New blown film die heads: Significantly higher performance combined with shorter cleaning and changeover times

Technology

Blown film lines

Reifenhäuser Blown Film is setting new standards in blown film production. The newly developed “Ultra Die” die heads address the biggest challenges faced by film manufacturers by enabling faster, more efficient, and more flexible production.

Blown film manufacturers face challenges: While price pressure in the market is increasing, equipment efficiency is declining due to more frequent product changes resulting from the trend toward smaller orders and more flexible production. Sometimes, film manufacturers have to flush the residues and color pigments of the old material from the blow head nozzles several times a day before they can reset the equipment for the next product. This costs time and money.

Improved plant efficiency is needed

To make matters worse, the market for packaging films is highly competitive, particularly for commodity products. When operating three- and five-layer lines, maximum output is therefore crucial for production efficiency. With barrier films, on the other hand, perfect single-layer tolerance is required: Since barrier materials such as EVOH are significantly more expensive than PP and PE, manufacturers have a clear cost advantage by making the barrier layer as thin as possible while still maintaining barrier properties.

The increasing use of recycled material in blown film production can impact plant effectiveness. The recycled material introduces a higher level of contamination, significantly shortening the cleaning intervals for the die heads—plant downtime increases and efficiency decreases.

In light of these challenges, Reifenhäuser Blown Film has further developed its proven die technology: “With the new ‘Ultra Dies,’ we have taken the dies - which are critical to the system’s performance - to a new level,” says Tim Conradis, Director of Sales at Reifenhäuser Blown Film. “The innovative blow heads improve quality, speed up cleaning processes, and increase output by up to 30 percent.”

Advantages of the new die heads

50% faster assembly/disassembly and maintenance
30% higher performance
25% faster product changeovers
25% faster cleaning
15% tighter individual layer tolerances

Ideally positioned to meet the needs of the blown film industry

Ultra Die 3-5 Layer

Boost Your Output

Ultra Die 7 Layer

Boost Your Barrier Output

Ultra Die 9+ Layer

Boost Your Barrier Quality

The new “Ultra Die” blow heads are designed for the production of films ranging from three to eleven layers. Reifenhäuser’s advanced die heads are distinguished by the following features:

Innovative Design
With its new generation of die heads, Reifenhäuser has reimagined the design, making the component ready to meet the challenges faced by blown film manufacturers today. The “Ultra Die” die heads are designed to ensure maximum internal cooling and maintain a stable pressure level even at peak performance. This has a stabilizing effect on the processing and film quality. In addition, the new die heads are more compact and, thanks to their innovative design, are even easier to bolt on. This is reflected not least in the reduced number of bolts required for assembly. Maintenance tasks can thus be carried out significantly more efficiently and quickly.
Higher Overall Equipment Effectiveness (OEE)
In combination with the new Ultra Cool GEN3 cooling system, the new design of the blow heads increases the performance of blown film lines by up to 30 percent: this enables a material output of an unprecedented 1,050 kilograms per hour with a die diameter of 350 mm. This leap in performance alone has a positive impact on return on investment. In addition, manufacturers benefit from significantly faster cleaning and maintenance thanks to the compact design of the blow heads.
Greater flexibility and faster product changeovers
This accelerated cleaning of the die heads eliminates long downtime during product changeovers. This is a key advantage in the competitive market for three- and five-layer films. The new blow heads thus contribute to greater flexibility.
Cost advantages for barrier films
The new “Ultra Die” die heads ensure better single-layer tolerances. For barrier films, this allows for better control of the required layer thickness of high-cost barrier materials, such as EVOH. Costs can be limited and calculated more accurately. In addition, the seven-, nine-, and eleven-layer films produced impress with their outstanding film properties. For nine- and eleven-layer films, the design of the blow head also ensures improved optical film properties, such as higher transparency and a reduced haze value.
Increased Use of Recycled Materials and PFAS-Free Resins
Thanks to faster maintenance and cleaning of the blow molds, it is now cost-effective to process recycled materials and PFAS-free resins, which are in growing demand on the market but tend to have higher levels of contamination.

Reifenhäuser customers are already successfully using these innovative blow heads. Existing Reifenhäuser Blown Film systems can be retrofitted with them at any time.

"The EVO Ultra Die 3 has brought a new level of flexibility to our production. Polymer and color changes are incredibly fast, and the compact design makes purging quick and efficient - reducing significantly change over and cleaning time. What’s truly remarkable is the output increase and perfect film quality: despite its small footprint, the Ultra Die 3 outperforms larger die heads we've used in the past. It’s a perfect fit for our dynamic production environment. With this technology we heave not only kept our existing customer base, but we have been able to penetrate new markets."

Giuseppe Daldoss

Shareholder & CTO of DAP Materie Plastiche srl, Mairano (BS), Italy

"In our fast-paced market, adaptability and performance are key - and the EVO Ultra Die 3 delivers both. The die head’s versatility allows us to switch between products quickly, and the compact Die body makes cleaning and purging much faster. But what really stands out is the output coupled with perfect gauge control: The output is higher than any other die head of comparable or even larger size. The overall package gives us a real competitive edge without compromising on quality or efficiency."

Wayne and Kegan Hoffmann

Managing Director & Administrative Director of Novapac, Capetown, South Africa

"We’ve been running our new EVO 7-layer blown film line featuring the EVO Ultra Die 7, and the results have been exceeded all our expectations. The output rated we’re achieving are simply unmatched - no other supplier has come close. But it’s not just about speed the film quality is extraordinary. The consistance, clarity, and strength of the film are outstanding, allowing us to meet and even surpass our customers’ demands. This technology has truly elevate our production capabilities."

Pascual Martínez Pérez

Director General of Smurfit Kappa, Spain

"From day one, the EVO Ultra Die 9 has been a cornerstone of our EVO Aqua Cool line. Its consistent performance has enabled us to achieve outstanding optical film properties that continue to set our products apart in the market. The clarity, quality, and reliability of the films we produce not only meet but exceed industry standards. With the Ultra Die 9, we’ve maintained high output while delivering crystal-clear films that elevate our brand and customer satisfaction."

Sławomir Bielawski

Owner of DUET Sp. z o.o.