Flat Die PET Film: Innovative Extrusion Lines
Flat Die PET Film: Innovative Extrusion Lines
Flat Die PET Film: Innovative Extrusion Lines
Bandera history
1943 the first extruder was manufactured
in Luigi Bandera’s first workshop
1947
Costruzioni Meccaniche Luigi Bandera
officially started operating
1950
the company turned
into a joint stock company
2 (packaging/converting/agrifilm)
The way we are
Honesty, directness and respect are the main ingredients of
our everyday life. Our founder Luigi Bandera used to say the
essential asset held by his company is people and their value.
25,000
days of experience
in extrusion since 1947
15,550
active clients
all over the world
35,000
extruders installed
worldwide
in house design
and manufacturing
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Innovation
is a state of mind
Extrusion intelligence
The concept of extrusion intelligence is the essence of
®
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Bandera innovation
a synonym for excellence
Since 2000s, Bandera has developed and improved
a cutting edge extrusion system for the production
of PET sheet and foil from both virgin material and
recycled PET.
Up to the present, this unique Bandera co-rotating
twin-screw technology has been applied to more than
150 extrusion lines for the production of high quality Bandera is a
PET sheet and foil.
Bandera extrusion line achievable throughput exceeds
worldwide leader
2.5 tons per hour. Raw material standard composition -
for the twin-screw “core” layer - is 100% recycled PET
in designing and
flakes from post-consumer PET bottles and/or PET
skeleton waste from thermoforming and/or PET regrind
manufacturing top
bottle pre-forms. Bandera customers usually include performance
some virgin PET material as external capping layers
(functional barrier: up to 7.5% each layer) to obtain the flat die PET extrusion lines
classic A-B-A structure.
Flexibility on engineering
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Twin screw technology,
the ground-breaking concept
for PET processing
During the late 90‘s, on the basis of the very limited single screw
results obtainable, Bandera R&D Dept. focused its attention
on the co-rotating highly vented twin-screw extrusion
(HVTSE) technology, specially designed for the direct PET
Film production.
Ranging among the world leading twin-screw extruder
producers, Bandera has manufactured a dedicated PET
processing machine ready for testing within a few weeks...
Polishing and cooling calender
for PET rigid film (0.12 mm - 1.6 mm)
From the very beginning, results proved to be definitely
encouraging for both Bandera and its customers. By the end
of 1999, the first PET sheet extrusion line was successfully
installed in southern Italy (it featured a double twin screw
configuration). Bandera technology was promptly patented.
feeding zone
L/D 52
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Twin-screw technology
main advantages:
the energy saving concept
Power saving: power consumption up to ~ 35%
lower than conventional technologies.
ENERGY
CONSUMPTION
VI NG
A
OS TS
RC
POWE
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(no degassing)
Mission: safety,
energy saving, recycling
Bandera is focused, on two core aspects:
• Extrusion line safety operation condition
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Twin-screw technology main
advantages: best flexibility
• Superior flexibility in extruding alternative thermoplastic
materials (PLA - PS - PP) intended for packaging.
No screw replacement required, with excellent output levels
if compared with single screw extrusion technology and
twin screw extruders by other manufacturers.
Screw and barrel - co-rotating twin screw extruder Dosing system for both virgin and reground raw materials
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Twin-screw technology
main advantages:
best melt purification
Enhanced venting sections and empowered
vacuum pumps for maintenance-free
and high purification results.
Reliable venting and degassing sections with empowered
vacuum pumps - 10÷15 mbar residual vacuum - with very low
maintenance need and a very high melt purification effect
(FDA approved) easy extraction of unwanted volatile materials,
interstitial gas, residual moisture, oligomers, aldehydes and
any carbonious materials.
