Layout of blown-film line

First direct extrusion technology for production of multi-layer blown films

  • Employment of twin-screw extruder: no need for pre-drying or compounding
  • High filler levels of up to 50% possible
  • Improved film strength and film stiffness

Under the name “Evolution Ultra Fusion”, the company Reifenhäuser Kiefel Extrusion has introduced the first direct extrusion technology for the production of multi-layer blown. The new technology is intended to increase productivity and energy efficiency, and to reduce production costs. Tests conducted under production conditions in the Technology Center of Reifenhäuser Kiefel Extrusion confirm the advantages initially presented at K 2013, according to the company. Now, the technology will be further developed for commercial use.

The Evolution Ultra Fusion technology processes raw materials directly, without previous pre-drying and compounding, by employing a twin-screw extruder of the REItruder series directly in a blown film line. Compared with the processing of compounds and masterbaches, the direct extrusion technology can reduce the production costs for 3-layer blown films by more than 15 percent. The technology shows its full savings potential particularly in the production of filled multi-layer films in which expensive raw materials like polyethylene, are replaced in part with lower-priced fillers such as calcium carbonate (CaCO3). The technology enables producers to process especially high filling amounts of up to 50 percent. This allows to reduce production costs by about 20 percent. In addition to cost savings, the high filling amounts have a positive effect on the film properties: film strength and film stiffness are increased while elongation is reduced. Furthermore, special properties can be obtained with this technology, for example those needed for the production of breathable films.

Possible applications for the new technology:

  • Packaging bags for flower soil and peat
  • Compression bag film
  • Breathable and non-breathable diaper backsheets
  • Breathable film
  • Bio film, for example PLA plus filler

Evolution Ultra Fusion can already be tested by customers in the world’s largest Technology Center for the production of nonwovens, films and wood polymer composites at the company’s site in Troisdorf.


REItruder twin-screw extruder

The REItruder twin-screw extruder in a blown film line increases productivity and energy efficiency and enables the use of 50 percent of fillers, due to the direct extrusion (source: Reifenhäuser Kiefel Extrusion)

Main Picture: a typical line configuration of the Evolution Ultra Fusion technology (source: Reifenhäuser Kiefel Extrusion)


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