New generation of Reifenhäuser die heads impresses with throughput of more than 1,000 kilograms of barrier film per hour
Wine and juice are increasingly being sold in bag-in-box packaging. A sturdy cardboard box surrounds the drinks, which are filled into a plastic tube. A spout valve allows the beverage to be dispensed and prevents oxygen from entering - just like the plastic film of the tube. This prevents unwanted fermentation. When producing plastic films with an oxygen barrier, two things are important for manufacturers: the highest quality and cost-effectiveness.
Packaging specialist Smurfit Westrock is a leading global supplier of bag-in-box packaging. Until now, the company had manufactured the spout valve itself, but purchased the film for the tube. To save costs, Smurfit Westrock decided to manufacture all components of the packaging itself. For its plant in Alicante, Spain, the company therefore needed a modern blown film line on which the required seven-layer PE film with EVOH barrier layer could be produced.
High-performance line to guarantee high output and consistent film quality
Tim Conradis, Director of Sales at Reifenhäuser Blown Film, outlines the two most important requirements Smurfit Westrock had when purchasing the line: "Firstly, our contacts were looking for the most powerful line on the market in order to achieve the best possible output. Second, the quality of the film had to match that of the film purchased previously, including the lowest possible single-layer tolerance." The latter is particularly important for the high-priced EVOH barrier. Those who consistently achieve the minimum thickness of the barrier layer in production can enjoy enormous savings potential. “Depending on the production volume, savings in the six-figure range are realistic per year,” says Conradis.
Profile: Smurfit Westrock
The company was formed in 2024 through the merger of Smurfit Kappa and WestRock. While Smurfit Kappa was considered Europe's largest manufacturer of paper-based packaging, WestRock was the second-largest packaging manufacturer in the US. Smurfit Westrock is headquartered in Dublin and employs around 100,000 people in over 40 countries. The company operates more than 500 plants and specializes in innovative packaging solutions.
The individual film layers remain consistently thin
As an existing customer, Smurfit Westrock approached Reifenhäuser Blown Film with its request. Since a latest-generation blown film line had been set up in the company's own technical center, Reifenhäuser invited representatives from Smurfit to conduct trials with the required barrier structure. Reifenhäuser used a standardized measurement method to verify the single-layer tolerance. The film, which was up to 90 micrometers thick, was cut open at several points and then analyzed under a microscope. The result: the minimum thickness of the barrier layer was consistently achieved. The positive effects: the necessary oxygen barrier was maintained and the thickness of the high-quality EVOH material remained constant. This allows the amount of material used to be calculated precisely and minimized. Since the EVOH content is less than five percent of the total weight of the film, it is recyclable.
New generation of blow heads with maximum output
Reifenhäuser Blown Film's blown film line also impressed in the second decision criterion. After all, the seven-layer blown film line is more powerful than any other on the market. At the heart of the EVO line is the new EVO Ultra Die 7 blow head with a revised design. While higher throughput rates lead to critical pressure increases in conventional blow heads, the pressure remains stable in the new generation of blow heads from Reifenhäuser Blown Film.
The overall concept comprising the blow head, cooling system, and EVO Ultra Range Extruder enables throughput rates of over 1,000 kg/h in barrier applications - a previously unattainable value. “The results of the new EVO 7-layer blown film line with the EVO Ultra Die 7 have exceeded our expectations,” says Martinez Pérez, Managing Director of Smurfit Westrock Spain. “No other supplier achieves the nominal outputs we have achieved.”
The advantages of the new EVO Ultra Die 7 die head::
- Market-leading productivity:
Unique output of over 1,000 kg/h for barrier applications. - High film quality:
The multilayer films with barrier effect impress with their consistency and strength. - Perfect single-layer tolerance:
Consistently uniform minimum EVOH thickness in the production process. - Reliable material savings:
Precisely maintained tolerance values lead to calculable EVOH usage. - Maximum flexibility:
Quick changeover between seven-, five-, and three-layer films.
Air volume for internal air cooling crucial for high output
The development of the new generation of blow heads was based on a market analysis, as Conradis reports: “Some time ago, we looked at all the blow heads available on the market and examined the extent to which they were able to meet the current challenges faced by customers. Very little has happened in this area across the entire industry over the last 10 to 20 years,” says the expert from Reifenhäuser. “However, blown films are now a highly standardized commodity. To be competitive, it is necessary to become more productive.” Reifenhäuser therefore developed a new design concept for the die heads, whose geometry enables exceptional performance in terms of output and stability.
Flexibility meets performance: Fast product changeover guaranteed
But the line not only stands for maximum performance with first-class film quality, it also allows for maximum flexibility. If Smurfit Westrock needs to produce a five- or three-layer film at short notice instead of the seven-layer film, this can be done quickly. Despite the large geometry and high volume of the blow head, fast changeover times are guaranteed.
“We are proud that such a renowned customer as Smurfit Westrock chose our solution after exploring all available options on the market,” Conradis sums up. The new seven-layer blown film line has now undergone an internal certification process at Smurfit Westrock. From now on, it will be in operation around the clock in Alicante. “This technology from Reifenhäuser Blown Film will definitely improve our production capacities,” says Martinez Pérez, who is convinced that the line will complete Smurfit Westrock's value chain and bring about a significantly optimized cost structure.
Are you facing similar challenges in barrier film production as Smurfit Westrock? Then let our experts advise you on the “EVO Ultra Die 7” technology (also available for 3-5 layers and +9 layers):
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