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extrusion line
TECHNICAL DATA
Line Type 3-layer CoEx-Sheet-Line plus lamination -
high production
Dosing Unit Loss in weight dosing unit
Extruders Co-rotating twin screw with very Innovative multi-layers PET
long, high vacuum venting unit; sheet complete extrusion line
TR90 35D single screw with Reiloy 90 mm for rigid and thermoformed
barrel, air cooled and grooved feeding food packaging, with
zones, barrier screws • Largest production output
Die Head 3-layer slot-die-head with decklers • Availability of net foil width up
to 2 m
Calender 3 rolls horizontal cooling & polishing
• Highest level of energy
calendar stack; integrated lamination or
consumption savings
extrusion coating unit available on request
• Fully automatic production skill
Thickness control Control by air cushion sensor
Haul Off With silicon coating device and dryer are
combined in one unique frame
Foil accumulator Double rack with stock capacity 40 m, to
slow down line speed during reels changing
operations
Winding Automatic Multi-reel winder Revolver Type;
Line Control Touchscreen, Bandera IOE software
®
Typical applications
General packaging, food packaging, thermoforming foil or
similar applications.
RAW MATERIALS
Regrind or virgin PET (APET-CPET-GPET-EPET),
PP, PS, PLA or further resins
Foil width Up to 2000 mm net
TECHNICAL DATA
Line Type 3-layer CoEx-Sheet-Line plus lamination
Innovative multi-layers PET
Dosing Unit Loss in weight dosing unit
sheet complete extrusion line
for rigid and thermoformed Extruders Co-rotating twin screw with high vacuum
food packages, with very high venting unit;
production output Single screw air cooled highly vented
• Top accessories fully equipped
Die Head 3-layer flat die with internal decklers
• Best thickness tollerances
• Specialised for highest Calender 3 rolls horizontal cooling & polishing
standard quality PET films calender stack; Integrated lamination or
• Available also for TDO labels extrusion coating unit available on request
films and furniture special films Thickness control Control by air cushion sensor
• Dedicated also to new Haul Off With silicon coating device and dryer
applications of PET thin films combined in one unique frame
as credit card films sector
Foil accumulator Double rack to slow down line speed during
reels changing operations
Winding Semi automatic 2-station cantilever winder
with drive management by PLC;
Max reel diameter 1200 mm
Line Control Touchscreen, Bandera IOE software
®
Dimensions
Length 35.000 mm
Width 9000 mm
Height 6000 mm
Typical applications
General packaging foil, food packaging foil, thermoforming
foil or similar applications.
RAW MATERIALS
Regrind or virgin PET (APET-CPET-GPET-EPET),
PP, PS, PLA or further resins
Foil width Up to 1450 mm net
Typical applications
General packaging foil, food packaging foil, thermoforming
foil or similar applications.
RAW MATERIALS
Regrind or virgin PET (APET-CPET-GPET-EPET),
PP, PS, PLA or further resins
Foil width Up to 1300 mm net
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Cost effective innovative
multi-layer PET/PP or PS/PP
complete sheet extrusion line
for the production of rigid
thermoformed packages
(IN-LINE version available)
• Dedicated to thermoforming application (IN-LINE
configuration)
• Best thickness range availability
• Limited floor space requirement
• Very competitive price
• Maximum flexibility on raw materials
• Available also with medium/small outputs
• Extrusion section with main co-rotating twin screw extruder
or single screw extruder
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Rigid film lines for
converting application Innovative multi-layers PET
sheet complete extrusion line
Agility Line Series for rigid and thermoformed
food packages, with very high
TECHNICAL DATA production output
Line Type 3-layer CoEx-Sheet-Line plus lamination • Fully automatic operation
including PE film lamination
Dosing Unit Loss in weight dosing unit process
Extruders Co-rotating twin screw with high vacuum • Complete with raw material
venting unit feeding equipment and
Single screw air cooled automatic winding unit even in
limited floor space requirement
Die Head 3-layer flat die with internal deckles
• Whole complete production
Calender 3 rolls horizontal cooling & polishing platform with “plug & play”
calender stack modular installation
Thickness Control by air cushion sensor • Dedicated to short production
Winding 2-station auto revolver winder with drive slots avoiding scraps
management by PLC, automatic foil
cutting and threading, reel diameter max
800 mm
Line Control Touchscreen, Bandera IOE software
®
Typical applications
Form, fill, seal and converting application plus food and
thermoforming foil.
