S.despain SPI Film & Bag

Multilayer Films for the Retail Market & the Film Systems Required to Produce Them
Mission Flexible Packaging Good Day Mr. Packaging Manufacturer!
Your Mission, Should You Decide To Accept It Is!

1. Create new and better flexible packaging with;
Better barrier properties Improved graphics More functionality, etc.

2. And of course.it all must be done at a lower cost!
There are improvements out there for your use!

2
Reifenhuser EXTRUSION GmbH & Co.KG, proprietary information, all rights reserved
Look Around and See The Obvious

Take a walk in the grocery store Buy a toy for your kids
Eat some candy Take some medicine Make a salad
Trends in flexible packaging and industry

Flexible packaging Substitution of rigid packaging (e.g. stand-up pouch) More and more resins Thinner films Co-extrusion (3,5,7 or 9-layers) Larger orders but shorter runs (just in time) Faster printing and converting equipment Higher quality demands Bio-resins Industry Concentration (less suppliers / customers) Globalization Strong competition on cost and quality Flexible equipment is necessary for high quality and low resin consumption
What are the functionalities for packaging?

According to a Clemson University report, packaging is essential for four main reasons: Protection: Packaging must protect: The contents from environment: despoiling, breakages, contamination, polluting or leakage, bacteria protection of food. Shatter resistance: plastics avoid the cutting shreds of glass. The inside atmosphere: oxygen barrier to keep fresh organic produces.. Inopportune uses such as safety caps and child resistant packages. Containment is a primary reason to transport food, water, industrial, agricultural and domestic chemical packaging. Information & aesthetics: packaging can be transparent, opaque, colored, printed and decorated to mimic metal or wood to attract and inform the prospect, user or customer. Ease-of-use: The use of plastics in packaging allows for the continuous innovation of the most known of applications such as sealable, flexible, shrinkable, tear proof and barrier packaging available.
Packaging and Polymers

Worldwide it is estimated that the packaging market, the largest sector of plastic consumption is: Roughly one third of the total of all plastics consumed. A market that is continuously growing Currently estimated at $65B Worldwide
Courtesy of Basell
U.S. Flexible Packaging Industry Overview
2000 Total Flexible Packaging Industry Compound Annual Growth Rate (CAGR) last 10 years Number Companies Manufacturing Facilities Employees Avg $ Sales per Employee $ 19.0 B 4.2 % 665 1000 89 Thousand 213 Thousand
2005 $ 23.7 B 3.6 % 437 979 80 Thousand 273 Thousand
2010 $ 25.5 B 2.6 % 407 960 79 Thousand 322 Thousand
Source: FPA 2011 State of The Industry
U.S. Flexible Packaging Industry 2010
2010 Retail Poly Bags Consumer Products (Trash Storage Bags & Wraps) Other Poly Bags & Wraps Flexible Packaging Total ValueAdded $19.7 billion $1.9 billion $2.6 billion $1.3 billion $25.5 billion
Source: U.S. Census Bureau and Flexible Packaging Association 2010 State of the Industry Survey preliminary data
U.S. Flexible Packaging Industry 2010
2008 US Flexible Packaging Sales: Profit: Volume: $ Growth: GDP (real growth) $ 26.6 B Down Flat + 0.6 % 0.4 %
2009 $ 23.7 B Flat Lower 10.9 % 2.6 %
2010 $ 25.5 B Higher Higher +7.3 % 2.8 %
2011 $ 27.5 B Up Slightly Higher +8.1 % 3.0 %
Sales Source: 08 U. S. Census Bureau Annual Survey of Manufacturers, 09 & 10 FPA estimates and 11 FPA forecast
Converters Film and Resin Use By Category
Source: FPA 2010 State of the Industry Report preliminary data
10
Innovation and growth for barrier films
In price-driven flexible packaging markets, barrier film converters have found a competitive advantage in new technologies. They've developed new film structures and package designs that compete more effectively against foils and other traditional barrier materials. Key developments in flexible packaging include recent equipment advances that have enabled the co-extrusion of films up to nine layers. New package structures like multilayer standup pouches and metalized films have allowed plastic films to aggressively compete against rigid packaging in areas such as pet foods and specialty chemicals
11
The More is Less Vision
More preservation (through the absolute barrier effect) means a long shelf-life at room temperature and less use of energy for transportation and storage More barrier effect means less loss of the nutritional and health benefits of food More barrier efficiency and capability means less use of packaging material More convenience (through portability and portioning) means less food wastage More recycling means less use of virgin resources
Up to 50% of the worlds food, grown or produced for consumption is lost and wasted along the value chain from field to fork World Economic Forum 2010
12
Significant Market Opportunities
Conversion from rigid to flexible packaging continuing Sustainability advantages of flexible packaging Growth in emerging markets outside the U.S. Ongoing industry innovation Overall economy rebounding
53 percent of companies in the food industry are increasing their usage of flexible packaging, particularly the stand-up pouch. -- PMMI Flexible Packaging Survey, January 2010
13
Packaging as Part of the Lifecycle of Food
Process Preparation and consumption
Raw Material
Packaging
Production
14
Value Chain of Suppliers
Packaging Manufacturer Retaile r
Historical Value Chain

