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Increased Output through
Retrofitting of Older
Blown Film Extrusion Equipment
LINCOLN, RI, April 2008 – Converters in the flexible packaging sector have
known Windmöller &
Hölscher (W&H) for many years as a supplier of
blown film extrusion lines. A less known fact may
be that W&H is also
using their expertise in retrofitting older generation blown film extrusion
lines
(W&H and others) with state of the art components and modules from
its current product range.
W&H’s retrofit program is focused on increased output, improved film
quality and efficiency by
increasing up-time, flexibility and reducing waste.
Retrofit solutions include resin feeding, gravimetric feeding, extruders,
dies, sizing cages, haul-offs
as well as winders and automation modules.
It does not always take a new ling to increase the performance capacity
of your film production. Frequently, just the addition or replacement of individual
components is all that is required. For
example, effective bubble cooling is
essential for optimum output rates. Hendrik Steen, Head of
W&H Module Management
(Tetrofit program), states: “Experience has shown that, depending on
product
specifications, incorporating our modern MULTICOOL air ring does not only resulting
an increased output of 30%, but it also improves film tolerances significantly.
When considering an
average output of
1000 lbs/hr ( 450 kg), even a 10% increase in production would result
in approx. 740,000 lbs./hr (330,000 kg) additional film produced annually.”
Output is not the only positive aspect of a new air ring, but significantly
improved film tolerances,
greater consistency and smooth operation of downstream
equipment results in reduced waste.
“Customers who have integrated output and quality enhancing retrofit upgrades
are quite surprised
to see a return on their investment in only a few weeks’
time”, states Hendrik Steen.
Improved film quality can be attributed to the perfectly homogenous air distribution
provided by the MULTICOOL air ring, resulting in higher outputs. Increased flexibility is another advantage of the MULTICOOL. It just takes a few manual turns to replace a single-lip with a dual-lip or the special
HDPE air ring insert. Flexibility also applies to different die diameters and die designs.
W&H R&D is focused on new modular engineering concepts for complete
lines, components and retrofits. Take the Multicool air ring, for example,
allowing the customer to upgrade with a controlled
air ring when needed.
With the unique W&H design concept you can upgrade from a single air
ring to a gauge profile control
unit or to a double deck ring for double the
output. The W&H patented OPTIFIL® P3 or P3K systems
are used to control
the gauge profile.
The major advantage of retrofitting a single air ring with an OTIFIL P2K
gauge profile control system,
is that the already improved tolerances can
be improved still further. The W&H patented system uses heater cartridges
in the MULTICOOL air ring. The heater cartridges heat thick spots, minimizing
them as they occur, resulting in the tightest possible gauge tolerances. Electronics
that might fail and mechanical components affected by dirt have been removed
from the system, making if very robust and safe to operate.
OPTIFIL P2K advantages at a glance:
- Short start-up and change-overs
- Consistently tight gauge tolerances from start to finish
- Highly commercial efficiency due to resin savings
- Significant increase in output
- Can be easily retrofitted to all die models (W&H and others) including
stationary
and oscillating models
- Service friendly technology
The MULTICOOL air ring with OPTIFIL P2K delivery scope includes the gauge
measurement
module, also available for tacky films, oscillating system, PROCONTROL
TS operator console, wiring.
Windmoeller & Hoelscher is a leader in the design, manufacture and distribution
of 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 for the converting and packaging industry.
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