Three in one - extrusion line for lamination, barrier and bio films

At the K 2019 show in Düsseldorf, Macchi will present a seven-layer line, net width 2,700 mm, belonging to the new POD FLEX series. With this new range of systems, the Varese-based manufacturer meets the growing market demand of highly flexible extrusion lines, capable of extruding both lamination and barrier applications material, but also bio - materials.

The new POD FLEX series allows extremely rapid job changes and, at the same time, minimizes production wastes. Thanks to the introduction of important developments from both the technological and the automation point of view, the line on display will show how simple it is to shift from high-capacity productions (required for lamination films) to technical film productions, where control of layers related to barrier materials is fundamental.

Most important innovations introduced include:

- fully automatic and integrated continuous gravimetric system, ensuring rapid material changes and drastic reductions in production waste;

- extrusion screws which allow greater flexibility in the processing of different materials and, at the same time, ensure a greater extrusion capacity, thanks also to the innovative PVD technology;

- TE572 series extrusion head, complete with PVD treatment, specifically designed to manage both polyolefin and barrier film formulations on the same line;

- fully automatic and integrated high-flow rate air cooling ring, able to guarantee the perfect recipes repeatability, minimizing set-up times during job changes;

- double no-contact film thickness control system, capacitive and optical, suitable for real-time detection of barrier layers;

- ST426R series take off unit with an innovative reduced height design, securing easier and safer operating and maintenance activities and, at the same time, enabling a more rapid response to production change commands;

- evolution of the BO Plus winding system, complete with reel unloading and handling units with telescopic connecting rods and an innovative cutting system; the reinforced structure allows perfect winding of reels with diameters of up to 1,200 mm;

- new "Macchi 4.0" software release, generating complete data set concerning recipes, consumption, production and set points of the line, which can be integrated into customer's management systems;

- complete digitalization of the line, to guarantee the cleanliness of data exchange signals between the various components and reduce to zero any possible interference in the system network;

- MDO technology able to meet the growing demand for technical films with high mechanical properties and reduced thicknesses.

Throughout the fair, the plant will produce lamination, barrier and bio films with different structures.