Strictly-Extrusion

Microlayer technology developed by Extrusion Dies Industries, LLC (EDI) for thick film and sheet promises to extend the shelf life of retort, hot fill, and flexible food packaging, while increasing formability in thermoforming, the company announced today. EDI will feature the technology at K 2010 in a display of its innovative “layer multiplier” system (Hall 2, Stand G06).

At its Technology Center in Chippewa Falls, EDI (www.extrusiondies.com) is carrying out the first scientifically rigorous study of the benefits and limitations of layer multiplication, according to Gary D. Oliver, vice president of technology. “One result thus far is the development of a technique for selective multiplication of the barrier-resin layer of a multilayer film or sheet structure,” Oliver said. “By transforming a single layer of a resin such as EVOH into several microlayers, it is possible to reduce oxygen transmission rate (OTR) by 60 to 80%. And while EVOH is a crystalline, relatively brittle material, replacing a single thick layer with multiple microlayers increases formability for thermoforming and flexibility for vacuum skin packaging.”

The resulting benefits for food packaging include:

● Prolonged shelf life. Besides reducing OTR, layer multiplication substantially reduces total oxygen ingress over an extended period.

● Enhanced quality and lower material consumption.  In the case of deep-draw containers where corner-thinning has been a problem with less formable materials, for example, multiplication of the EVOH layer may eliminate the need to offset thinning by increasing sheet thickness.

An Advanced Layer Multiplier and Its Benefits for Food Packaging

The layer multiplier is a special tool that can be engineered to multiply some or all of the layers within a coextrusion “sandwich” provided by a feedblock. The resulting microlayer structure then passes into the manifold of an extrusion die, where it is transformed into film or sheet of target width and thickness profile. No matter how many microlayers there are in the structure, the overall thickness is no greater than that of a conventional coextrusion, and the structure contains the same amount of raw material.

In 2009, EDI introduced an advanced system that is easier to deploy, more compact, more accurate, and more versatile than any other layer multiplier, including one previously offered by EDI. It is available to purchasers without licensing or royalties.

In the research at its Technology Center, EDI used its new system to multiply the EVOH core layer in sheet used for thermoforming single-portion retort cups, such as those for packaging fruit cocktail and diced peaches. EDI extruded the sheet and used a commercial cup mold to solid-phase pressure form sheet with one, four, eight, and sixteen EVOH layers.

All sheet structures were 50 mils in thickness, with thick (41 to 43%) skin layers of polypropylene and tie layers between the skins and the EVOH core. Barrier resins included a standard general-purpose EVOH and a “retort” grade of EVOH.

Thirty days after retort, cups with a single layer of the “retort” grade of EVOH exhibited three to six times higher oxygen transmission rates (OTRs) than cups where a layer of similar material had been multiplied. In that same period, total oxygen ingress was also three to six times greater.

Gruber Extrusion (www.gruberextrusion.com) will use battenfeld-cincinnati extruders exclusively in all turnkey projects worldwide. All downstream equipment such as extrusion lines and calibration tables will come from Gruber Extrusion. The new partnership was sealed at the AMI Conference in Vienna on 16 May 2010, marking the second anniversary of the cooperation between Gruber Extrusion and Cincinnati Extrusion and the brand merger of Battenfeld Extrusionstechnik and Cincinnati Extrusion (as battenfeld-cincinnati).

Gloucester Engineering announced they have shipped a 4000mm, 7-Layer Cast Stretch Film Line to Scientex Packaging Film Sdn Bhd, a wholly owned subsidiary of Scientex Berhad. The line is scheduled to be commissioned in August of 2010. Click here for more information.

The recent stimulus initiatives and increased R&D spending by the U.S. government have proved advantageous for Davis-Standard’s Specialty Systems Group. Several new projects are underway that involve Davis-Standard equipment and development services. These include development of a more effective solar energy collection device, an improved industrial battery and advances in renewable energy. Recycling of different materials, including those derived from renewable resources, is also an area of growth.
Simon Dominey, Manager of the Specialty Systems Group, said Davis-Standard customers are working on new materials and processes for these interesting applications. According to Dominey, most of the projects are in the U.S.
“The majority of projects are still confidential, although some information may soon be released for a few applications,” he said. “Many unique solutions that will bring value to the marketplace are being developed. Some are as simple as careful web handling while others involve reactive processing and chemical modification. Particularly fascinating is learning about how non-conventional materials behave in processing and in end applications. It is an exciting time to be in the R&D business.”
Davis-Standard manufactures a complete line of laboratory and specialty equipment for nearly every extrusion application. The company’s versatile Killion product line is engineered for precision laboratory and mid-size production and includes everything from bench model and adjustable height extruders to downstream equipment and turnkey systems. This equipment can be used with a variety of polymers and compounds, and is easily adaptable to processing corrosive polymers, high temperature materials, and non-thermoplastics. Components can be customized to meet specific processing requirements and conditions.
To find out how Davis-Standard can support your R&D efforts, contact Simon Dominey at sdominey@davis-standard.com.

