Stories
13.01.2025
4044

Bogucki Folie Relies on PAM Automation

Technology
Flat Film
Value CPP
Interview: Packaging film manufacturer Bogucki Folie relies on PAM die and feedblock automation to become less dependent on the shortage of skilled workers.

Poland's leading film manufacturer Bogucki Folie has invested in a new Reifenhäuser MIDEX Cast Barrier line including PAM. Lars Bergheim, Area Sales Manager at Reifenhäuser Cast Sheet Coating, spoke with owner and board member Wiktor Bogucki about the advantages that were decisive for him.

"Thanks to our highly automated PAM system for feedblock and die, Bogucki is now able to produce film of the highest quality with 100% reproducibility. The new line increases Bogucki's capacity in the high barrier film market, and thanks to its versatility, the company is now also able to enter other markets as well. The new high barrier cast extrusion line will certainly expand the company's portfolio."

Lars Bergheim
Area Sales Manager at Reifenhäuser Cast Sheet Coating

Lars Bergheim: Mr Bogucki, your company is one of the market leaders in the production of polyethylene films with different physical and chemical properties. What goals are you pursuing with your company and your production facilities?

Wiktor Bogucki: Bogucki Folie specializes in the production of high-quality, multi-layer food and technical packaging films as well as barrier films. Our traditional product is a three-layer, thin thermostretch film for beverage packs.

However, the production facilities in our company are getting a bit aged. We have decided to invest in new technologies to increase our production capacity, lower production costs, and reduce production waste while maintaining or improving the quality of the products. We also want to achieve a higher level of automation in order to become less dependent on skilled personnel. The shortage of skilled workers is one of the biggest problems in our industry in Poland.

Therefore, as part of our investment plans, we were looking for an efficient, reliable and automated line that would meet our growing requirements."

About Bogucki Folie

Bogucki Folie is a family business founded in 1983 in Jatne (Poland). Initially, the company's activities focused on the production of printed carrier bags. Today, Bogucki Folie is one of the market leaders in the production of polyethylene films with different physical and chemical properties. The manufacturer specializes in efficient order processing and offers its customers comprehensive technical support in the implementation of new projects.

How did you come up with Reifenhäuser?

WB: We carried out extensive market analyses and worked intensively with various manufacturers and suppliers of raw materials.

Reifenhäuser has been present on the global market and the Polish market for many decades. It has very good references from packaging film producers. A major advantage is the possibility of carrying out tests in advance in the Reifenhäuser technical centre at the company headquarters in Troisdorf (Germany) on the latest production equipment, where both raw material formulations and product optimizations can be tested.

The Reifenhäuser systems met our expectations during the tests. In particular, the completely new, mechatronic die and feed block automation PAM - has reduced the time for product changes on our line to a minimum. We also produce significantly less waste during set-up. Overall, PAM gives us maximum flexibility and resource efficiency thanks to the use of automated actuators instead of the usual thermal expansion bolts, which also consume significantly more energy due to the permanent power supply.

Reifenhäuser MIDEX CPP Line at Bogucki Folie
Type: (11-120/2x80/105/60/2x80/3x50-3200)
Product: Cast Barrier-Film for food packaging
Raw material: Polyethylen / Polyamid
Throughput: 1,500 kg/h

PAM Automation 

The PAM automation option (precise, autonomous, mechatronic) for flat dies and coextrusion adapters from Reifenhäuser makes work easier for machine operators, increases productivity and enables the simple production of top film quality. Mechatronic actuators automatically adjust the feed block and die via the system's control panel. This makes producers less dependent on a shortage of skilled workers. Once recipes have been saved, even less experienced system operators can reproduce them at the touch of a button.


From my point of view the collaboration with Bogucki Folie was fruitful right from the start of the project. Your team has been very professional and very familiar with the requirements that packaging manufacturers have to face today. The technological knowledge on your side has been visible right from the start. As a professional - how do you rate the consulting process?

WB: The communication and exchange of information with the Reifenhäuser sales team and the technical service team specializing in the project was always fast and straightforward. From the very first meeting, we were given the feeling that our needs and wishes as a customer were paramount. The new equipment of the system was explained and presented to us in detail at the Reifenhäuser research and development center. The production tests in the Reifenhäuser technical center, in which we were able to successfully test the recipes we had selected, as well as the high quality of the components and the easy operation thanks to the PAM automation of the system were decisive factors in our decision to opt for the Reifenhäuser CSC line.

What added value do you create for your company with this system?

WB: Our production will be more environmentally friendly, more efficient and more economical than before - while maintaining the same high film quality. The investment in the new line will also give us the opportunity to accept more demanding orders in shorter series. PAM supports us here when starting up new products, as once stored recipes can be reproduced at the touch of a button. The products are of the highest quality, while at the same time we significantly reduce energy consumption and other production costs.

Thank you very much for the interview!

In addition to the flat die, Bockucki Folie has also equipped the coextrusion adapter with PAM automation.

The aim of the investment in the new line was to increase production capacity.

The entire hot part of the system - from the extruder to the die - was perfectly coordinated by Reifenhäuser.

PAM can be easily operated via the system's control panel and automatically adjusts the feedblock and die.

Thanks to its contact-free operation, PAM also offers maximum work safety.

PAM makes it easy to produce top film quality.

Would you like to find out more about the project and the technical solutions? Please feel free to contact us.

Lars Bergheim
Lars Bergheim
Reifenhäuser Cast Sheet Coating
P
+49 2241 481-590
P
+49 151 125 231 36

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