How you benefit from water cooling and vacuum calibration

Technology

Blown film lines

EVO Aqua Cool systems enable blown films that combine the highest optical properties with optimal mechanical properties and thermoformability. The key to this is a water-vacuum calibration unit that is unique in the blown film market.

At the heart of Reifenhäuser's EVO Aqua Cool blown film lines is a technology that rapidly cools the melt: the EVO Ultra Quench water cooling and vacuum calibration chamber, positioned between the die head and the film take-off, supplements the conventional air cooling rings with an additional highly efficient cooling system. As it passes through the chamber, maximum heat is extracted from the melt in a very short time through direct contact with water. The result: the rapid cooling stops the crystallization process of the melt, producing films with exceptional properties. Film produced on the EVO Aqua Cool line is highly transparent, robust, puncture-resistant, and at the same time thermoformable, with a low thickness tolerance. This combination makes Aqua Cool films ideal for demanding applications in the food and medical industries.

Vacuum makes the difference

The “Ultra Quench” water cooling and vacuum calibration chamber, the heart of EVO Aqua Cool blown film lines, offers film manufacturers decisive advantages:

1
Process stability through vacuum

Unlike conventional water cooling systems, the vacuum in the “Ultra Quench” chamber creates uniform pressure. This stabilizes the bubble in its position and ensures a smooth, trouble-free process. Breaks or holes, which can typically occur due to bubble movement, are effectively prevented. This stability enables higher production speeds coupled with the highest possible throughputs.

2
Powerful water cooling

The water surrounds the outer side of the film and is distributed evenly in the chamber by means of a vacuum, which in turn ensures rapid and homogeneous cooling of the entire melt and enables consistently high film quality. In addition, the vacuum completely removes the water from the film before it leaves the chamber. This keeps the water in a closed circuit and eliminates the need for additional drying of the film after the calibration chamber.

3
Quick format changes

The “Ultra Quench” technology enables format changes within just 30 minutes by simply replacing the calibration rings. This allows quick adjustment of the film width from 800 mm to 1600 mm and the thickness from 55 µm to 300 µm, making the system extremely flexible for various production requirements.

Ideal for food or medical packaging

Ultra-Quench technology produces film properties that are ideal for a variety of applications, including multilayer thermoforming films, lid films, vacuum skin packaging, and vacuum pouch packaging. Abdelali Rouhi, specialist for water-cooled blown film lines at Reifenhäuser, emphasizes: “Depending on the manufacturer's desired production output, flexibility, and product diversity, Aqua technology is unbeatable.” He adds: "In some cases, air-cooled blown film lines or cast lines may be the better choice. As the Reifenhäuser Group, we cover the entire spectrum of plant technologies and advise our customers to find the optimal solution for their specific requirements."

Properties of the film