Press releases
20.06.2022
291

Using sustainability as a success driver, benefiting from digitalization, increasing productivity: at K 22, Reifenhäuser will show how it can be done

The Reifenhäuser Group will be represented with four booths at the world's leading trade fair for plastics processing, K 2022, from October 19 to 26. Under this year's Reifenhäuser motto "The Time is Now", the extrusion specialists will show producers of films and nonwovens valuable solutions for the three major topics of the industry: sustainability, digitalization and productivity.

Bernd Reifenhäuser, CEO of the Reifenhäuser Group, explains: "The world and our industry are facing major challenges. There is uncertainty, disorientation and unanswered questions on many topics. And yet they will not tolerate any delay. Now is the time to act and turn challenges into opportunities. We have know-how for this as well as great, immediately applicable solutions in our luggage, with which we enable our customers and partners to do so."


The Reifenhäuser K 22 booths at a glance:

Hall 17 / C 22:
Reifenhäuser main booth (blown film, flat film, nonwovens lines, service, digitalization, components)

Hall 11 / C16:
Reifenhäuser screws, barrels and extruders

Hall 1 / D 91
Reifenhäuser flat dies

Circular Economy Forum
(CE 07)
:
R-Cycle

Reifenhäuser lines and components at a total of four exhibition booths

The Reifenhäuser Group will be represented at three of its own booths and one joint booth in Duesseldorf. The main booth with approximately 1,200 square meters is located in Hall 17 (C 22) and impressively showcases the Reifenhäuser Blown Film, Cast Sheet Coating and Reicofil business units. With the help of machine exhibits, visual presentations and concrete solutions for end products, visitors will learn, among other things, how they can manufacture fully recyclable products economically, process recyclates safely, increase their output and network the entire production without becoming dependent on systems, specialists or manufacturers. To ensure smooth production even after purchase, Reifenhäuser Service shows how customers can get the best out of their Reifenhäuser products and increase their productivity with refurbishment solutions, modifications, training programs and digital services.

The component specialists of the Reifenhäuser Extrusion Systems business unit will additionally present their portfolio at two other exhibition booths. In Hall 11 (C16), everything revolves around screws, barrels and extruders - and why, especially for processing recycled material, high-performance wear protection is essential for reliability and high economic efficiency. The well-known Reifenhäuser Reiloy wear protection alloys for screws and barrels have repeatedly achieved top values in independent tests, proving that investing in high-quality wear protection pays off. In Hall 1 (D91), Reifenhäuser Extrusion Systems will showcase its innovations for flat dies and coextrusion blocks and their perfectly coordinated interaction for maximum productivity.

R-Cycle: Sustainability meets digitalization
in the Circular Economy Forum

In addition to its own booths, Reifenhäuser will also be present as a partner of the R-Cycle initiative as part of a joint pavilion on the open-air site in the so-called Circular Economy Forum (CE 07). R-Cycle is a cooperation project of various technology companies and organizations along the entire life cycle of plastic packaging. The interdisciplinary team has developed an open traceability standard for sustainable plastic packaging that makes recycling-relevant information transparent by providing a Digital Product Passport. This enables waste sorting facilities to more precisely identify recyclable packaging and form recycling-friendly and single-variety fractions. This is the basis for obtaining high-quality recyclates to build a functioning circular economy.

From the exhibition booth to the Reifenhäuser Technology Center

A special highlight for visitors to the Reifenhäuser trade fair booths is the opportunity to additionally participate in the in-house exhibition on October 20, 21 and 24 at the Reifenhäuser Technology Center. For this purpose, Reifenhäuser organizes a free bus shuttle between the Duesseldorf trade fair and the Reifenhäuser headquarters in Troisdorf, which is only about 70 kilometers away. Here, the guests can experience various blown film and flat film lines in operation during two moderated live demonstrations per day. Interested parties can contact their Reifenhäuser representative to inquire about participation.

Details on the product highlights are available here as separate press releases:

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Reifenhäuser Blown Film provides technical solution to one of the biggest challenges in the processing of recyclate

Reifenhäuser Blown Film provides technical solution to one of the biggest challenges in the processing of recyclate

The line manufacturer Reifenhäuser Blown Film has developed a technology that makes blown film producers independent of highly fluctuating recyclate qualities and ensures a stable production process - even when processing low-quality input material: EVO Fusion upgrades recyclate qualities.

With EVO Fusion, blown film producers also process previously unusable, lowest-quality recyclates into high-performance blown films for simple applications, such as trash bags or mailing bags. Until now, such low-grade recyclates could only be used for simple and thick-walled injection-molded products. In addition, producers can make higher-quality film from recyclates that could also be processed in the past.

Eugen Friedel, Director Sales at Reifenhäuser Blown Film, explains, "In order to drive the circular economy, recycling content in blown film products must increase and classic downcycling must be limited. With EVO Fusion, we offer a unique process that enables customers to process even low recyclate grades easily and economically into high-performance products and increase the recyclate content. In this way, processors open up new fields of application for recycled products."

The EVO Fusion process relies on direct extrusion, which eliminates the need for energy- and cost-intensive regranulation of the raw material. This means that fluff (film shreds) and all types of production waste and PCR material can also be processed directly.

This is made possible by the twin-screw technology, which homogenizes the melt better and thus ensures a stable process. In addition, processors can degas the system very easily and effectively, removing unwanted components in the recyclate.

For processing better quality regranulates, Reifenhäuser recommends the EVO Ultra single-screw extruder. Thanks to optimized barrier as well as shear and mixing parts, this extruder processes recycled material as reliably and naturally as other raw materials - the ideal prerequisite for success in the growing market for products with a high recycled content.


EVO Fusion at K 22:
Reifenhäuser main booth – hall 17 / C 22

Thanks to the twin screw and degassing unit, the EVO Ultra Twin Extruder can also safely process low-quality recyclate. The system can be degassed very easily and effectively to remove unwanted components in the recyclate.

With EVO Fusion, even fluff (film snippets) and all kinds of production waste and PCR material can be directly processed into functional films for applications such as trash bags or mailing bags.
Pictures: Reifenhäuser

Record output rates beyond 600 kg/h for form-fill-seal sack applications with Reifenhäuser Ultra Cool 2.0 FFS

Record output rates beyond 600 kg/h for form-fill-seal sack applications with Reifenhäuser Ultra Cool 2.0 FFS

Reifenhäuser Blown Film is introducing a new high-performance cooling system for its "EVO FFS" blown film line, which has been specially developed for heavy-duty sack applications. This system increases the cooling capacity by more than 20 percent compared to conventional systems on the market. In the production of heavy-duty sacks, record output rates of more than 600 kg/h can thus be achieved from a die with a diameter of 175 mm - while maintaining the best film properties.

The production of blown film for form-fill-seal (FFS) bags for heavy goods puts manufacturers in a tough competitive environment where output is the key to economic success. Thanks to the increased cooling capacity, producers can now exceed the market's peak output values by around 50 to 100 kg and thus gain a significant competitive advantage in terms of productivity.

Eugen Friedel, Director Sales at Reifenhäuser Blown Film, explains: "With our record output capacity beyond 600 kg/h, we enable our customers to achieve an attractive return on investment and the potential to be successful on the market in the long term. EVO Ultra Cool 2.0 FFS achieves unrivaled performance values without compromising quality or process reliability."

EVO Ultra Cool 2.0 FFS is suitable for all common FFS recipes and applications (petrochemical, fertilizer, salt bags, etc.) while offering ease of use and high line availability. In terms of mechanical film properties and thickness tolerances, the best results have been demonstrated in all product tests, enabling high throughputs in the filling process and stability for bag handling. Long service life, easier machine start-up and reliable quality also ensure high competitiveness and ease of operation. In order to also participate in the growing market for sustainable products, the line reliably processes recyclates and recyclable raw materials.

