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Reifenhäuser Blown Film has succeeded in achieving stable production of a 14 μm MDO-PE film for stand-up pouches |
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The sustainable Cast All-PP stand-up pouches are not only highly recyclable, but also highly functional thanks to their easy-tear effect (Pictures credit: Reifenhäuser) |
At K 2025, Reifenhäuser showcased a wide range of end applications that perfectly combine sustainability, quality, and profitability. Together with raw material partners and packaging manufacturers, Reifenhäuser presented two records in terms of output and downgauging.
14 micrometers: the world's thinnest MDO PE blown film for sustainable
all-PE pouches
Reifenhäuser Blown Film has succeeded in producing a 14 μm MDO-PE film with stable processability. Just a year ago, the extrusion specialists set a new market record with an 18 μm MDO PE film and announced further downgauging potential. This has now been impressively realized with the improvement to just 14 μm and will be presented at K 2025 in the form of a market-ready all-PE stand-up pouch. The technology behind it is called EVO Ultra Stretch – a patented MDO unit that is positioned directly in the haul-off section of the blown film line and stretches the film from the first heat. In combination with specially developed raw materials from Borouge and Borealis, this process makes the process particularly stable, which is often the limiting factor for material reduction. Ultra Stretch provides additional added value when EVOH is used for barrier films. The barrier effect of this expensive raw material is enhanced by the stretching process, so that less of it needs to be used. Overall, this reduces production costs to a competitive level compared to conventional films, which is the decisive criterion for market acceptance.
1,000 kg/h output: high-quality collation shrink film for maximum profit
With the new EVO GEN3 blown film line generation, Reifenhäuser has set a new output record for shrink film. The film is used in the logistics sector (among other areas) to bundle several individual packages – such as bottles, cans, or cups – into handy sales units. This protects the products during transport and, when shrunk under heat, ensures stable, transparent bundle packaging. Reifenhäuser uses ExxonMobil Signature Polymers for the film, which offer enhanced flow and processability as well as better mechanical performance and optics. In addition to the raw materials, the ExxonMobil Signature Polymers team also provided technical expertise in processing. With an output of 1,000 kg/h, the film is unique in the market and offers maximum profitability.
35 percent PCR content: High-performance industrial film for stretch hoods
At K, Reifenhäuser showcased applications with a particularly high proportion of recycled material from household waste collection (PCR). One striking example is a stretch hood film with a 35 percent PCR content. The film is a high-performance application in which a PCR content of this magnitude was previously not possible. This is made thanks to Reifenhäuser's EVO Fusion twin-screw extrusion technology, which offers an absolutely stable production process with advanced mixing and degassing. This enables film manufacturers to use PCR, even from household waste collection, to produce sustainable and profitable film that will be in increasing demand against the backdrop of rising regulatory requirements for recycled content (PPWR).
Cast MDO pouches combine recyclability and functionality
The flat film experts at the Reifenhäuser Group showcased, among other things, a high-performance cast all-PP stand-up pouch with a high oxygen barrier, which – in addition to excellent recyclability – also impresses with its functionality and can be manufactured particularly economically.
The films for the pouch were produced on a Reifenhäuser Cast MDO line at RC-Film and further processed in collaboration with TPN Food Packaging and Wipf. Reifenhäuser's MDO technology saves material costs for barrier films through stretching, as the process enhances the EVOH barrier effect. This allows the EVOH content to be reduced to less than five percent of the total weight of the packaging, which is also a prerequisite for its recyclability.
The MDO process offers a special added value for end customers with its so-called easy-tear effect: the packaging can be torn open in one direction, as if pulled along a straight edge, and resealed using internal clips or zippers. Until now, such packaging functions in stand-up pouches were usually implemented using laser perforation, which can have a negative effect on the structure of the packaging, the barrier effect, and thus the shelf life of the packaged product. Thanks to Reifenhäuser Cast MDO technology, this property is achieved solely by stretching the film – without impairing other important film properties.