Packaging Consumer Goods Manufacturer Company Retaile r Consumer
Retailer
Consumer goods company
Consumer
Packaging Manufacture
Consumer 15
Retailers Becoming More Influential In Packaging

More & more retailers are dictating what they need but not necessarily how to get there.
The consumer goods companies dictate the packaging technologies used. Only in rare occasions do we ask for special packaging to be designed. Senior Buyer Dry Groceries, major mass merchandiser The club stores and mass merchandisers tell us what they want in packaging (overall), but they dont really know what they want (specifically). They expect us to come up with the innovations. Packaging Purchasing Manager, major consumer goods (food) company
Source: Strategic Analysis Inc.
Key Dynamics Effecting Retail Markets

65% of households w/2 people or less
Demographics
Growing ethnic population Oil Prices

Population Mix
CONSUMER
Distribution of Food Expenditures
Dual Income Families
Work Schedules
Restaurants Vs. Stores
Work more. Less time to cook prepared meals
17
Retail Food Consumer Highlights

Grocery expenditure by category
Flexible Packaging Market

Grocery % of annual category expenditures Fresh meat 16% Main meal items and condiments 15% Beverage 12% Produce 11% Dairy 10% Non-food grocery 9% General merchandise, H&B 8% Frozen food 8% Bread & baked goods 6% Deli 5%
Non-food, 23% Food Non-food Food, 77%
Estimated size $25.5 billion
Source: Progressive Grocer and FPA
18
Warehouse Club Effect
19
Impact on Flexible Packaging
TREND ANAYLSIS SEGMENTATION Packaging Format

Blister packaging Multipacks Bundling prepared food Bundling club pack
Food Packaging
Pre-packaged meat Produce Freezer section Shelf stable foods
Non-Food Packaging
Health & beauty pharmaceutical pkg. Pet food Lawn & garden
20
Blister Packaging
In a rare instance, Wal-Mart actually asked for more blister packaging to be used for prescription drugs.
TREND DRIVER
Pharmaceutical sales growth ($225 billion NA) Need for more information/directions, provides more advertising space Dosage compliance Labor cost savings IMPACT ON FLEXIBLE PACKAGING Blister packaging
Blister packaging will realize strong growth because it is being pushed by WalMart, which will make it more available to other retailers.
Vice President Marketing & Research; drug store chain
21
Multipacks
We are buying more products with flexible packaging overwrap because it is neater looking and allows graphics to be seen.
Senior Buyer, Snack Food; mass merchandiser
TREND DRIVER Decrease stocking cost Increase dollar ring Clean shelf appearance Billboard effect
TREND Increase in: Large unit multipacks Smaller unit multipacks
IMPACT ON FLEXIBLE PKG. Shrink Film Overwrap
We dictate packaging needs to CGCs by telling them that we need smaller case packs (fewer items) for different lines. If the CGC is only allotted 16 units on a shelf, 24 case packs are problematic.
Category Manager, grocery store chain
22
Prepared Food
IMPACT ON FLEXIBLE PKG. TREND DRIVER Convenience Perceived value to consumer TREND Unique combination of product offerings Breathable films Film lidding Lay flat bags Re-sealable bags Mesh netting
Examples: Pre-packed deli platters Vegetable platters Assorted cheese and chip platters
23
Bundling Club Pack

TREND DRIVER Complimentary product combinations Perceived consumer value TREND Club Packs IMPACT ON FLEXIBLE PKG. Shrink films Overwrap
Shrink film allows us to put together club packs, which have been tremendously successful and is our predominate packaging strategy, because of our focus on families. VP of Merchandising & Presentations; club store
24
Pre-Packaged Meat
TREND DRIVER Consumer convenience Retailer cost savings Increased SKUs Lack of skilled labor Food safety TREND Case ready meat & poultry Deli products IMPACT ON FLEXIBLE PKG. MAP Vacuum packaging High quality barrier packaging Re-sealable bags
Case ready meat streamlines distribution, which gets the product from the manufacturer to the consumer faster. Cost savings meets our goal to pass savings on to the consumer. VP of Merchandising & Presentations; club store
25
Produce
IMPACT ON FLEXIBLE PKG. TREND DRIVER Demographics Lifestyle Convenience Retailer cost savings TREND On the go and value added packaging for produce Breathable films Film & foil lidding Lay flat bags Re-sealable bags
81% of produce is still purchased from traditional grocery stores

