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Battenfeld Extrusionstechnik is a leading supplier of inline and out-of-line extrusion systems which are also available as high-performance lines:
- mono- and multi-layer deep drawn PP, PS or PET film up to 7 layers
- film thicknesses of 200 µm - 2 mm
- main applications in food packaging, esp. packaging of dairy products
inline extrusion systems can be combined with all automatic thermoforming machines currently on the market.
Battenfeld Extrusionstechnik offers a specially tailored line of extruders for the production of deep drawn films/sheet that enables processors to run their own production process very efficiently.
- high specific output rates
- degassing extruders for optimum melt quality
- constant mass throughput and therefore excellent thickness tolerances through the use of melt pumps
- state-of-the-art flat dies adapted to end product
- raw material savings and recycled material can be used without problems
low energy consumption
- modern, compact, maintenance-free drive technology for main- and co-extruder
For the production of thermoforming films/sheet, Battenfeld Extrusionstechnik manufactures especially tailored roll stacks that ensure superior end product quality.
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Battenfeld Extrusionstechnik manufactures complete inline and out-of-line extrusion systems for Polyester (PET) film:
- film thicknesses of 100 µm - 1200 µm
- multi-layer and laminated film
- main applications are in food packaging
With Battenfeld Extrusionstechnik's specially designed co-rotating twin-screw extruders for A-PET film extrusion, non-pre-dried material can be run without problems.
Thus, processors benefit from:
- energy savings
- higher flexibility
- better film quality
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Aquaflex
Downward Extrusion Blown Film Lines
Aquaflex blown film lines are world?s highest output downward extrusion water quenched universal application film lines to produce various combinations of PP and PE grades. These lines are offered up to three layer configuration to process diversified, water quenched film products and can be up-graded to incorporate auxiliary equipments and alternate assembly modules. Line to process Nylon, as also to produce blood bags, is offered; tailored to customer's specific requirements.
These lines incorporate latest technological advancements like oscillating die or oscillating take-off, load cell controlled winders, large filtration area candle filters, grooved feed barrier screw extruders with interchangeable mixing pin, static and dynamic melt blenders, fully automatic center-surface-gap turret winder etc.
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Foilex
Monolayer Blown Film Lines
Offering a wide range of monolayer blown film lines - to suit a broad spectrum of applications and capacities, not many manufacturers in the world offer such a vast range.
Foilex series of monolayer blown film lines are available with outputs ranging from 30 kg/hr to 650 kg/hr and lay-flat widths ranging from 50 mm to 5000 mm for processing polymers as diverse as LD, LLD, HM / HDPE, EVA and Nylon. Applications include PE general purpose films, HDPE pick-up bags, LD / LLD / HD lamination films, HD twist wrap films, stretch and cling films, shrink films, anti-rust films and paper like films.
Foilex blown film lines are also available in special configuration to process wide width HDPE film through high stalk bubble. Similarly these lines are also available with up to 4 color inline rotogravure / flexographic printing.
Foilex lines incorporate advanced features like-grooved feed section, barrier screw, gravimetric feeding system, Liquid PIB dosing system, manual as well as automatic screen changer, oscillating die / platform / haul-off, internal bubble cooling, automatic bubble cage, online thickness monitoring and automatic air rings, surface and center winders with tension control.
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The POLARIS blown film lines are designed to achieve the main following advantages:
- High output with low energy consumption;
- Great versatility in production of low, low and linear and high density polyethylene film (LDPE/LLDPE/HDPE);
- Low maintenance cost due to updated and rational design;
- Comprehensive variety of different sizes and outputs, components and accessories to meet different requirements and film specifications;
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Multifoil
Multilayer Blown Film Lines
Multifoil series co-extrusion blown film lines are available in a wide range of configurations from two to seven layers to produce variety of films like liquid packaging films, food packaging films, ultra high barrier films, high dart resin sacks films, meat and cereal packaging films, oil packaging films, pharma and medical grade films, shrink hooding films, green house films, silage and mulch films, geomembrane and chemical / soap packaging films.
Seven layer high barrier film with PP or PE / CXA / Nylon / EVOH / Nylon / CXA / PP or PE can find application in retortable pouches as well as long shelf-life food and meat packaging. Thick seven layer film is also used in vacuum forming applications for food containers.
