With precision and pioneering spirit: how Reto Maeder automates flat film extrusion

Technology

Flat Film

For a long time, starting up or changing the product on a flat film extrusion line was “a science in itself”. Only with a great deal of experience and skill was it possible to set the die perfectly for an optimally profiled film. Reto Maeder has this experience and has incorporated it into the development of an automation solution that is unique on the market. It enables the perfect adjustment of the die at the touch of a button - a decisive advantage in times of increasing global shortage of skilled workers.

To date, over 160 systems worldwide have already been equipped with the patented system. Since 2022, the technology has been part of the Reifenhäuser portfolio under the name PAM (precise, autonomous, mechatronic). We spoke to Reto Maeder about the development story behind it and the partnership with Reifenhäuser.

Mr. Maeder, what was the inspiration behind your development?

Reto Maeder: Users of flat dies are often dependent on experienced machine operators who have perfect knowledge of the system. Especially in multi-shift operation, it has become extremely difficult to find sufficiently qualified employees who are also prepared to work nights and weekends. The shortage of skilled workers is not only a European problem, but is increasing worldwide. The need for automation in this area was and is therefore high. In our view, the large proportion of manually operated systems was primarily due to the technically unsatisfactory solutions on the market. The established systems are generally based on thermal expansion bolts, which are slow and sometimes imprecise, and at the same time consume a lot of additional energy, as the individual bolts require constant power, depending on the die. We therefore saw great potential in the use of precise and efficient mechatronics to develop a better solution.

What were the first steps in the development process?

RM: We have been active in the field of flat film and sheet extrusion lines since my father founded our company in 1983, where we developed various components such as multi-web large roll winders. When it came to mechatronic die automation, we started in 2009 from scratch, as there were no comparable systems to date. We presented the first maku-DieTool® prototype at the K plastics trade fair in Düsseldorf in 2010 and immediately received a lot of interest. The first orders and deliveries to our customers followed in 2011. At that time, the system initially only had a die lip adjustment. In 2016, we also integrated the restrictor bar adjustment. Since 2020, we have been offering fully automatic internal and external deckling adjustment. The system has a modular design. When fully equipped, it has a total of 10 servo axes. The partnership with Reifenhäuser and international marketing as the PAM automation option took place in 2022, giving us a further boost and greater visibility in the market.

From the start of development to the first delivery in less than 3 years - that sounds very fast. Did everything work smoothly right from the start?

RM: Generally speaking, the concept worked well and we were able to quickly convince our customers of the added value. However, the details, as is so often the case, took a lot of time and testing. But our customers believed in the technological approach and went down this path with us. The hardware is designed to be relatively simple and robust. We approach each adjustment screw individually with a mechatronic screwdriver that carries out the setting. Most of the development work has gone into controlling the system and the underlying software. Over 15 years of experience from more than 160 customer projects have gone into this. On request, we can implement PAM in combination with a thickness measuring system and offer a complete control loop. I can't go into the exact details of the control system, but believe me, the know-how behind it is essential.

Reto Maeder, Managing Director maku AG

How the maku-DieTool® became the Reifenhäuser PAM automation solution

In 2009, Swiss engineer Reto Maeder and his father Robert Maeder started developing a completely new automation solution for flat dies at maku AG, a family business founded in 1983. Instead of the usual manual adjustment or automatic control using thermal expansion bolts, they developed the first system with electric actuators on the market. The so-called maku-DieTool® regulates the die lip and/or the restrictor bar, the internal and external deckling as well as the lower lip. Compared to previous solutions, the system is highly precise, fast and significantly more energy-efficient, as the actuators only need to be supplied with power briefly during adjustment and not permanently. Since 2022, the technology has been marketed, supported and further developed within the Reifenhäuser portfolio under the name PAM (precise, autonomous, mechatronic) as part of a strategic partnership. maku AG also continues to market the solution directly as maku-DieTool® in sales areas that are not served by Reifenhäuser.

PAM Automation

The PAM automation option (precise, autonomous, mechatronic) for flat dies and coextrusion adapters from Reifenhäuser makes work easier for the machine operator, increases productivity and enables easy production of the highest film quality. Mechatronic actuators adjust the feed block and die automatically via the machine's control panel. This makes producers less dependent on highly qualified specialists. Once recipes have been saved, they can also be reproduced by less experienced system operators at the touch of a button.

And the mechatronic approach is still unique on the market?

RM: In this particular form, yes. In the meantime, the first competitors are trying to implement lip adjustment in a similar way. PAM is still the only mechatronic automation system for restrictor bars, deckling and coex adapters. And in terms of maturity and field experience, we have a very comfortable head start. This is also reflected by our customers who use the system. Of course, we also protect our know-how with corresponding patents.

What added value makes PAM score most highly for users?

RM: That depends on the market. At the moment, the shortage of skilled workers and labor costs are one of the main drivers for more automation in plastics production - across all regions. This also goes hand in hand with the issue of occupational safety. When using PAM, there is no longer any need to make adjustments to hot metal elements on the die or feed block. Burns or other injuries caused by working on the running system are therefore eliminated. In this way, producers can easily meet the legal occupational safety requirements in high-tech markets such as North America or Europe and protect their employees in the best possible way.

And what about the costs?

RM: Profitability is of course decisive in the end. In addition to personnel costs, PAM significantly reduces operating costs. With the help of our ROI (return on investment) calculator, we can show exactly how quickly the investment pays for itself. Depending on the application, throughput and material, etc., we are easily talking about cost savings of more than 100,000 euros per year, which we achieve through the reduction of start-up rolls, rejects, energy consumption and higher utilization of the system. Here too, our experience helps us to calculate the savings potential very precisely in advance so that the customer's expectations are met after the purchase.

What advantages does the partnership with Reifenhäuser offer you?

RM: On the one hand, we gain access to a globally established sales and service network. On the other hand, our technologies complement each other perfectly. PAM can be ordered as an automation option for Reifenhäuser dies of the Cast Sheet Coating lines or as a component - both for Reifenhäuser dies and for third-party dies - via Reifenhäuser Extrusion Systems. Existing systems, of which Reifenhäuser supports thousands, can also be easily retrofitted with PAM. Conversely, all customers who already use a maku-DieTool® benefit from Reifenhäuser's broad global service.

Are you still available for PAM customers?

RM: Of course! Even though my Reifenhäuser colleagues are now responsible for many sales and service projects worldwide, I am always available to answer any questions customers may have. This is an essential part of our partnership. I also focus on further technical development with Reifenhäuser. The need for automation in the plastics industry is currently greater than ever. We will leverage this potential together!

Thank you very much for the interview!