Strictly-Extrusion

At the recently closed K’2004 exhibition, Macchi shown the latest development of their COEX flex® units. One of the well known Macchi innovative concepts is to incorporate all the extruders on a single platform, resulting in the COEX flex® modules. Easy to transport, install in confined spaces and fully wired, these coextrusion platforms can often be installed and running on the same day.
This idea was a great success and today almost 90% of the 3 layer co-ex lines made by the Venegono House are engineered around them.

The newly developed “Size 6” platform, “World Premiere” at the K, consisted of 2 side extruders having 80mm of screw diameter and 1 core extruder of 100 mm of screw diameter. Equipped with a 500 mm IBC die this setup is capable of producing more than 900 kg/h of LDPE based structures and 700/750 kg/h running with more complex LLDPE structures. In proportional terms, this means a production of 1,5 to 1,9 kg/h/ per each mm of die diameter, compared to typical production standards of 1,1 to 1,2 kg/h/mm of die diameter. This without any compromise in the quality of the final film. The film design run in Dusseldorf was a demanding one, having skin layers respectively of 90 and 95% mLLDPE and more than 60 mLLDPE content as total formula content.

Amongst other novelty features the collapsing frames, assembled on the 2400 mm oscillating take off unit, engineered to reduce to a minimum the planarity deformation and dramatically decrease the film temperatures resulting from this remarkable throughputs and line speed.

The BO PLUS® on display, flagship of Macchi’s winders, had new software for accurate winding tension control on all winding modes, surface, gap and center-surface. The well known Easy Load® system, integrated with automatic roll and shaft handling system was the logical completion of one of the finest piece of machinery in hall 17.

Line computerized supervision and controls concerning extrusion parameters, automatic gauge profile and downstream services like Corona treaters, edge guiders and chillerplant were integrated into the most recent version of Easy Control Plus® , centralized on a 15” Siemens Touch Screen operator terminal, making the line extremely easy to operate.

As demonstrated with the daily runs, where the Macchi’s film consistently resulted of even superior qualities from the ones of the similar products obtained by competitive machinery Makers, the line performed flawlessly with impressive output rates, receiving tangible signs of praise from qualified observers and competitor Experts as well. Doubtless the impressive white Macchi line got full visibility under the Dusseldorf limelights, consolidating its manufacturer position within the selected group of the Leading Experts of coextrusion.

COEX flex® size 6 and Easy Control Plus® represent another step forward in integration, modularity and productivity in the field of blown film extrusion lines, bringing a solid meaning to the Macchi’s pay-off: Modular Engineering for Creative Solutions.

Vinyl will remain the market leader in total U.S. siding demand through 2008, but growth between 2003 and 2008 will be virtually static at 0.4%/yr. Fiber cement and metal panels, meanwhile, will post solid annual growth of 6.7% during that period, while brick will grow 1%/yr, and stucco will gain 2% annually. The vinyl siding market will account for 40.1 million squares in 2008, up from 39.3 million in 2003. The overall siding market will be 110.5 million squares in 2008, up from 103 million in 2003, which translates to annual growth of only 1.45%.
These findings come from a new report from Freedonia Group, Cleveland, titled “Siding.” While volume gains will be relatively anemic, the value of the siding market will increase 3.9% annually from 2003 through 2008 to $10.2 billion, on the strength of higher-end siding, customer preferences for special features like integrated foam insulation and special finishes, and the rising cost of raw materials. In 2008, vinyl siding will account for 40.1% of the market, essentially unchanged from 39.3% in 2003. Fiber cement and metal panels will be No. 2 at 23.7% of the market, while stucco will be third at 19.2%. The 315-page report costs $4100. Tel: (440) 684-9600, www.freedoniagroup.com

Austrian extrusion equipment maker Cincinnati Extrusion GmbH has opened its first U.S. office. Cincinnati Extrusion Inc. is located at 1455 Jamike Dr., Erlanger, Ky., 41018. It is headed by Hans Matthesius, formerly v.p. of Krauss-Maffei’s extrusion div. The former European extrusion branch of Milacron Inc., Cincinnati Extrusion was bought by SMS Plastic Machinery Group (parent of Battenfeld Extrusionstechnik and Battenfeld Gloucester Engineering) in 1999. Cincinnati Extrusion makes single- and twin-screw systems for pipe, profile, and sheet. Tel: (859) 866-2411; e-mail: matthesius.h@cet-austr ia.com; www.cet-austria.com