Lines are offered in a host of configurations to suit various end product requirements with outputs ranging from 120 kg/hr to 1200 kg/hr and lay-flat width up to 5000 mm.
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Multilayer Cast Film Lines:
To manufacture multi-ply packaging materials of 15 to 150 microns thickness, such as Stretch films, Cling films, Barrier films, Masking films, CPP films and Blister films.
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Division profile
Systems to manufacture blown film have formed part of ALPINE's product range since 1955.
The reliability of these film blowing lines is well known, just as are the long years of experience we have had in the design and manufacture of such complex production equipment.
Our three testing centres - in Augsburg, USA and Japan - are equipped with state-of-the-art machines and components, and are used for both customer and development trials. Test series using the laboratory equipment can be carried out under as-real conditions so that the results fully reflect Alpine's capabilities.
Program Overview
Blown Film Lines
Extruder
Film Die Heads
Film Cooling
Film Calibration
Film Take-off units
Film Winders
Film Orientation Lines
Process Control
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Blown Film Lines (with or without Rotatory Die.)
For manufacturing HDPE/LDPE/LLDPE monolayer & multilayer Blown films with low and wide width products for manufacturing Shopping bags, Liners, General purpose bags, Garbage bags, Detergent bags and Multilayer films for various packaging applications.
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Globally, blown film lines have become a mass product, for which there is high demand in diverse areas of application. The increased variety of products, as well as the growing production quantities go hand in hand with increasing quality requirements. The Reifenhäuser product program for blown film extrusion lines meets all these demands, thanks to the innovative components and overall concept.
Areas of application
The range of applications of blown films produced on Reifenhäuser lines
is huge. Antistatic films, stretch films and protective films are used in the automotive and electronics industries, for example. In the field of industrial packaging, shrink hood films, stretch hood films and heavy duty sack film are manufactured on Reifenhäuser lines. A remarkably wide product range include films for the consumer goods industry, fine shrink films, pallet wrap films, furthermore it includes laminating and adhesive films, as well as barrier films. Lines for agricultural products, such as crop forcing, cover and silage films, as well as building protection films, have been a Reifenhäuser speciality for many years.
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EXTRUBOOST
GEAR PUMP
BLOWN FILM TECHNOLOGY
THE NON-COEXTRUSION SYSTEM THAT OFFERS SAME BENEFITS OF A 3 LAYERS COEXTRUSION LINE IN 100% REGENERATED RESINS.
• High flexibility
• Reduced energy consumption
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EP SERIES LLDPE/LDPE FILM BLOWING LINE SPECIFICATION
MODEL EP-452 EP-45N EP-50N EP-55N EP-65N
Screw Design Mixing Type Screw with Nitrided Steel
Screw Dia 45mmφ x 2 / 26D 45mm φ / 26D 50mm φ / 26D 55mm φ / 26D 65mm φ / 26D
Extrusion Output 55 kgs/hr 45 kgs/hr 55 kgs/hr 70 kgs/hr 90 kgs/hr
Inflation Die Range 80 mm φ 80 mm φ 90 mm φ 100 mm φ 150 mm φ
Width of Tube 600 mm/Max 600 mm/Max 600 mm/Max 750 mm/Max 900 mm/Max
Thickness of Tube 0.08 ~ 0.1 mm
Roller Width 650 mm 650 mm 650 mm 800 mm 1000 mm
Take-Up Speed 10 ~ 100 M/Min
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FBL5 - 13/20 Compact
5 LAYER BLOWN FILM LINE FOR THE PRODUCTION OF COEXTRUDED GAS BARRIER FILM FOR FOOD VACUUM PACKAGING AND NON GAS BARRIER FILM FOR FOOD PACKAGING AND TECHNICAL APPLICATIONS.
• 4 extruders in a radial layout equipped with D.C. or A.C. vector motors, bimetallic barrels, ceramic lined heater bands, low-shear barrier screws.
• Five layer stationary head specifically designed for low resident time of melt in heat-treated, high stability steel.
• High self cleaning ratio also in case of high percentage of master batches (film for milk package).
• 200-250 and 300 mm diameter die internally chromed or nickel plated.
• High performance dual lip cooling ring.
