Reifenhäuser presented its new EVEREX generation of flat film lines for cast and sheet applications at K 2025. The technology offers a degree of automation that is unique in the market. From automatic PAM control of the coextrusion adapter and die to width adjustment and automated winder, the system performs numerous tasks completely autonomously – a decisive advantage in view of high staff turnover and a shortage of skilled workers.
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The new Reifenhäuser EVEREX flat film machine generation offers unique automation features that enable film manufacturers to simplify operation for their employees and increase profitability in the long term |
Reifenhäuser has fundamentally revamped its flat film line technology. EVEREX is the name of the new generation, which offers one thing above all else: a huge leap forward in automation, making line operation easy, safe, and reliable even for less qualified or inexperienced operators. In addition, EVEREX enables the efficient use of barrier raw materials thanks to edge encapsulation and offers a completely redesigned HMI (Human Machine Interface) for significantly more intuitive operation. The clear dashboard layout with an intelligent color concept allows users to make flexible adjustments and impresses with a fast-reacting touch interface.
PAM 2.0 – Fully automated width adjustment
With EVEREX, errors are a thing of the past. The Reifenhäuser PAM automation option (precise, autonomous, mechatronic), which is already successfully established on the market, has been significantly expanded and now offers even more patented functions throughout the entire production process. Previously, PAM used high-precision electric actuators to control the die and coextrusion adapter fully automatically during operation. Once saved, recipes can be reliably reproduced at the touch of a button. With PAM 2.0, the systems involved in width adjustment have now also been consistently automated, thus achieving complete automation of the line. Producers can now control all quality-critical adjustments during a product change mechatronically and save up to 80 minutes compared to a manual product change, while at the same time increasing occupational safety. Product quality and the reproducibility of the process steps are also significantly increased. Precise, repeatable processes save users valuable time and reduce the potential for errors – _resulting in a noticeable boost in productivity.
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| The EVEREX HYBRID mechatronic polishing stack offers maximum flexibility and |
Best film quality and precise cutting
The automation of the width change covers four areas of the system: edge pinning and the vacuum box, as well as pre-trim and final trim. While the latter two systems are relevant for cutting the film, the first two ensure the all-important contact between the film coming out of the die and the chill roll. This is an important process step, not only to minimize unwanted constriction of the edge areas, but also to achieve high optical film properties – especially in terms of transparency. In principle, each of the four systems can be automated individually. However, the greatest added value is offered by equipping or upgrading from edge pinning to final trimming. In addition to new Reifenhäuser lines, existing lines – even those from third-party manufacturers – can also be equipped with the automation solution.
New edge encapsulation for cast lines saves up to €150,000 per year on barrier films
In the case of flat films, encapsulating the barrier layer prevents expensive barrier raw materials from ending up in the edge areas of the film, which are cut off before winding. The edge trim can then be immediately returned to the production process. The result: the film edges consist only of the less expensive raw material, enabling producers to save an average of up to €150,000 per year in costs. Reifenhäuser EVEREX systems rely on a particularly elegant solution for this, in which the barrier layer is encapsulated not at the die, but already in the coextrusion adapter.
EVEREX HYBRID mechatronic polishing stack:
Maximum flexibility and downgauging without compromise
The trend in flat films is clearly toward increasingly thinner materials in order to save raw materials and costs. However, there have been limits to this so-called downgauging up to now. With standard polishing stacks, for example, PP films could not usually be produced thinner than approximately 380 μm without the use of an additional air slot die, which in turn limits the productivity of the line.
The new EVEREX HYBRID 4-in-1 polishing stack combines three rolls and an air slot die, which can be activated as needed. The special feature is the flexibly swiveling third roller, which enables a wide range of film thicknesses from 150 to 2,500 μm. This gives producers maximum flexibility and material savings thanks to downgauging with 100% reproducible product quality through mechatronic control.
EVEREX HYBRID is particularly suitable for PP films with precise cooling requirements, but can also be used flexibly for other applications. The polishing stack can also be easily integrated into existing systems and is ideal for manufacturers with varying product requirements and frequent product changes.