API Group is to sell its Converted Products division, including its polypropylene film businesses, to a new management team for £12.2m (E17.3m). Nigel Trilk and Martin Urquhart, supported by GE Commercial Finance, will take over the three-leg business that includes Filmcast Extrusions, a manufacturer of mono and co-extruded PP packaging for markets such as food, medical, textile and magazines. The other two businesses specialise in the coating of film and paper with either adhesive or silicon. In total the division has 250 employees. Filmcast, based in Nelson, Lancashire, employs 70 people and has annual sales of around £5m (E7.5m).

With the ZSE MAXX range, a new machine series from Leistritz, will take the successful ZSE conception to a new dimension and will gradually replace its ZSE HP range. The foremost and most important feature is the maXXvolume, which leads to an increase in performance by 25 to 35% by means of an optimised volume/torque ratio. The drive unit of the MAXX enables the optimum screw speed and torque in correspondence with the application. The increase in flexibility was made possible by a new shaft-element joint, called maXXshaft — patent pending. The new processing unit can be downgraded to the ZSE HP series because of the common centreline distance of the screw shafts. Increased ease of use is also an important factor in the new machine design. By completely shrouding the drive unit, a reduced noise level can be achieved. A water cooled barrel cover makes operating the extruder even safer. A new frame design with integrated barrel cooling, facilitates easier assembling and disassembing of the heating cartridges and barrels. Thus exchanging the complete processing unit can be done much more conveniently. The term maXXcooling describes a new barrel cooling system with a 30% increase in cooling capacity by means of a sophisticated system of pipes, bores and heat exchangers.

The company has taken over two Finnish packaging specialists: Nordpak, which produces flexible multi-layer film for use in the food industry, and Avanspack, which prints and laminates the films. The two companies employ around 100 people and have a turnover of around E30m. Klöckner said the acquisition will expand its capabilities. As well as taking over Avanspack’s printing expertise, it will now use blown film technology for the first time – a speciality acquired from Nordpak. The Finnish companies are also strong in Scandinavia and Benelux, where Klöckner now expects to see “significant growth”. Klockner Pentaplast has 25 production plants worldwide, 3,800 employees and a turnover of more than E1bn.

Xtrutech, a new word in twin-screw service technology, has been designed to support spares and service requirements for all users of co-rotating twin-screw extruders. It is backed by process know-how and many years of experience in twin-screw design. Graham Edwards, Managing Director and Richard Johnson, Sales Director, with over 50 years of experience between them with Baker Perkins and APV Baker and more recently with Theysohn TSK, have set up Xtrutech and are developing a one-stop service centre for all twin-screw users that coat effective and accessible to all. Whilst Xtrutech specialises its service on Baker Perkins, APV and Theysohn extruders, they also provide service support for W&P, Leistritz, Maris, Berstorff, B&P, prism and Clextral machines including screw elements, shafts, barrel sections and heater bands. Xtrutech is more than just a manufacturer and supplier of screw elements, shafts and barrels and more than just a provider of service engineers. It also provides: process optimisation; screw and shaft cleaning and re-configuration; retrofit barrels &/or barrel upgrades for powder coating users; machine up-grades; managed maintenance programmes; and project and design engineering support.

US flexible packaging group Bemis has acquired Dixie Toga in Brazil, consolidating its position in South America. Bemis, which has operations in Europe, paid approximately $250m (E190m) for all the voting shares and 43% of the non-voting preferred stock of Dixie Toga. The two companies have operated a flexible packaging joint venture called Itap/Bemis in Brazil since 1998. The venture represents about one-third of Dixie Toga’s total annual sales, which were more than $300m (E230m) in 2004.
Dixie Toga employs over 3,000 people in South America and operates nine manufacturing plants in Brazil and two in Argentina. Its products include flexible packaging, injection moulded containers, laminated tubes, printed labels and folding cartons.