How Merba Plastik is taking off as a newcomer in the packaging sector with a Reifenhäuser Value PET system

Technology

Flat Film

A real newcomer in the packaging sector - that's how you could describe Merba Plastik. The company, which is based in the outskirts of Istanbul, decided two years ago to enter the production of PET rigid films for food products. A Reifenhäuser PET line offers Merba maximum efficiency in film production thanks to fast and uncomplicated material and product changeovers, while at the same time increasing energy and cost efficiency.

"As a newcomer in the packaging sector, it was important for us to have a reliable and experienced partner at our side who could provide us with perfect technical and product-related advice and support in advance to ensure a successful start," says Resid Cizmeci, General Manager at Merba. After extensive consultations with Reifenhäuser, Merba decided to purchase a Reifenhäuser PET thermoforming sheet line with twin-screw technology and degassing with a 5mbar vacuum pump.

Merba Plastik, Kocaeli, Turkey

Manufacturer of food-safe PET/RPET rigid film
Product range of coextruded and laminated (e.g. PE/EVOH laminated) rigid films
EFSA and FDA approved technologies/standards
PETCORE member

www.merbaplastik.com

A major advantage for the customer is the possibility of fast material and product changeovers, for example between post-consumer PET bottle regrind (PCR), post-industrial PET production waste (PIR) and new PET. The EFSA/FDA-compliant PET process uses a co-rotating twin-screw extruder and a specially developed high-performance vacuum system that allows producers to process recycled PET material directly - without pre-treatment, pre-drying or a reactor process, as is necessary with other processes. The system unbinds moisture from the PET flakes during the extrusion process and is therefore not only energy-efficient, but also enables fast product changeovers thanks to its high flexibility. Another advantage of the single-stage process is that edge trim can be fed directly back into the process without the restrictions that occur with multi-stage technologies. The system also impresses with its high raw material flexibility. This means that under different product scenarios (100% PCR, PET virgin material, return of PET/PE laminates), a consistently high output can be guaranteed with unchanged high quality.

Mechatronic polishing stack ensures high film quality even with extra width

The width of 1800 mm at 200 µm poses a particular challenge in production. The polishing of an extra-wide film by a polishing stack requires particular precision, as it is technically highly demanding to maintain homogeneous thickness tolerances in a range of 0.2-1.2 mm across such a width. " It is physically much more difficult to achieve good results over such a large area. The fact that we still achieve such a high film quality is thanks to the precise mechatronic polishing stack with axe crossing," says Resid Cizmeci.

Energy savings of more than 35 percent and high cost efficiency

By opting for the Reifenhäuser solution without a pre-treatment process, Merba was able to avoid investing in an additional system component. In addition, the Reifenhäuser solution significantly reduces energy and maintenance costs: the elimination of pre-treatment and pre-drying saves an average of 200kWh/t in production. Energy efficiency that pays off directly for Merba: with an average electricity price of around €0.10 kWh, the company achieves substantial annual savings of around €1.8 million. "We were impressed by the energy efficiency of the system," explains Cizmeci. "Compared to a single-screw configuration with pre-drying, we were able to achieve energy savings of more than 35 percent."

In Reifenhäuser, we have found a partner who has convinced us with the quality of its systems and its service. The acquisition of the Reifenhäuser PET-Sheet line gave us the opportunity to firmly establish ourselves in the thermoforming sheet sector with a competitive technology and to be one step ahead of our competitors.“

Resid Cizmeci

Merba General Manager

Successful start with a broad product portfolio and high output

The professional support of the Reifenhäuser team of experts during installation and the high degree of automation of the Reifenhäuser systems allowed Merba to enter the world of packaging production quickly and smoothly. The line went into operation in the third quarter of 2023 and has been impressing with a strong output of 2500 kg/h ever since.

“We are now able to extrude PET film from 200µm up to 1200µm with silicon, corona, anti-block, AF and peelable applications. Also at our in-line lamination system PE layer starts from 40 µm : low, medium and high barrier options are available. Additionally, we offer a large product range in a width from 200mm to 1800mm.” Onur Kacar, Sales and Marketing Specialist at Merba Plastik.

A vision that nothing stands in the way of. "As a newcomer in the packaging sector, our customer Merba has learned extremely quickly and has already shown great results within a short space of time. With the Reifenhäuser PET system, the company is now in an excellent position," praises Benjamin Pott, CSC at Reifenhäuser.

“In Reifenhäuser, we have found a partner who has convinced us with the quality of its systems and its service. The acquisition of the PET-Sheet line gave us the opportunity to firmly establish ourselves in the thermoforming sheet sector with a competitive technology and to be one step ahead of our competitors.“ Resid Cizmeci, Merba General Manager