In addition to the premium cooling ring "EVO ULTRA COOL 2.0 FFS", Reifenhäuser also offers the standard version "EVO COOL FFS" for its EVO FFS lines, so that the perfect solution can be found for every requirement. The performance is above the market average in any case. All EVO FFS lines are equipped with Reifenhäuser's proven EVO extruders and die heads, thus ensuring optimum melt quality at lowest melt temperatures.


Ultra Cool 2.0 at the K 22:
Reifenhäuser main booth - Hall 17 / C 22

With the Reifenhäuser Ultra Cool 2.0 FFS cooling system, blown film producers produce more economically than ever before thanks to output rates of more than 600 kg/h.

Today, the constant further development of Reifenhäuser technology ensures the highest output rates for form-fill-seal sack applications.
Pictures: Reifenhäuser

Fully recyclable pouch – now also with barrier effect for food packaging

Fully recyclable pouch – now also with barrier effect for food packaging

At K22, Reifenhäuser Blown Film will be presenting a fully recyclable pouch with a barrier effect against oxygen and water vapor that is suitable for food packaging. The solution is a further development of the All-PE mono-pouch already established on the market. The Reifenhäuser barrier pouch makes a further contribution to higher plastic recycling rates and a functioning circular economy.

While fully recyclable pouches for non-food packaging have been established on the market for some time, the necessary oxygen barrier in food packages - and the materials and film thicknesses required for this - has stood in the way of their recyclability. The Reifenhäuser barrier pouch achieves the necessary barrier effect with an EVOH content of less than five percent and thus meets all the requirements for complete recycling. The use of the patented EVO Ultra Stretch stretching unit makes it possible: it increases the barrier effect of the EVOH and thus reduces the EVOH content while maintaining the barrier effect.

Eugen Friedel, Director Sales at Reifenhäuser Blown Film, explains: "The demand for recyclable products is growing steadily. This also increases the demand for EVOH, which is already hard to come by. With our fully recyclable barrier pouch, we meet two challenges at the same time: the pouch meets all market requirements for sustainable packaging and at the same time enables resource-saving handling of scarce and high-priced EVOH."

As before, the film produced can be further processed and converted easily. Thanks to the patented position of the stretching unit directly in the haul-off of the blown film line, the film is stretched at the ideal time and from the first heat, which makes the process particularly efficient and stable.

Fully recyclable barrier pouch at the K 22:
Reifenhäuser main booth - Hall 17 / C 22

Reifenhäuser EVO Ultra Stretch enables the production of mono-material composites (All-PE film) for fully recyclable flexible packaging.

The Reifenhäuser barrier pouch - a further development of the ALL-PE mono-pouch - is fully recyclable thanks to an EVOH content of less than five percent.
Picture: Reifenhäuser

EFSA/FDA-compliant production process enables manufacture of food-safe film from PET recyclate

EFSA/FDA-compliant production process enables manufacture of food-safe film from PET recyclate

Reifenhäuser Cast Sheet Coating has developed a particularly efficient production process with which PET recyclate can be processed directly into food-safe film without a pre-drying process. The process meets the criteria of both the US Food and Drug Administration (FDA) and the European Food Safety Authority (EFSA). This was proven via a so-called challenge test.

If recycled goods come into direct contact with food, special certification by the EFSA or the FDA is required in advance in some markets. The production of films for such food packaging is correspondingly complex and demanding. Reifenhäuser Cast Sheet Coating now facilitates the economical production of such films for flat film manufacturers with a simpler production process and provides advice on certification.

Mark Schuster, Product Manager PET Sheet at Reifenhäuser Cast Sheet Coating, explains: "The market for recyclable food packaging made of PET already has a high volume. At the same time, the growth potentials are equally interesting considering the current global collection rates. We are now making it easier for customers to successfully participate in this market."

The EFSA/FDA-compliant PET process uses a co-rotating twin-screw extruder and a specially developed high-performance vacuum system that enables producers to process PET recycling material directly, without pre-treatment and pre-drying - as is necessary with other processes. Processors thus save the investment in an additional line component and avoid additional energy and maintenance costs, which leads to significant savings, especially in times of rising energy prices. Fast material and product changes are also possible, for example between post-consumer PET bottle scrap (PCR), post-industrial PET production waste (PIR) and virgin PET. The end product, for example a meat tray, meets the highest hygiene standards and can be used safely in direct contact with foodstuffs in accordance with the criteria of the authorities.


