and efficiently.’