Extrusion International 6-2024-USA

52 Extrusion International 6/2024 BLOWN FILM – CASE STUDY Production of Flexible Monomaterial Packaging – MDO Plant in Latin America The Colombian packaging manufacturer Microplast Coldeplast, based in Medellín, has invested for the first time in a 5-layer blown film line with inline MDO from Hosokawa Alpine. The plant went into operation in 2023 and produces PE and MDO-PE films for various laminating films, which are then used in flexible packaging solutions. This not only increases the company's production capacity, but also contributes to the circular economy in the packaging industry. M onomaterial packaging – i.e. packaging that consists only of polyethylene – has a decisive advantage over plastic packaging that combines different materials such as PE, PET, PP or PA: it is much easier to recycle and can be reused for end products after the recycling process without any loss of mate- rial. This makes full PE packaging a much more sustainable solution than other packaging materials and also complies with the principles of the circular economy. The desire for more recyclable packaging so- lutions also drove the Colombian company Microplast Coldeplast: "In many markets, the demand for re- cyclable packaging has risen sharply or is even encouraged by laws and government regulations. To remain competitive in the long term and open up new markets, we need to adapt our technology," says Lina Fajardo, Head of Technical Market- ing and Sustainability at Microplast Coldeplast. Hand in hand for more sustainability The company has been produc- ing flexible packaging solutions at two production sites in Medellín since 1956, including for food, pet food, household and care products and building materials. Microplast Coldeplast mainly processes PE, PET, BOPP, PA, aluminium and paper and supplies its customers with rolls and bags. In line with its corporate strategy and global market trends, the company needed to increase its production capacity and make its products more recyclable. Al, PET and BOPP should therefore be replaced by PE monomaterial solu- tions in some laminations. In search of a partner to realise this project, Microplast Coldeplast turned to Ho- sokawa Alpine. The decisive factor in this decision was the global ex- perience that the Augsburg-based machine and plant manufacturer has in the field of full PE packag - ing solutions. "As a pioneer in MDO technology, we have been working with monoaxial stretching of blown film for over 25 years. Over 100 of our systems are in use around the world," says Marcelo Gräf, Senior Sales Manager at Hosokawa Alpine. The company relies on customised systems that are developed and adapted specifically for the custom - er's product. Optimised film properties and reduced material consumption The MDO process begins with a heating phase: here, the film is con - veyed on heated rolls and brought to the ideal temperature. In the fol- lowing stretching phase, the film is stretched between two rollers to achieve the desired stretching ratio. At the same time, thefilmthickness is reduced, while optical and mechani- cal properties such as transparency, rigidity and barrier properties are improved. "The thinner film thick - ness reduces the amount of mate- rial required. This not only conserves resources, but also saves on material costs," explains Gräf. Temper roll- ers then reduce the stresses created during stretching. The film then runs over two chill rollers and is brought to a suitable temperature for wind- ing. Depending on the application, the film runs over a total of eight to Susanne Schwenk, Project Manager Marketing, Business Unit Blown Film, Hosokawa Alpine AG Microplast Coldeplast produces full PE films for various flexible packaging solutions on a 5-layer blown film line from Hosokawa Alpine