Higher output, better quality, faster converting: Tropic relies on EVO Ultra Flat technology in blown film production
As market leader, Ismail Simjee, CEO of Tropic, knows the competitive market for flexible packaging material in South Africa and on the African continent very well. In 2025, he saw the need to invest in another line: ”We had to increase the capabilities and capacities in our production.“ In particular, in the premium product segment, Tropic wanted to specifically expand extrusion volume by purchasing a new line – and at the same time offer value with even higher-value film quality.
Among other things, Tropic produces food packaging that requires more complex film structures than standard films, including special laminating films with a thin sealing layer. The existing Tropic lines were reaching their limits in this regard. “In addition, we received more and more inquiries for recyclable PE mono-material structures and for thinner films that perform just as well or better than the films being replaced, despite downgauging“, says Simjee.
Placing functional layers exactly where they are needed
When searching for the right line, Tropic's decision-makers turned to Reifenhäuser – not least because a very close business relationship has developed between the two companies over the past 20 years. After comparing requirements with capabilities, the choice fell on another EVO 5-layer blown film line. Simjee sees a clear advantage in this: ”The five layers allow us to place the desired functions exactly where they are needed in the film.“ This film structure allows more cost-intensive layers to be limited to the respective layer. ” Our customers can now receive higher-performance packaging at a competitive price, and the new technology enables us to innovate on an industrial scale – not just within pilot trials,“ Simjee sums it up. Optionally, recyclates can be used in both subskins, i.e., in the second and fourth layers.
Fact sheet:
Tropic Plastic & Packaging Industry (PTY)
Founded in 1963, the company headquartered in Durban is today the largest manufacturer of flexible packaging material in South Africa, supplying both the domestic and the African market. Tropic's products are used in beverages, food, household products, and in speciality use cases. In production, the company follows the principle of vertical integration, carrying out printing, laminating, and converting in-house alongside film production. Through the use of solar systems and comprehensive ESG strategy, Tropic is forging ahead on the sustainability front.
Visit the website of Tropic Plastic & Packaging Industry
EVO Ultra Flat for outstanding flatness
For Tropic, another aspect was of central importance when acquiring the line: efficient converting of the film. After all, the company handles large parts of the value chain in-house – Tropic extrudes, prints, and laminates the films itself. In doing so, their flatness must meet the highest standards, especially as films become ever thinner, in order to make converting as economical and efficient as possible. After all, films that are not flat slow down the printing process and increase not only ink consumption but also adhesive consumption during lamination. „As an essential part of the 5-layer line, we recommended Tropic our patented Ultra Flat technology which is tailor-made for their purposes,“ says Sascha Skora, Senior Sales Manager at Reifenhäuser Blown Film. Ultra Flat enables high flatness because the smoothing system is integrated directly into the film take-off, so the film is moderately stretched while still warm. A significantly more effective and energy-efficient approach than the usual practice of letting the film cool down first.
„With Ultra Flat, film can be made up to 40% flatter, allowing up to 30% faster printing speed, which enables savings in adhesive, ink, and raw material,“ emphasizes Skora. Tropic CEO Simjee confirms: „In practice, it has become clear that we get a higher-quality film that we can convert faster and more evenly.“ Due to these qualities, Tropic reserves the new EVO 5-layer blown film line for its most technically demanding product range, spanning films for food with critical shelf life, transparent bread bags, and specialized films. In addition, the new line allows the production of recyclable PE mono-material structures.
High performance, reproducibility, and control
Since March 2026, Tropic has been producing on the new blown film line from Reifenhäuser, which meets all the expectations placed on it – especially regarding production costs and film quality. „Thanks to the line's high throughput, producing complex film structures has become particularly worthwhile for us,“ emphasizes Simjee. Five-layer structure and downgauging also contribute to profitability: more cost-intensive PE compounds can be placed precisely, reducing film thickness while maintaining consistent quality. The excellent flatness also enables higher printing speeds with less ink and adhesive use on every order. „These advantages never appear in the balance sheet of the extrusion line itself,“ says Simjee, „but for converters like us, they are decisive.“
Another advantage of the EVO blown film line is its ease of operation. A digital operating system and automated product-change assistants make it quick and easy to control the line, as well as ensuring reproducibility of film quality. An important aspect, especially given the shortage of skilled workers.
Tropic CEO Simjee therefore sums up: „The key advantages of the new Reifenhäuser line are: first, high performance, which allows us to produce more complex films. Second, high reproducibility of these films through digital assistance systems, and third, control, since there is an increase in precision.“
Advantages of the EVO 5-layer blown film line with Ultra Flat technology
- Maximum layer flexibility:
The five-layer line allows the precise placement of functional layers or recycled material. - Outstanding flatness for optimal converting:
Ultra Flat technology for up to 40 percent flatter film enables higher printing speed and lamination quality in converting, with less ink and adhesive use. - Maximum production output:
Maximum output for demanding film structures. Up to 1,000 kg/h at 2,600 mm width. - Cost-efficient downgauging:
The same film quality with less material use helps produce ever-thinner films without having to accept any loss of quality.
Setup and commissioning went smoothly
Setup and commissioning of the line had already gone smoothly. Production was therefore able to start on the agreed date. For Tropic CEO Simjee, this is not a given for a line of this size and the logistical effort involved. „It was important for us to be able to rely on a Reifenhäuser team on-site that not only accompanied the installation and trained the operating staff but also handled the commissioning.“ The result: the line was successfully accepted right at its first start-up. „The on-schedule start of production was the result of perfect teamwork,“ says Reifenhäuser manager Skora. „In addition to the experienced Tropic team, our local partners Beswick and IOSA also made a significant contribution to commissioning.“
The new EVO line will help Tropic reinforce its role as South Africa's number one in flexible packaging films. At the same time, it strengthens Tropic's position as a full-service provider, capable of offering everything from extrusion to conversion from a single source – while maintaining consistently high quality.
Would you like to learn more about the benefits of technologies like Ultra Flat in blown film lines? Then contact our experts. They will be happy to advise you:
