When the Flex coextrusion adapter is the right choice

Technology

Precise film profiling enables manufacturers of multilayer films to significantly reduce their production costs. With Reifenhäuser coextrusion adapters, the individual layer tolerances can be perfectly adjusted so that only as much raw material as necessary is processed. Exceeding the ideal layer thickness, on the other hand, costs valuable margin and worsens the sustainability balance.

Fix (left), Flex (center) or Pro (right) - Reifenhäuser offers three different coextrusion systems for the extrusion of cast, sheet and coating applications. The Flex variant is the latest addition. Launched in 2024, this highly flexible and cost-effective system complements the performance spectrum between the Fix and Pro models. But for whom exactly does the Flex make sense? And where is the Fix sufficient or should it be a Pro?

The Flex coextrusion adapter is exactly the right choice for these three requirements:

1
Changing product mix

You want to be able to switch quickly between different film structures or layer thicknesses and flexibly profile the film on the system yourself using adjustable profiling inserts.

2
Low investment costs

You can forego the Pro features (profiling during operation and complete automation option) in favor of an attractive price position.

3
Compact design

You would like to retrofit a variable coextrusion system to an existing line, but only have limited installation space. The particularly compact design of the Flex coextrusion adapter enables easy integration, even where space is limited.

The new Flex coextrusion adapter from Reifenhäuser enables high flexibility at low investment costs. It offers significantly more flexibility than the Fix version, but at the same time dispenses with some Pro features. The Flex version is therefore the new - in the best sense of the word - mid-range model that offers an optimum price-performance ratio, especially for producers with a changing product mix.

The key unique selling point

Compared to the Fix version, producers can use the Flex to make quick changes to the film profiling on the system themselves using adjustable profiling inserts. For processing particularly sensitive materials such as PMMA or PC, the adjustable profiling inserts can be replaced with single-piece inserts once the perfect setting has been found. These enable better film quality due to their static geometry. Less demanding applications, on the other hand, can also be run permanently with profiling inserts. The layer structure of the film can also be changed quickly using channel packs (e.g. from ABA to ABB). The shear speeds are set automatically in relation to the percentage layer structure (e.g. from 10/80/10% to 20/60/20%). Compared to Reifenhäuser's top model “Pro”, however, film profiling on the Flex version cannot be carried out during the extrusion process or be fully automated.

The reduced range of functions enables a significantly better price and a more compact design, which is particularly advantageous for retrofitting existing systems with limited installation space. The Flex coextrusion adapter is therefore the perfect choice for producers who want to switch regularly, independently and quickly between different film profiles and layer structures on their system. With special profiling inserts and channel packages, the changeover is quick and uncomplicated.

Pro variant with full PAM automation on request

For multi-layer composites with the highest demands on the quality of layer thickness distribution, it is recommended to use the Pro version, which also allows profiling during operation and can be adjusted fully automatically and mechatronically with the Reifenhäuser automation option PAM using electric actuators.

The coextrusion adapter Pro is the only coextrusion system on the market that enables the profiling of individual layers while the system is running. PAM fully automates this setting and simplifies adjustments and optimizations through recipe management. Once saved, recipes can be reproduced at the touch of a button.