26
Dairy Packaging
IMPACT ON FLEXIBLE PKG. TREND DRIVER Lifestyle Convenience Destination area TREND On the go and value added packaging for produce Shrink sleeves Quality barrier films Re-sealable, lay flat, peggable bags
27
Frozen Foods
IMPACT ON FLEXIBLE PKG. TREND DRIVER Lifestyle Convenience Product position TREND Home meal replacements On the go meal solutions Metallized films Dual ovenable bags Re-sealable freezer bags Form fill seal pouches Microwavable films
Mastio & Company
28
Pet Food & Lawn & Garden Packaging

Pallets, bags and leaking products are our biggest problems with packaging. However, the ultimate purchase price is the major deciding factor for the materials we select to purchase.
Seasonal Seed, Mulch and Soil Buyer, home improvement company
TREND DRIVER Specialty product offerings Prevention of: Product loss Leak & spills Use of outdoor retail space
IMPACT ON FLEXIBLE PKG. Re-sealable pouches High quality barrier bags Shrink film Stronger ply film bags Waterproof films
29
Internet / Mail Order

Example: Prescription drugs grew 6% in 2004, but mail order prescriptions grew 18% for drug stores. TREND DRIVER Shipping/handling costs Product protection Flexibility for packaging various orders Convenience IMPACT ON FLEXIBLE PKG. Packaging bags Padded envelopes Bubble wrap Rapid fill air cushions Suspension packaging
30
Point to Point Handling

IMPACT ON FLEXIBLE PKG. TREND DRIVER Decrease handling cost Shipping efficiencies Conveyable cases Multipacks Shoppable pallets Aisle hangers Floor displays TREND Stretch film Shrink film Pouches Peggable lay flat bags
Getting product on the store floor (pallets) or on the shelves (trays/multipacks) with a minimum of handling is essential. Its both a JIT issue as well as a cost and labor issue
Director Product Development & Merchandising, mass merchandiser
31
Retail Segment Growth Areas

Retail Sector Internet Mail Order Category Killer Growth 15% - 20% 10.5% Key Areas of Packaging Growth Bubble Wrap, rapid fill air cushions, padded envelopes High quality barrier films, overwrap, shrink films, lay flat peggable bags, resealable bags Barrier films, blister packaging, MAP, metallized films, overwrap, resealable bags, standup pouches, stretch film, shrink film, shrink sleeves Barrier films, MAP, layflat bags, overwrap, stretch film, shrink film, resealable bags Shrink sleeves, metallized packets, expandable labels, blister packaging Barrier films, breathable films, dual ovenable films, form fill & seal bags, resealable films, microwavable films Form fill & seal bags, resealable films, microwavable films
Mass Merchandiser
7.5%
Club Store Drug Store Grocery Store Convenience Store
7.5% 6.5% 2.5% 2.5%
32
Which Improvements?
Improvements in extrusion equipment, polymers and formulations must lead to: Better properties of the film Cost reduction of the production process / product Improvements in blown & cast film line equipment: Modular and flexible line to achieve all necessary film properties Universal screws - Extruders have to process all necessary polymers Die head and extruders designed for a wide range of different layer distributions High capacity cooling Improvements in polymers and formulations: Better bubble stability Suitability for blending / Use with less tie-layers New polymers with new (wider range of) properties
Improving your ROI High Output - Low Energy Consumption
Key Elements of production costs

resin down time interest energy labour costs
The Requirements for a Cast Film Line

Our process provides the maximum material flexibility with efficient product changes, while producing the highest quality film.
Twin Screw Extruders in Cast Film
If you see double you see right Cast Film Lines combined with REItruder Twin Screw Technology
36
Advantage of a Twin Screw Extruder

Dosing Vacuum Domes
Dosing screw
P1
P2
P3
P4
P5
Intake Zone
Mixing Zones
Pump 1 Pump 2
Minimizing of down times ! Cleaning process can be reduced Why? Absorbing of monomers by Vacuum
Vacuum Pump
37
Advantage of a Twin Screw Extruder

Dosing Vacuum Domes
Dosing screw
P1
P2
P3
P4
P5
Intake Zone
Mixing Zones
Pump 1 Pump 2
Inline Refeeding ! Up to 50% Inline - Refeeding of the total web width without Die deckling possible Why ? Special and flexible screw segments
38
Vacuum Pump
Reifenhuser Proprietary Co-extrusion Feedblock