Certification made easy: Consulting

Reifenhäuser Cast Sheet Coating supports customers in the certification process with the relevant authorities. For this purpose, not only the cleaning process of the ground material, but also the quality monitoring of the input material and the production under the criteria defined by EFSA are considered.


EFSA audits made easy: automatic documentation

Another feature of the line is the automatic documentation of relevant production data. For EFSA audits, recipe- and product-related data of the certified process must be stored for several years. The specially developed ExtrusionOS Production Compliance software bundle helps to monitor and securely document production processes and compliance with EFSA-relevant thresholds in a data-based and real-time manner. A live dashboard transparently shows ongoing production and its thresholds, enabling fast action in case of irregularities. ExtrusionOS Production Compliance is based on Reifenhäuser's connectivity solution ExtrusionOS Core & c.Hub Middleware, and can also be retrofitted to existing lines.


Recycling made easy: Digital Product Passport

Via ExtrusionOS, production data can also be transferred to a Digital Product Passport - for example, via the open R-Cycle standard. Digital Product Passports are data records clearly linked to primary and end products that contain relevant data on materials, ingredients and the use of the product. Via special markings, they can be used, among other things, for data-based and thus more precise waste sorting and recycling processes.


EFSA/FDA-compliant food-safe film from PET recyclate at K 22:

Reifenhäuser main booth – hall 17 / C 22


More information about food-safe film from PET recyclate: PET recycling: food-safe sheet made from recyclate

Reifenhäuser PET Sheet lines produce sustainable PET film from up to 100 percent PET bottle flake for direct food contact (according to EFSA/FDA).
Picture: Reifenhäuser

New "Ultrathin Coating" process enables production of particularly lightweight and cost-effective film/nonwoven composites

New "Ultrathin Coating" process enables production of particularly lightweight and cost-effective film/nonwoven composites

Reifenhäuser Cast Sheet Coating will showcase a completely new production process for cost-effective film/nonwoven composites with outstandingly low grammage, which allows economical production also in Europe.

The Covid-19 pandemic and current supply shortages have exposed the dependence of companies on global supply chains. This situation is both a warning signal and an opportunity to boost and reorganize the local production of semi-finished products from the ground up. Reifenhäuser Cast Sheet Coating has now developed a trend-setting production process termed Ultrathin Coating, in particular for the sector of medical protective clothing. The process will permit customers to produce particularly lightweight film/nonwoven composites with greater cost efficiency and, as a result, more competitively.

The patent-pending process has several advantages: It cuts film grammage by 66 percent; material consumption in the overall composite is reduced by 28 percent; and it slashes costs by up to 34 percent compared to conventional semi-finished products. Significant cost savings are achieved in various ways, for example, by replacing hotmelt adhesives, which rises line availability by reduced maintenance effort at the same time.

Mark Borutta, Sales & Marketing Specialist at Reifenhäuser Cast Sheet Coating, explains: "We are currently experiencing a sustained increase in demand for medical protective clothing combined with a return strategy for local production capacity. Against this backdrop, producers achieve a fast return on investment and high profitability with Ultrathin Coating - even when production is based in Europe."

Even if manufacturers already produce medical protective clothing and prefer to handle the coating process internally in the future instead of importing the necessary composites, it is worthwhile to set up an in-house production facility. In either case, the investment in Ultrathin Coating usually pays for itself in less than 12 months. The lower material input also reduces the consumption of fossil raw materials and this in turn responds to the increased demand for more sustainable products.

What is so special about Reifenhäuser Cast Sheet Coating’s solution is that its sister company, Reifenhäuser Reicofil, an experienced and global leading manufacturer of nonwoven lines, provided their invaluable support to the development. Customers already operating a Reicofil nonwovens line or installing a new one will thus receive a perfectly matched extrusion coating line for seamless semi-finished product production.


