POD: heralded success

According to Macchi, its POD (PolyOlefin Dedicated) system for the coextrusion of 5-layer blown film is well on its way to becoming the benchmark for high-output production of non-barrier structures. There are two main advantages of 5-layer films over their more traditional (and so far more widely used) 3-layer counterparts: the possibility of extruding extremely thin layers reduces formulation costs; the use of pure resins optimizes their performance, making it possible to reduce thickness to levels never achieved before.
The sectors benefiting most from this new application of shrink-wrap polyethylene film are beverages, sauces, preserves and cosmetics. In the EMEA area (Europe, Middle East and Africa), these sectors collectively consume 85% or more of polyethylene film (with beverages alone accounting for half), roughly a million tons a year.
As for the construction of extrusion systems, the company from Venegono Inferiore (Province of Varese) stands as a trailblazer and its current performance confirms the trend away from 3-layer to 5-layer film.
The 1,000 kg/hr plant unveiled at K 2013 generated a surge of interest that has played out in an increasing number of purchase orders. While still far from a climate of economic recovery, relatively simple films for shrink-wrap applications are still a primary need in packaging, and their yearly growth of 2% can scarcely pass unnoticed. Furthermore, in the effort to make the 5-layer POD system available in other sectors, Macchi offers a complete range of machines meeting a broad array of needs from 500-mm tubular films for heavy-duty FFS sacks to flat bags with widths of 2200, 2500 and 3200 mm.
During a recent open house at its headquarters, the company presented - together with three lines featuring the POD system in various stages of production - a line for producing technical agricultural films that is ready for delivery to a Lithuanian converter and a more traditional 3-layer line used to produce a wide variety of substrates for the packaging and conversion industry in Central Europe.
According to Macchi estimates, POD systems represented 3-5% of its total extrusion plant sales volume in 2012, whereas now this percentage is approaching 20%. Hence, this technology is fully ripe for displacing its 3-layer counterpart and gaining affirmation as the new standard for the industry.