Adaptor plate Extruder adaptors
quick change cassettes

Exchange module - interchangeable cassette version Slide module
all layers (also center layer) adjustable by slides slides adjustable individually as well as synchronous optional adjustable encapsulation
Die head adaptor
Reifenhauser REIcofeed II Coex Feedblock Provides Flexibility in Layer Control
Coathanger channel
Index pins
Profiler Inline profile-adjustment
Central gap adjustment
40
REIcofeed II Provides Layer Consistancy When Resin Viscosities Change

Layer tolerances - different viscosities
Low viscosity layer High viscosity layer at die entrance in the film
After Feed Block adjusting
41
REIcofeed II Co-extrusion Feedblock
42
The Requirements for a Cast Film Extrusion Line Flat Die
Flat die-heads:
Various die designs up to 5000 mm width Automation with thermo bolts or fast-reacting translators Hardened die-lips as protection against scratches Optional internal deckling adjustable during production
43
The Requirements for a Cast Film Extrusion Line Automatic Die
Adjustment of the die gap with fast reaction time
Edge Encapsulation on a Reifenhauser T- Channel Die

from Edge Resin Extruder
Flow Splitter
Park Position
Main Coathanger Flow
45
The Requirements for a Cast Film Extrusion Line Casting Section
The Requirements for a Cast Film Extrusion Line Casting Section

Cast unit and haul-off:
motorized positioning of cast unit in height and longitudinal direction casting rolls with high temperature accurancy ( 1 C) on surface edge fixing by electrodes or air nozzles film threading unit as startup support angle-accurate drives for sensitive web tension control central operation panel, mounted at cast unit
The Requirements for a Cast Film Extrusion Copper Cooling Roll

Chrome surface Supporting inner shell
Copper shell
Copper cooling rolls for cast film process
48

Cooling process
Polymer Cooper cast roll Temperature Standard cast roll

Distance to the die exit
49

Advantages of copper shelled cooling rolls
Cooling water with higher temperature can be used with identical heat transfer times The total energy consumption of the chiller unit can be reduced The Line speed can be increased The line capacity can be increased The film quality can be improved
50
The Requirements of A Blown Film Line
EVOLUTION Ultra Range Extruders

Optimized barrier screw design for all kinds of polyolefins and barrier resins. Increased output rates combined with melt Temperature reduction. Best possible melt homogeneity to produce high quality products. Screw diameters from 50 to 200 mm
A wide variety of polymers and blends, such as LDPE, LLDPE, mLLDPE, EVA, Ionomers, MDPE, HDPE, PP, adhesives, CoPA, PA6, blends of PA, EVOH, COC, PETG, PS, K-Resin can be processed with outstanding homogeneity and optimal melt temperatures.
EVOLUTION Ultra Range Extruders for Barrier Film Lines

Flexible screw design for production of PE-LD, PE-LLD, PA, EVOH, K-resin, PETG without screw-change. Low temperature screws, high efficiency mixer. High output at reduced melt temperature. Grooved feed section and 26 and 30 L/D extruders. Armouring of barrels within the Reifenhauser group by Reiloy Metall GmbH. Own development, design and manufactoring of extruder screws. Extruder barrel with cooling and heating unit.
Centrifugal casting machine
Die Head
Function: Distribution of the multi-channel flow to a multi-layer annular flow Very good gauge tolerance of the individual layers Situation: Profile control smoothes the overall TD thickness Gravimetric system controls the MD tolerance Gauge tolerance of the individual layers can be influenced only by the design and accuracy of the inner die gaps and spiral mandrels
EVOLUTION Ultra Range Blown Film Die Heads

Our EVOLUTION Ultra Range Blown Film Die Heads are a synonym for best performance in the market.
Best Tolerances
Rheological optimized melt flow channels. Binary pre-distribution.
Flexibility in resin types regarding MFI, viscosity, etc. Very broad operating window of each individual layer.
Short melt flow channels / compact design. No dead spots / areas. Perfect self cleaning effect
Highest Flexibility
Fastest Product Change
The Requirements of A Blown Film Line
Collapsing Haul-off Turner Bar
The Requirements of the Blown Film Extrusion Line
Collapsing Frame with side guides or side gussets