Ultrathin Coating at K 22:

Reifenhäuser main booth – hall 17 / C 22

LAMICOR-CL Laminator: The heart of the Ultrathin Coating extrusion coating line.
Picture: Reifenhäuser

Film-nonwoven mono composites as a lightweight and recyclable alternative to paper-plastic packaging

Film-nonwoven mono composites as a lightweight and recyclable alternative to paper-plastic packaging

For packaging products to be recyclable, they must primarily be made from only one material. Some emerging packaging trends, such as paper-plastic composites, are therefore not conducive to the circular economy. At K 22, Reifenhäuser will be presenting highly functional, recyclable alternatives in the form of film/nonwoven mono composites. The innovative look and feel of such composites also help manufacturers stand out from the crowd.


Fully recyclable nonwoven film composites for bulk packaging applications

For bulk material applications, Reifenhäuser Reicofil offers a turnkey line concept that enables customers to produce high-performance nonwoven film composites made of PP mono material and significantly reduce their material consumption: Fully recyclable sacks for a variety of free-flowing bulk materials, such as cement, grain or animal feed, can be produced with 25 percent less material. At the same time, compared to paper-film composites, the barrier effect against moisture increases while at the same time allowing air permeability, which enables air-conveyed filling. The composite can also be used for medical packaging: The material enables steam sterilization of already packaged products.

The manufacturing process combines the Reicofil RF5 BiCo spunbond line with an extrusion coating line from sister company Reifenhäuser Cast Sheet Coating. Customers thus receive a perfectly matched solution from a single source. Together with project partner Starlinger, world market leader for machine and process technology for woven plastic sacks, Reicofil also offers a complete turnkey solution including printing unit and sack converting. Together, a production-ready process including the end product - the valve box sack "REICO*STAR" - was successfully introduced to the market.

Dr. Andreas Rösner, responsible for strategic product development at Reifenhäuser Reicofil, explains: "With REICO*STAR and the process behind it, we have shown that nonwoven film composites are a sustainable and economical alternative. They also offer a better moisture barrier and a higher-quality feel than standard paper-film composites. This offers enormous potential to participate in the growing demand for fully recyclable packaging products."


Mono-PP pouches made from laminated nonwoven film composites

In addition to extrusion coating, laminated nonwoven film composites made of mono-material also offer great potential for more sustainable and visually and haptically appealing packaging. In cooperation with its sister company Reifenhäuser Blown Film and raw material partner Borealis, Reicofil offers here an overall concept that is also ready for series production and economical for producing nonwovens for mono PP pouches in the area of high-quality food packaging, for example. The nonwoven can be perfectly laminated with flatness-optimized PP blown film to form mono-composites.


Film-nonwoven mono composites at K 22:
Reifenhäuser main booth – hall 17 / C 22

The "REICO*STAR" film/nonwoven composite sack made of PP mono material is fully recyclable and offers over 25 percent material savings compared to standard products on the market.

With RF5 spunbond lines in combination with blown films or flat films, customers can produce innovative and sustainable packaging solutions.

Highly wear-resistant screws and barrels enable safe recyclate processing

Highly wear-resistant screws and barrels enable safe recyclate processing

Whether film manufacturer, injection molder or line manufacturer: the processing of recyclate involves many challenges because recyclate is a rather complex raw material and a stress test for the plasticizing unit. Highly wear-resistant barrels and screws from Reifenhäuser Reiloy give the unit a long service life and ensure high product quality.

Recyclate is often a grab bag, because it is not always clear how carefully the starting material has been sorted and cleaned, or which additives and possibly aggressive residual components are contained. In addition, high-quality recyclate processing requires special additives that enable the polymer to become a high-quality product again. However, many of these additives are also challenging because, among other things, they have an abrasive effect or adhesive tendency - others have an aggressive effect due to inorganic acids. Many colorants and fillers also stress the components.