RAW MATERIALS
Recycling or virgin PET (APET-CPET-GPET),
PP, PS, PLA or further resins Dimensions
Foil width Up to 860 mm net Length 12.000 mm
{
TIE PE VIRGIN MATERIAL
RESINS (LAYER A)
A
B
A PET FOIL
TIE RESINS PE
EVOH
TIE RESINS VIRGIN MATERIAL
(LAYER A)
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B
A
100% RECYCLED PET (LAYER B)
New packaging solutions
In line extrusion coating
IN-LINE COATING TECHNOLOGY
Coating section
The IN-LINE coating system allows the user to have full
flexibility in terms of raw material choice and management,
thus resulting in large potential reduction of production costs
compared to standard multi-layer film technology.
A PET FOIL
Bandera technology can be applied to PP and PS sheet and B
COATING
LAYERS
{
TIE RESINS PE
EVOH VIRGIN MATERIAL
TIE RESINS (LAYER A)
A
B
A
100% RECYCLED PET (LAYER B)
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The ultimate innovative solutions:
lowering packages weight
STRUCTURAL FOAM PET SHEET TECHNOLOGY PATENTED
AMAZING FLEXIBILITY
A standard Bandera PET rigid sheet extrusion line can be
versatilely converted to foam PET sheet production
(universal extrusion twin screws design for both rigid and foam
PET production) by adding an appropriate gas injection system
and process adjuvants. To obtain a superior quality foam
PET sheet, Bandera is able to supply dedicated extrusion
equipment to optimize the whole extrusion process.
The same principe can be developed by using alternative resins
such as PLA, PS,...
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E-PET film
Results obtained by Bandera R&D are definitely interesting
and encouraging. Typical PET density is 1.33 ÷ 1.35 kg/dm3.
In case of ABA or BBB structure (B layer being 100% Post
Consumer Waste - mixed with industrial skeleton waste) weight
reduction values are the following:
R APET V
R PCR PET Density ~
= 0,95 ÷1.05 kg/dm3
PCR E-PET
R PCR PET Sheet thickness 0.74 µm
R APET V
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Lowering packages weight?
Ask Bandera
Lighter Packaging
®
campaign.
Advantages of Bandera
as technological partner
in flat die technology
Over the recent months Bandera has managed to strengthen its
leading position on packaging market worldwide - the supply of
several A-PET, C-PET, PET-G, PP, PS and PLA sheet extrusion
lines has ranked the renowned Italian company on top of major
extrusion companies. Several Bandera customers are major
suppliers of packaging products for the most important food
industries worldwide, outstanding for the following:
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OEEE
OVERALL EXTRUSION
EQUIPMENT
EFFECTIVENESS CONCEPT
OEE - Overall Equipment Effectiveness - index has originally
been applied to Lean Production System.
Bandera OEEE has now been adapted to film extrusion
production working on 3 key concepts:
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Close to Top loyalty
our customers level
More than 150
Headquarters
PET lines sold in the world 2000-2016 complete PET lines
Service centres
• Germany
installed worldwide,
• Brazil since 2000,
• China
with full customers’
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• Indonesia
• Canada satisfaction
Bandera developments
in North America PET and PLA
From the end of 2010 up today Bandera assembled several
HVTSE corotating twin-screw extruder at the largest north
American processors in the thermoformable PET and PLA
rigid film extrusion sector. Downstream line section has been
designed and manufactured by PTI Processing Technologies
International LLC. Bandera and PTI Processing Technologies
International LLC entered a 10-year agreement for the supply
of the extrusion lines within North American region. Besides a
PLA foil output to reach 2500 kg/h, the large sized extruder is
equipped with a powerful cutting-edge degassing unit for the
extrusion of top-quality PET foil. 27
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briefinglab.com
You and Bandera, inside the new markets of PS/PP/PET
and PLA rigid and semi-foamed packaging films, will drastically
reduce energy consumption, extensively widen the usage of
recycled and biodegradable materials, process challenging
new applications for lower weight packages and now,
exclusively with Bandera, speed up the Overall Extrusion
Equipment Effectiveness (OEEE), by the specific instruction ®
Top packaging
and converting solutions