• Self-centering non-marking calibrating basket with motor driven rollers approching to the tubolar.
Adjustable upward motion.
• Oscillating take-up unit horizontal –diverging type, with air cushion rollers.
• A choice of automatic winders in width 1300 mm or 1600 mm designed to offer together with an easy
operation and simple maintenance, a constant film winding.
• A choice of upstream and downstream accessories to back up demanding customers.
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FBL 3 - 2000 Polietistar Auto
THREE LAYER BLOWN FILM COEXTRUSION LINE
FOR THE PRODUCTION OF QUALITY TECHNICAL FILMS FOR FOOD PACKAGING AND GENERAL APPLICATIONS
• The 3 extruders are on parallel lay-out on common frame (or upon request on radial lay-out); 2 of them are 65 mm. and the midlayer is 75 mm. screw diameter. All are with a.c. vector motors, bimetallic barrel, ceramic lined heater bands, low-shear barrier screws.
• The coex head is the well reputed Multisplit type (direct seeding and binary repartition), featuring a very minimum melt resident time, a low-working pressure and a quite high self-clearing factor.
• The IBC construction is vertical passing through the head, thus granting an absolute temperature homogeneity of the steel mass, to the benefit of the thickness distribution.
• The dual lip cooling ring is coupled with an automatic film profile control system (a segmented flow design), that, thru 48 actuators, a circular scanner with capacity type head and a powerful software grants gauge variations below the threshold of ± 4%.
• The oscillating nip is a 360° horizontal – diverging type, with air cushion rollers and option for additional nip-roll on the film descent section, before the photocell edge guide.
• The 2 station automatic flat-ped winder is the latest development in the “Dolci” winders family and, for this line, can be assembled in face-to-face or back-to-back lay-out and includes the following outstanding features: GAP winding with taper tension control and reverse winding. The reverse winding
is particularly welcome in case of sticky films on one side, and for turning the corona treated side on recto or verso, according to job needs.
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LINES SERIES “FAL”
• Multilayer very-wide-web blown film lines, output up to kg/hour 1600.
• Coex lines for “green house fotoselective film, till 18 meters.
• Coex line for thermic and isolation film.
• Coex lines for mulching, fumigation or silage films.
• Coex lines for geomembrane till 7 meters, with plain or embossed surface.
• Coex lines for combined productions.
• Systems for gussetting, folding or unfolding.
• Special shaftless winders, till 5 meters width.
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CAST POLYPROPILENE
FOR POLYPROPILENE FILM (CPP)
LDPE EMBOSSED FILM FOR DIAPERS
COMBINED LINES
TECHNOLOGY, NOW-KHOW AND QUALITY
LINES FOR CPP
- excellent film clarity and gauge uniformity
- optimum physical properties and film processability
- ideal for metallizing, heat seal films, twist effect and general purpose applications
- gear pump technology on mid layer extruder
- available in width 1600 mm, 2100 mm and 2800 mm
- net output from 400 to 1100 kg/hour
- working speed from 40 to 300 m/min
- finished rolls diameter: from 600 to 1.000 mm
- high level of line automation and process control
- available in 3 layers and 5 layers with automatic T-die
- automatic contact and gap winders with options for utomatic shaft handling and re-coring.
LINE CHARACTERISTICS
- 3-layers with 3 extruders
- Gear pump technology on each extruder
- Wet and dry embossing systems available in width 1600, 2100 and 2500 mm
- Working speed from 40 to 300 m7min
- Automatic winder with in-line slitting
- Precise and uniform cross web embossing
CAST FILM LINES FOR EMBOSSED FILM
Applications:
- baby diapers back- sheet
- napkins film
- hygiene films
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CAST COATING
Multi-stage lines for the production of gas barrier films, that combines the “cast film technology” with the “extrusion coating technology”. With these exclusives lines we allow: higher line output, no “curl” effect, optimum film transparence, perfect gauge control, maximum rate of edge trims reintegration in the line.
Film formulations (example)
PA /LDPE
PA/EVOH/EAA/LLDPE/IONOMER
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WIDE-WEB LINES
3 meters cast film line for up to 6 rolls-on-shaft of stretch film
• 3 layer, 5 layer and 7 layer versions, with output up to 2000 kg/hour, with option for side encapsulation head.
