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| The PP or PE monofilm becomes stiffer through the stretching process, so that PET film can be replaced in the packaging. Pictures: Reifenhäuser |
With the PPWR coming into force in Europe, the demand for production technologies for recyclable mono-material solutions made of PP or PE is also growing in the cast sector. The answer is the same as in the blown film sector: MDO (Machine Direction Orientation) stretch units, which give the films extra stiffness, better optical properties and up to double barrier properties. PET films can therefore be replaced in composite materials in favor of a monomaterial solution.
Marcel Perrevort, CSO of the Reifenhäuser Group, explains: "We entered the cast MDO market at an early stage, which means that, in addition to the hardware, we have a firm knowledge of the process. Together with partners, we develop high-performance end products such as Cast All-PE stand-up pouches. As a line manufacturer, we always pursue one goal: to develop technology for recyclable films that are both functional and economical to produce. We will be showcasing the successful results at K 2025."
Manufacturers who produce film for barrier packaging save material costs with MDO technology simply by stretching, because the process reinforces the EVOH barrier effect. The EVOH content can thus be reduced to less than five percent of the total weight of the packaging, which is a prerequisite for its recyclability and saves costs. Reifenhäuser cast systems also offer a further option for significantly reducing production costs: a particularly clever edge encapsulation process that eliminates the EVOH content in the film waste - without the need to invest in an additional extruder, which is necessary with other solutions. The encapsulation of the barrier layer is carried out directly in the coextrusion adapter. The result: the film edges and the resulting edge trim contain only low-cost raw material. This allows producers to save up to 150,000 euros per year on average.
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| Reifenhäuser Cast-MDO enables the easy-tear effect, as the polymer chains are oriented in the machine direction by stretching the film. |
The Reifenhäuser Cast MDO unit offers special added value for end customers thanks to the so-called Easy Tear effect: the packaging can be torn open in one direction exactly straight. It can then be closed using internal clips or zippers. Until now, packaging, such as stand-up pouches, was usually perforated in advance with a laser, which can have a negative effect on the structure of the packaging, the barrier effect and therefore the shelf life of the packaged product. With Reifenhäuser Cast MDO technology, this product property is achieved simply by stretching the film - without impairing other important film properties.
The MDO technology from Reifenhäuser CSC is available for all in-house and almost all third-party cast systems. The unit can be ordered for new systems as well as retrofitted in the field as long as the width of the system does not exceed 3.60 meters.