A devastating facility fire in April 2009 could have spelled disaster for North America’s largest picture frame manufacturer, MCS Industries. The company’s subsidiary corporation in northern Mexico, MCS de Mexico, burned to the ground and brought over 30 percent of the company’s production to a temporary halt. Despite an uphill battle and countless challenges, MCS turned a difficult situation into a fresh start. In only eight months, a new MCS corporation, TFM, emerged from the ashes in an impressive 233,000 square-foot (21,645 square-meter) “green” facility with extensive recycling capabilities. Davis-Standard was the primary machinery supplier, equipping TFM with over 30 extruders, a sheet line, and a reclaim line to support the company’s environmental initiatives and increased capacity. In less than a year since the incident, TFM is 95 percent operational and manufacturing hundreds of decorative home products in a sustainable manner.

“We were overwhelmed when the Mexico plant burned down,” said Richard Master, Chairman and CEO of MCS Industries. “Instead of focusing on all the negatives of the situation, we decided to rebuild a facility that would be larger, better, faster and environmentally sustainable. Davis-Standard was an integral part of that process and exceptionally receptive. They supplied the equipment we needed under very tight deadlines. Our throughput has increased by over 10 percent, and over 50 percent of the products manufactured at TFM are made from recycled material. It has been an exciting venture across the board.”

The new factory has the capacity to produce over 80,000 picture frames per day from start to finish, including coextrusion, foiling and embossing capabilities. According to Master, Davis-Standard’s equipment plays a role in all of these processes and is essential to MCS’s vertically integrated operation. Davis-Standard also customized the equipment and provided proprietary feedscrew technology to support TFM’s aggressive recycling efforts.

All of the profiles manufactured at the new facility are made of recycled plastic. TFM has the capacity to recycle 10 million pounds of polystyrene and Styrofoam per year. To achieve this goal, MCS has established collection points where material is either compressed or melted down for transportation to the TFM facility. These materials are then mixed with additives resulting in a usable plastic pellet that can then be made into a product.

“We take materials that would ordinarily end up in a landfill and extrude them into a profile that can be laminated, embossed, and decorated to create the beautiful finishes required by sophisticated American consumers,” said Dallas Kohler, Director of Engineering for MCS. “This fits in well with the green initiatives practiced by our customers, which comprise 2,000 retailers throughout North America.”

Kohler noted that in addition to recycling, the energy saving features built into the facility combined with Davis-Standard’s equipment have helped TFM reach power usage goals. Davis-Standard’s engineering efforts and on-site operator training has helped optimize extrusion efficiencies. The facility’s fluorescent lighting system with motion sensors saves enough energy to supply power to 36 average size homes. The equipment cooling system saves 720,000 gallons of water per year, enough to supply 11 average size homes. Skylights provide natural lighting during the daytime hours. These are just a few examples of sustainable manufacturing practices that make TFM and MCS proud.

For more information about MCS or TFM, visit www.mcsframes.com. For more information about Davis-Standard’s recycling, sheet or profile capabilities, visit www.davis-standard.com.

or how to promote your products online…

Strictly-Extrusion (www.strictly-extrusion.com), the largest online platform of the extrusion industry, celebrates its 10th anniversary. Thank you for your support and feedback. And now we want to give you something back, or in other words: Tips & Tricks to promote your products and services online and get enquiries from potential customers.

Press Releases:
Online Press Releases are certainly one of the best ways to promote your extrusion products and services. But consider following:

• Short, fact-bound, avoid blah blah: Nowadays professionals in the extrusion industry have no time to read long-drawn-out press releases. Come to the point and keep it short, and fact-bound. Tell what is different from your competitors rather than use terms such as “the best” “unique” etc… Professional decision makers know how to judge.

• Use key words: This is the main difference to its printed counterpart. Online press releases live from keywords! Think about functional key words which describe your products or services. This is important to get found in Search Engines later. To get new keyword ideas you can also use Googles Keyword Tool.
• Send us your Press Release: The structure and content of Strictly-Extrusion is very Search Engine-friendly. Many of the published press releases, can be found by Google & Co shortly afterwards. AND: your press release will never get “lost” because of our search engine friendly “Archive”.
• Use pictures, even better simulations/animations: Our statistics show that such of press release are more read.
• Imperial vs. Metric: Press releases live from figures and performance data. And you don’t want your potential customer to figure out conversion factors between imperial and metric. If you are an international operating company, use both, e.g. “…the part weight of only 1 lb (0.453 kg)…”
  
• Use the free press releases services: Frankly speaking, almost no extrusion insider will visit these websites to read your article. But again, search engines browse through and you will get found. Also very useful for accessories and niche products. Sample Site: www.freepressreleases.co.uk , www.1888pressrelease.com , www.free-press-release-center.info

Supplier Directory:

• List your company in our Supplier Directory: It is the largest directory of the extrusion industry for equipment, parts and extruded products. And it is for free. Click here.

If you have any suggestions or ideas how to further promote your products or services, please contact us. We listen.

Your Strictly-Extrusion team!
www.strictly-extrusion.com