New Bandera line takes flexibility to a new level

Düsseldorf, Germany — The new seven-layer blown film line displayed at K 2019 by extrusion machinery manufacturer Bandera has been designed to offer customers the highest possible degree of flexibility, said Andrea Rigliano, general sales and marketing director at the company.

Called the Barrier Flex Seven, it can run both barrier and high-barrier blown film, as well as polyolefin film. The flexibility of the new line does not affect either hourly output performance, in the case of polyolefin film production, or end-product quality level with unrivaled tolerance ranges when producing barrier film.

The company introduced the line for the first time at K in Dusseldorf.

"Compared to the previous version, we've made a number of modifications, including adding a brand-new Human Machinery Interface," Rigliano said. The new line control system maximizes the communication with industrial equipment and systems for data collection and monitoring, simplifying processes, reducing mistakes and optimizing time.

"That is one of the top characteristics of this innovative line," he added. Remote control technology makes it possible to connect using a tablet or smartphone for simplified diagnostics, for driver and motor predictive maintenance and increased process-control parameter accessibility.

"What's also is we designed a die that, even though it is a seven-layer one, can run three, five or seven layer polyolefin-dedicated formulations. Moreover, it can be adapted to barrier film with EVOH and polyamide," Rigliano said.

Other modifications included the addition of low-energy drivers and ABB SynRM2 reluctance motor systems for synchronized operation. This results in lower noise emissions and considerably simplified maintenance requirements. As the operational temperatures are lower, cooling servo fans become unnecessary, which increases reliability and continuity of operation.

The line also features Bandera's new winder. The ESR winder series is now available with a torque motor, which allows it to run at a higher speed for more efficient production.

Yet increasing efficiency was not the only reason for modifying the line, emphasized Rigliano.

"We think that the requirements of the circular economy will also lead to the use of biodegradable or biocompostable material, in addition to conventional resins. Also, the legislation passed in the EU calls for less use of mixed plastics — in other words, laminate structures consisting of different materials. We need to develop monomaterial solutions to ensure their recyclability," Rigliano noted. The new seven-layer line provides the necessary flexibility to run these materials.

Right now, he said, recycling capabilities are the most important issue in the extrusion space.

"We have a lot of solid inquiries to supply machinery that run both recycled material and easily recycled material. And not just scrap." Legislation is driving this trend, as well as the market. "Big food industry players are also trying to increase the quantity of recycled material they use, as they see consumers increasingly becoming more aware of what their packaging is made from. A year and a half ago, we launched a process called Pure that makes it possible to produce recyclate able to meet the standards of the FDA and EFSA for PET recycled films."

The Pure system includes a pretreatment process that allows a high level of decontamination to be reached that is achieved by using Bandera's Highly Vented Twin-Screw Extruder technology, which exceeds the requirements of current legislation, he said.

For Bandera, this is the direction materials are heading: toward recycled and recyclable, suitable for all applications due to supercleaning as well as bio-based. While this may raise the price somewhat, the price gap between plastic and other materials is so great, that plastics have room to become more expensive, without losing their competitiveness, Rigliano said.

In addition to exhibiting at K, the company is also hosted an open house during the show at its headquarters in Busto Arsizio. There, in the research and development center, visitors can view additional working lines, including three-, five- and seven-layer blown film lines, as well as line sections for multilayer agrifilm extrusion and waterproofing geomembranes.

The company is also showing a brand-new flat die extrusion line for the rigid packaging sector, mainly dedicated to the production of rigid five-layer PET and PLA film for food packaging applications. "We couldn't bring it to the show," Rigliano said with regret.

"Last, but no less important, we also have the Condor line, which is a sort of learning lab. Here, customers from everywhere in the world come to Bandera headquarters to make trials on industrial size machine."

The project includes a complete flat-die extrusion line equipped with an in-line extrusion coating section — nine extruders as a whole — to test new biodegradable and/or recyclable materials, obtain thinner and lighter films and to increase the use of mineral fillers.

Bandera

Hall 17/C07

'We think that the requirements of the circular economy will also lead to the use of biodegradable or biocompostable material, in addition to conventional resins.'

Andrea Rigliano

Bandera