Carbon fibre rollers = low weight low heat transfer Long collapsing frame with angle 8 -10 degrees Brush Rollers another option For sensitive film prone to creasing, carbon fibre side guiding elements can be used. PLA grades can be very stiff Latest development with multi-point adjustment
Tempering Rolls in the Haul-off Section Chrome-plated tempering rolls mounted after the haul-off with an Swrap Optimise the web flatness Reduces wrinkles
Thickness Measuring Thickness Regulation
Thickness Regulation C1: adjustment of air volume in a segmented upper chamber of the air ring C2: adjustment of temperature in a series of heaters around air ring
Automation
Production of multi-layer films leads to complex machine equipment and high numbers of film recipes
The automation has to assist the operator: Central operation and control of the entire system from one panel (temperature, screw rpm, throughput, profile control, width control, etc.) Touch screen panel for intuitive operation Preventive maintenance Recipe memory for exact repeat orders Reporting for quality control Easy handling, operation and maintenance
EVOLUTION C Base Automation

Integrated in a central pivoting operation panel using a Windows based industrial PC with 24" true color touch screen display and USB port. Complete and intuitive line control. Temperature control for extruders and die. Fast and well arranged 24 h trend display. Remote diagnostics via integrated VPN or modem. Power interruption shut down circuit to avoid bubble break in case of power failure up to 1 second.
Automation options: Color printer. EVOLUTION C Viewer EVOLUTION C Interface EVOLUTION C QIS EVOLUTION C IMS
Remote display of screens. to customers network. Storage of trends in a SQL data base up to 1 year. Information management system / alarm PLC.
62
EVOLUTION C Base Automation
63
Perfect Winding
Question: How important is winding for high-tech films? Answer: Very important! The film must leave the winder with the best quality The best quality is provided by the film, which must meets customers requirements The winder must guarantee economic film production Different winding modes and modules are necessary Only in cooperation with the other modules of a blown film extrusion line can the winder achieve the required film quality
Conclusions
Because the film market is constantly innovating, an extrusion line must be as flexible and as modular as possible to meet the changing market requirements
Quality Is Your Business Card!
Thank you very much for your attention
www.Reifenhauser.com www.Reifenhauser-Kiefel.com

S.despain SPI Film & Bag

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Multilayer Films for the Retail Market & the Film Systems Required to Produce Them

Mission Flexible Packaging Good Day Mr. Packaging Manufacturer!

Your Mission, Should You Decide To Accept It Is!

Better barrier properties Improved graphics More functionality, etc.

There are improvements out there for your use!

Look Around and See The Obvious

Eat some candy Take some medicine Make a salad

Trends in flexible packaging and industry

What are the functionalities for packaging?

Packaging and Polymers

U.S. Flexible Packaging Industry Overview

2005 $ 23.7 B 3.6 % 437 979 80 Thousand 273 Thousand

2010 $ 25.5 B 2.6 % 407 960 79 Thousand 322 Thousand

Source: FPA 2011 State of The Industry

U.S. Flexible Packaging Industry 2010

U.S. Flexible Packaging Industry 2010

2009 $ 23.7 B Flat Lower 10.9 % 2.6 %

2010 $ 25.5 B Higher Higher +7.3 % 2.8 %

2011 $ 27.5 B Up Slightly Higher +8.1 % 3.0 %

Converters Film and Resin Use By Category

Source: FPA 2010 State of the Industry Report preliminary data

Innovation and growth for barrier films

The More is Less Vision

Significant Market Opportunities

Packaging as Part of the Lifecycle of Food

Process Preparation and consumption

Value Chain of Suppliers

Packaging Manufacturer Retaile r

Historical Value Chain

Consumer goods company

Retailers Becoming More Influential In Packaging

Source: Strategic Analysis Inc.

Key Dynamics Effecting Retail Markets

Growing ethnic population Oil Prices

Distribution of Food Expenditures

Dual Income Families

Restaurants Vs. Stores

Work more. Less time to cook prepared meals

Retail Food Consumer Highlights

Flexible Packaging Market

Non-food, 23% Food Non-food Food, 77%

Estimated size $25.5 billion

Source: Progressive Grocer and FPA

Warehouse Club Effect

Impact on Flexible Packaging

TREND ANAYLSIS SEGMENTATION Packaging Format

Source: Strategic Analysis Inc.

TREND Increase in: Large unit multipacks Smaller unit multipacks

IMPACT ON FLEXIBLE PKG. Shrink Film Overwrap

Source: Strategic Analysis Inc.

Source: Strategic Analysis Inc.

Bundling Club Pack

Source: Strategic Analysis Inc.

Source: Strategic Analysis Inc.

81% of produce is still purchased from traditional grocery stores

Source: Strategic Analysis Inc.

Mastio & Company

Source: Strategic Analysis Inc.

Pet Food & Lawn & Garden Packaging

Source: Strategic Analysis Inc.

Internet / Mail Order

Source: Strategic Analysis Inc.

Point to Point Handling