Reifenhäuser Reiloy offers a reliable solution for this with its highly wear-resistant screws and barrels and regularly sets benchmarks in terms of quality and performance. The components offer a demonstrably longer service life, precise matching of raw materials and additives, exclusive alloys developed in-house, and process-optimized surfaces. Manufacturers of injection molded and extruded products thus benefit from the best cost-benefit ratio in the industry. Higher resistance to wear is provided by special iron-based alloys and nickel-based alloys that match the raw material being processed. The decisive factor here is the composition of the alloys, because wear protection depends not only on the hardness of the layer.

Ralf Pampus, Managing Director at Reifenhäuser Reiloy, explains: "We are the only screw and barrel manufacturer to develop and produce the hard material alloys - and even the powders required for wear protection - in-house in our own materials laboratory. This means we offer expertise across the entire process that is unique in the market. Recent independent tests have again proven that Reifenhäuser Reiloy's wear protection is the best on the market and that the investment pays off - because high-quality components need to be replaced less frequently, produce consistent quality and thus ensure the productivity of a line."

Reifenhäuser Reiloy has decades of experience in wear protection systems and takes a holistic approach to wear protection consulting: Reiloy experts determine the optimum interaction between barrel and screw armor for each plasticizing unit and select the appropriate surface treatment.


Highly wear-resistant barrels and screws, and further components on the K 22:

  • Reifenhäuser main booth: Hall 17 / C22
  • Reifenhäuser screws, barrels and extruders: Hall 11 / C16
  • Reifenhäuser flat dies: Hall 1 / D91


More information about wear resistance:

Recyclate is complex as a raw material and a stress test for the components of the plasticizing unit. Abrasion, corrosion and adhesion can lead to surface damage.

Screws and barrels from Reifenhäuser Reiloy regularly set benchmarks in wear protection and offer proven longer lifetime.

Reifenhäuser is the only manufacturer to develop and produce the hard alloys for the wear protection of its screws and barrels in-house.

Pictures: Reifenhäuser

Cross-vendor approach: Reifenhäuser launches digital offensive that focuses on enablement of film and nonwovens producers

Cross-vendor approach: Reifenhäuser launches digital offensive that focuses on enablement of film and nonwovens producers

Countless producers of films and nonwovens could be more productive today if they fully exploited the enormous potential of digitalization. Reifenhäuser has therefore launched a digital offensive to help all producers get started with digitalization. In doing so, the company is focusing on the empowerment and independence of customers - and is deliberately turning away from the usual vendor-centric approaches. Instead, Reifenhäuser offers easy-to-implement, open digital solutions designed to help producers of films or nonwovens worldwide to increase their production efficiency (OEE) independently and sustainably. All customers, regardless of company size, thus benefit from a new dimension of process transparency that for the first time includes all line manufacturers and line types of a production.

The core of the digital solution is the so-called c.Hub, a middleware that ensures the secure exchange of data between different IT systems, applications, extrusion machines and line controls. This includes Reifenhäuser systems as well as third-party systems. The c.Hub becomes the single point of truth for all production-relevant data by merging and harmonizing production data streams. The central advantage is that all users can access all data from anywhere at any time and document them securely. The data is collected and stored on premises without interfering with the production process. The producer retains full control over the data at all times.

"So far, digitization in our industry has mostly failed due to heterogeneous factories with machines and peripherals from different vendors and of different ages and types, as well as applications that are not connected with each other," says Daniel Kajan, Director Product & Operations at RE:, a Reifenhäuser Group subsidiary specializing in digital products for extrusion line operators. "Without looking at the big picture, however, production is inefficient and error-prone. Unnecessary complaints, material loss and downtime are the result. Only a cross-vendor solution maps the production reality of our customers and thus offers real benefits," Kajan continues.

To enable customers to easily connect all their equipment in production, Reifenhäuser offers out-of-the-box connectors for the most important industrial protocols. They enable fast and complete acquisition of all production data. The associated ExtrusionOS software provides user-friendly applications and dashboards that help monitor, manage, store and analyze this data. Line operators can, for example, monitor the condition of their connected equipment and adjust it optimally based on the knowledge gained. They also have the option of monitoring defined thresholds and KPIs and, if desired, receiving notifications when thresholds are exceeded. This enables users to act faster and more efficiently, thereby significantly reducing errors and customer complaints. Legal requirements such as compliance with EFSA-relevant threshold values when processing recyclate for direct contact with food can be monitored and documented securely.