• Jumbo size chill roll with slip control.
• Rugged automatic winder with side supports and central support of air shafts.
• Cartesian type or integrated robotized shaft handling system.
• Single or twin reprocessing trim line with side extruders. 4 meters cast film line for up to 8 rolls-on-shaft
• 5 or 7 layer versions with output up to 2300 kg/hour.
• Jumbo size chill roll with slip control.
• 4,5 meters nip-roll with 2 diverging assemblies to avoid central bleed trim.
• Twin winder with central shoulder and “twin” shaft-handling systems.
• Twin reprocessing trim line with side extruders.
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Extruders
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When product-sensitive and energy-saving applications are involved, the EVAPplus plate falling film evaporators are exactly the right choice. State-of-the art technology ensures high-efficiency concentration of juice from sugar beet and cane. The special feature of EVAPplus is the combination of tube and plate evaporators. The plates are arranged in such a way that two separate flow channels result: a tubular channel with 6 or 9 mm diameter for the juice and a corrugated channel for the condensing steam or
vapour. The plate packs are fully welded without the need for gaskets.
Retrofitting Robert-type evaporators
The advantages of the EVAPplus can also be used to achieve greater efficiency by retrofitting existing Robert evaporators. In most cases no changes are necessary to buildings, foundations or the static design of the plant. The calandria from the old Robert evaporator is simply removed and replaced with an EVAPplus plate pack and the respective distributor. With minimum expenditure the heating surface area and the system efficiency is considerably increased.
Simple to clean
The EVAPplus can be easily and quickly cleaned to maintain its maximum performance. Evaporators used for processing beet sugar juices are cleaned at the end of each campaign. When processing cane sugar juice, a sensible cleaning cycle is every one to two weeks.
Outstanding features
- High density of heating surface (170 m²/m³ or 240 m²/m³)
- Outstanding overall heat transfer values
- Low temperature differences
- Short residence time of the of the juice in each effect
- Low juice colour formation
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One of the most important fibers, polyamide 6, is produced by polymerization of caprolactam. Large quantities of extraction effluents are produced in this process. The effluents are cleaned in evaporation plants: the valuable substance is recovered, waste products are minimized, and existing energies from the caprolactam production can be used.
Moreover, evaporation plants are used in this process as sump evaporators for distillation plants.
The particular features of GEA Wiegand plants are:
Economic conception in order to minimize the caprolactam losses
Long operating periods thanks to an optimum temperature
Many years of experience in the application of mechanical vapor recompressors
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GEA Wiegand designs and constructs complex plant systems for the treatment of effluent and the recovery of solvent. The concepts of the different operating processes mainly focus on high degrees of purity, the energetic situation and low residual product quantities.
For the treatment of industrial effluent, our process engineers develop concepts for plant systems that are especially designed for the relevant effluent problem on the basis of a detailed analysis of the current situation.
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Steep and wash water that contain a high proportion of valuable nutrients are produced during the processing of corn, potatoes and rice. For recovering these nutrients, steep and wash water are concentrated in evaporation plants, namely corn steep water to 50 % TS, wash water from the production of wheat starch to 20 - 30 % TS and potato starch effluent up to 60 - 70 % TS.
5-effect falling film evaporation plant for monosodium glutamate heated by thermal vapour recompressor, evaporation rate: 25,000 kg/hr
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GEA Wiegand designs and constructs complex plant systems for the treatment of effluent and the recovery of solvent. The concepts of the different operating processes mainly focus on high degrees of purity, the energetic situation and low residual product quantities.
For the treatment of industrial effluent, our process engineers develop concepts for plant systems that are especially designed for the relevant effluent problem on the basis of a detailed analysis of the current situation.
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For the production of fruit juice, fruit and vegetable juice is concentrated from stone, pomacious and soft fruit from approx. 11 % TS to approx. 72 % TS or citrus juice is concentrated from 10 % TS to 60 - 70 % TS. Normally evaporation plants are used for this.
Before or during the evaporation process, volatile aroma substances are extracted from thin juice. These aroma substances are removed and added to the fruit juice later on for intensifying the typical fruit flavor.
