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Nordson Corporation, through its Polymer Processing Systems (PPS) division, announced that Huhtamaki’s Elif division, a global leader in sustainable flexible packaging solutions, has successfully implemented Nordson’s BKG® continuous melt filtration technology to improve blown-film production performance while increasing the use of recycled materials.
As part of its sustainability strategy, Elif set out to increase recycled content in its polypropylene (PP) and polyethylene (PE) blown-film applications. However, the variability typically associated with recycled feedstock created significant processing challenges on its extrusion line operating at 350 kg/h. The company experienced frequent production interruptions, elevated waste levels, and visible film defects due to inconsistent melt filtration.
To address these challenges, Elif partnered with Nordson Polymer Processing Systems to evaluate a continuous melt filtration solution designed for demanding blown-film applications.
Addressing Downtime and Product Quality Challenges
Elif’s existing discontinuous filtration system proved insufficient to handle fluctuations in melt purity inherent in recycled materials. As a result, the operation faced:
• Frequent downtime caused by filtration interruptions
• Increased gel content leading to product quality issues
• Reduced operational efficiency and higher material waste
• Limited flexibility in processing varying recyclate qualities
These challenges impacted productivity, commercial output, and the company’s sustainability objectives.
Nordson BKG® Continuous Melt Filtration Solution
Nordson provided a BKG® HiCon™ K-SWE-HD/RS continuous melt filter for on-line testing. Installed downstream of a 90 mm extruder and operating at inlet pressures of up to 550 bar, the system delivers filtration fineness between 125 and 150 µm.
• The BKG® HiCon™ system offers several performance advantages:
• True continuous filtration eliminates process interruptions
• Stable melt pressure and temperature ensure consistent film quality
• Robust handling of recycled materials with varying contamination levels
• Reduced waste and improved overall line efficiency
• Proven reliability in high-performance blown-film applications
The system’s advanced backflush technology enables continuous, automated screen cleaning without interrupting production, ensuring stable processing even during contamination peaks.
Measurable Performance Gains
Following a short trial period, Elif reported immediate and measurable improvements, leading to the purchase and full implementation of the system.
Key benefits achieved include:
• Elimination of unplanned downtime related to melt filtration
• Increased output of sellable product
• Reduced material waste and improved process efficiency
• Significantly enhanced film quality with minimal gels
• Improved operator safety through fully automated, hands-free operation
• Increased flexibility in processing a broader range of recycled materials
“The introduction of the fully automated self-cleaning filter greatly improved our operator safety. With the BKG® HiCon™ K-SWE-HD/RS, we were able to replace manual filter changes on a running machine – which previously posed high safety risks – with an automated, waste-free process requiring no operator intervention,” said Karim Saber, Global Senior Manager Extrusion & Recycling Operations.
Supporting Sustainability and Profitability
By stabilizing extrusion conditions and eliminating filtration-related interruptions, Elif has strengthened both its sustainability performance and operational profitability. The ability to reliably process higher levels of recycled content without compromising quality supports the company’s broader environmental goals.
“This project clearly shows the value of continuous melt filtration when processing recycled materials,” said Frank Thomas, Manager Sales, Nordson BKG®. “By combining automation, process stability, and robust filtration performance, we help customers like Elif achieve their sustainability goals while improving safety, efficiency, and profitability.