"Our open digital ecosystem helps producers capture all production data from the first meter to the last meter of the roll, easily gain insights from it, and benefit from their data in the long run," Kajan explains.

The digital package can either be purchased together with Reifenhäuser machines or retrofitted on existing lines and servers.


c.Hub & ExtrusionOS at the K 22:

Reifenhäuser main booth - Hall 17 / C 22

Reifenhäuser enables cross-vendor data exchange between all line types and systems - and thus creates more transparency in production.
Picture: Reifenhäuser

The Reifenhäuser Group: Over 100 years of experience, competence and pioneering spirit

The Reifenhäuser Group: Over 100 years of experience, competenceand pioneering spirit

The Reifenhäuser Group is a leading supplier of innovative technologies and components for the extrusion of blown films, flat films and nonwovens. Since the early days of the plastics industry in the 1950s, Reifenhäuser has supported countless customers build successful production and become top suppliers to their industry. As a market leader and family-owned company, Reifenhäuser has four specialized business units that combine their knowledge in design, process engineering, automation, project planning, manufacturing, project management and logistics. Together, the Reifenhäuser Group forms the world's largest competence network for plastics extrusion technology. Even more than 100 years after its foundation in 1911, the company is 100 percent family-owned. Today, the brothers Bernd and Ulrich Reifenhäuser are the third generation to lead the group.


Reifenhäuser Blown Film: Specialists in blown film technology
With technologies and know-how along the entire value chain, the Reifenhäuser Blown Film business unit supports its customers in the economic production of high-quality blown films that ensure business success. Reifenhäuser blown film lines enable producers to face the requirements regarding recyclable products, recycled content and biodegradable plastic products, to use the sustainability change as an opportunity for economic success.


Reifenhäuser Cast Sheet Coating: Modular lines for the production of cast films, sheets, and extrusion coatingsReifenhäuser Cast Sheet Coating develops and manufactures standardized and tailor-made cast film, sheet and extrusion coating lines, as well as individual components such as coextrusion feedblocks, cast parts, polishing stacks, and winders that perfectly match customer requirements and offer decisive competitive advantages in terms of quality, reliability and cost-effectiveness.


Reifenhäuser Reicofil: specialist for innovative spunbond, meltblown and composite lines
Reifenhäuser Reicofil is a specialist and the world's leading manufacturer of complete spunbond, meltblown and composite lines that enable producers to meet the highest quality demands in hygiene, medicine and filtration. Reicofil accompanies its customers from the planning of the production plant to the commissioning of the line and the further development of the products, thus ensuring unique quality and reliability.


Reifenhäuser Extrusion Systems: Customized components for extrusion and injection molding Reifenhäuser Extrusion Systems develops and manufactures tailor-made melt-guiding and forming components for extrusion and injection molding at the price of standard solutions and supports producers in manufacturing top quality efficiently and economically. Customers are guided step-by-step to the ideal component or production is carried out according to specified drawings. The portfolio includes screws, barrels, extruders, coextrusion adapters, flat dies, spinnerets and microcomponents. In addition, Extrusion Systems is a specialist for wear protection: Reifenhäuser Reiloy is the only screw and barrel manufacturer to develop and produce the hard material alloys - and even the powders required for wear protection - in-house in its own materials laboratory.