The concentration of fruit and vegetable juice means:
the possibility of compensating differences in quantity and quality of different vintage.
the possibility of compensating fluctuations in price in years of cheap and expensive fruit (large and small harvest)
the possibility of storing 6 or 7 times as much harvest in the existing tank space available
considerably less requirements on the storage process
reduction of investment costs, because the apparatures for the production of concentrate are cheaper and involve lower manufacturing costs than the storage tanks that would be necessary otherwise.
simpler and cheaper transportation, because weight and volume of the juice are reduced to a fraction.
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For the production of starch conversion products, the starch molecules are either entirely or partially broken down into their basic constituents by hydrolysis, i.e. by catalytic action of acids and enzymes in an aqueous suspension.
Dextrose
pure D-glucose, a final product that cannot be hydrolytically decomposed any further.
Glucose syrup (starch syrup)
contains D-glucose, maltose, isomaltose and high molecular sugar and it is produced by prematurely stopped hydrolysis. The decomposition degree of this product ranges from 20 to 65 DE. The DE value (dextrose equivalent) indicates the degree of conversion. It refers to the content of D-glucose relative to the total dry substance.
Maltodextrine
a starch decomposition product of less than 20 DE and more than 3 DE.
Maltose syrup
consists of approx. 72 % maltose, 18 % glucose, 10 % iso-maltose. It is produced by enzyme conversion of starch of different origin.
Isoglucose syrup
partially isomerized glucose juice (FCS = high fructose corn syrup).
Typical composition:
D-glucose 53 %
D-fructose 42 %
oligo-saccharide 5 %
The indexes 42, 55 or 70 indicate different fructose contents.
D-sorbitol
reduction product of D-glucose (starting material for vitamin C synthesis).
D-mannitol
reduction product of D-glucose.
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Evaporators
Since 1908, evaporators are planned, designed and delivered world wide for different fields of application at the location of the ANA-Verfahrenstechnik GmbH.
This longtime experience is to you at the disposal. We design the evaporating plants according to customers’ requirements. We deliver units ready to use as well as single components.
ANA- evaporators come up to all requirements in view of product attributes, operator convenience, reliability and economics. Such requirements are very different in several ranges where we operate.
Industrial applications follow in the food industry, pharmaceutical and chemical industry.
Evaporating plants of ANA-Verfahrenstechnik GmbH are used to concentrate:
* milk, whey and derivatives
* fruit juice like e.g. from citrus fruits incl. aroma recovery
* starch and beet sugar juices
* essences from coffee and plants
* glue and gelatine
* acids, bases and salts like sodium aluminates, sodium sulphite and – hydrosulphide
* organic and inorganic solutions like lactam water as well as
* sewage
In ANA- evaporators following constructions are used:
* down-draught evaporator
* cimbing evaporator
* recirculation evaporator
* forced-circulation evaporator
* falling film evaporator and
* agitator evaporator
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Fives Cail has been providing outstanding evaporators to its customers for more than 150 years. Drawing on this long experience, the Group continues to revolutionize evaporator technology by efficiently adapting the falling film to cane sugar processing. It has built the world's largest evaporator, with an exchange area of 7,540 m2.
Fives Cail now offers 3 distinct evaporator designs perfectly adapted to beet and cane sugar plants and refineries: rising film evaporators, and distinct falling film models for beet and cane sugar.
With more than 500 units sold, Fives Cail evaporators are acknowledged for their excellent heat-exchange performance, minimal colour increase and entrainment.
Easy installation
Local fabrication ensures rapid delivery and lower cost
Easy adaptation: small footprint; outdoor installation possible; easy integration in existing multiple effect stations
Outstanding performance
High heat-exchange coefficient for both beet and cane applications thanks to specific and well adapted designs
Low ΔT on all juices (high or low brix)
Unrivalled reliability
Integrated skirt protects the tube bundle from vibrations
Proven designs ensure maximum sugar yield
Easy maintenance
Falling film (beet design): low risk of fouling and minimal juice colour increase thanks to short retention time
Falling film (cane design): removable upper part facilitates cleaning (cleaning frequency reduced by 2 to 3)
Fives Cail's equipment for evaporation :
Falling Film Evaporator
Rising Film Evaporator
Tubular Juice Exchanger
Barometric and multi jet condenser
Optimise your boiling house
Control brix in your evaporator by installing our Hydrotrac or Monotrac probes.
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