The Reifenhäuser Group at a glance

  • Year of foundation: 1911
  • Employees: 1.750
  • Production sites: Troisdorf, Worms, Kabelsketal, Heinsberg, Maize (USA)
  • Technology Center: Blown film, cast film, sheets, nonwovens (Troisdorf)


Management

Bernd Reifenhäuser (CEO)

Dr. Bernd Kunze (CTO)

Ulrich Reifenhäuser (CSO)

Karsten Kratz (CFO)

Headquarter: Troisdorf, Germany

R-Cycle: Digital Product Passport enables circular economy for plastic packaging

R-Cycle: Digital Product Passport enables circular economy for plastic packaging

Digitalization meets sustainability - more and more companies are using
R-Cycle's Digital Product Passport for sustainable plastic packaging. The passport enables all stakeholders in the value chain of plastic packaging to easily exchange recycling-relevant information in an open standard format across company boundaries and to make it accessible for data-based and thus more precise waste sorting. R-Cycle was founded as a cooperative initiative by the Reifenhäuser Group and other technology companies and organizations and developed to market maturity.

Looking at today's waste streams, recyclable packaging cannot be sorted with sufficient precision for high-quality recycling. Thus, even fully recyclable products usually end up in thermal recycling or, at best, downcycling to lower-quality products takes place. With R-Cycle, production machines automatically read and record recycling-relevant data as soon as a package is produced, route it through the value chain, and make it retrievable via appropriate marking (e.g., digital watermarks or QR codes) on primary and end products. This allows waste sorting facilities to easily identify recyclable packaging and form single-variety, recycling-friendly fractions. This is the basis for obtaining high-quality recyclates and building a functioning circular economy.

The R-Cycle data platform can be networked with a wide variety of software systems, right down to individual production lines: from film or injection molding machines, to processing, packaging and filling machines, to waste sorting and recycling systems. The tracing technology behind R-Cycle is based on GS1 standards – the leading global network for cross-industry process development and founding member of R-Cycle. In addition, under the auspices of GS1 Germany, the standardization project PDS4CircularPlastics (Processes and data sharing approach for enabling circular plastics value networks) has been launched. The project has the goal to develop a GS1 guideline and is based on the results of the R-Cycle initiative.

Dr. Benedikt Brenken, Director R-Cycle, explains: "R-Cycle is accessible as an open community for all companies, institutions and stakeholders that have a legitimate interest in the field of circular economy for plastic packaging and want to use, support or further develop R-Cycle themselves. Members gain access to a broad network of application-experienced partners and know-how in digitalization and sustainability. The goal is to realize their own applications, generate benefits by networking the value chain and jointly establish R-Cycle worldwide."

In addition to improving product sustainability, manufacturers also increase their process efficiency and product quality by using the Digital Product Passport. Accurate information about source materials accelerates and optimizes production, while recording product properties represents a benefit for customers in the downstream process. In addition, the Digital Product Passport facilitates the fulfillment of (emerging) legal information requirements, such as in the calculation of the carbon footprint, proof of recycled content, or in the area of Extended Producer Responsibility (EPR). In this way, time-consuming manual calculations can be automated to meet requirements from legislators or customers.


Interested companies can obtain all membership information at here: www.r-cycle.org/en/community


R-Cycle will be presented at K 22 on a joint booth of the R-Cycle Initiative in the Circular Economy Forum (CE 07).

R-Cycle records all recycling-relevant data of plastic packaging via Digital Product Passports.

Fully recyclable and identifiable R-Cycle Pouch.
Pictures: R-Cycle

About R-Cycle

R-Cycle is a cross-company initiative to develop an open and globally applicable tracing standard for sustainable plastic packaging. The aim is to automatically record recycling-relevant packaging properties during production by providing a digital product passport and to pass them on through the value chain. Recyclable packaging can then be identified in the recycling process via special markings and fed into pure waste fractions. This is the key to obtaining high-quality recyclates to close the loop.


The R-Cycle Community:

ARBURG, BRÜCKNER MASCHINENBAU, COMEXI, European EPC Competence Center (EECC), ENGEL, EREMA GROUP, GS1 GERMANY, Institut für Kunststoffverarbeitung (IKV), ILLIG, IN.PACK, KAMPF, KAUTEX MASCHINENBAU, MULTIVAC, OLBRICH, PRODATA, REIFENHÄUSER GROUP, SIDEL, SIKOPLAST, STEINERT


www.r-cycle.org

R-Cycle at LinkedIn

R-Cycle at Twitter