Agricultural Film 2012

Agricultural Film 2012

www.luigibandera.com 1

Breaking news ďƒ˜

BANDERA ran the biggest five-layer blown film line in the world for agriculture purposes at Ardeer plant, Scotland

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ďƒ˜ 5-Layer Die Ă˜ 2000 mm to produce up to 20 m open width agrifilm

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Bandera Production Program -1 Mono & Multilayer Complete Lines for Agrifilm & Geomembrane Extrusion

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Bandera Production Program -2 ďƒ˜ Extruders up to TR 220 screw diameter Extrusion Heads: 1, 3 & 5 layers Take-off up to 8.000 mm width, with collapsing frame & gusseting devices up to 20 m long Winders: automatic type, up to 6.000 mm width, for small & big rolls Wide choice of Peripherals and Attachments

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Bandera Single–Screw Extruders TYPE

SCREW DIAMETER

mm

L/D RATIO

TR 85

TR 100

TR 120

TR 140

TR 160

TR 180

TR 200

TR 220

85

100

120

140

160

180

200

220

30

30

30

30

30

30

30

30

HEATING ZONES

n°

6

6

7

8

8

9

9

9

AC MOTOR

kw

132

160

250

315

400

500

560

710

OUTPUT (LDPE 0.7)

kg/h

300

400

550

700

850

1.150

1.400

1.800

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Bandera Extrusion Heads 3-Layer Agrifilm Lines: die diameter up to 2500 mm for 24 meters open width film.

5-Layer Agrifilm Lines: die diameter up to 2200 mm for 20 meters open width film.

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Bandera Extrusion Hardware Solution (3-layer) Agrifilm Open Width (m) *

Die Ø (mm)

Coex 3-Layer Configuration

Output (kg/h)

4-6

700

TR 100 + 2*TR 85

700

5 - 10

1.000

TR 120 + 2*TR 100

1.000

6 - 11

1.200

TR 140 + 2*TR 100

1.200

7 - 12

1.400

TR 140 + 2*TR 120

1.400

8 - 14

1.600

TR 160 + 2*TR 120

1.600

9 - 16

1.800

TR 180 + 2*TR 120

1.800

10 - 18

2.000

TR 180 + 2*TR 140

2.000

12 - 20

2.500

TR 200 + 2*TR 140

2.400

•for BUR between 1.6 to 2.7, running LDPE & LLDPE based blends recipes, up to 220μ. Layers typical ratio 1:1:1 and 1:2:1

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Bandera Extrusion Hardware Solution (5-layer)

For BUR between 1.6 to 2.7, running LDPE & LLDPE based blends recipes, up to 220 Îź. % of each layer: up to 30%. Possibility to run barrier resins as PA and EVOH.

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Bandera Take - Off Fixed Take-Off Type, With Upper Nip Rollers working Width from 2.500 mm up to 8.000 mm Collapsing Frame & Gusseting from 8 to 20 m long, motorized and with remote control. Tilting system

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Bandera Take - Off Agrifilm Open Width (m)

Collapsing Frame & Gusseting lenght (m)

Take-Off & Winder Width (mm) 4-fold rolls

Winder Width (mm) 8-fold rolls

4-6

6

2.000

-

5-8

8

2.500

-

7 - 10

10

3.000

2.000

8 - 12

12

3.500

2.000

9 - 13

14

4.000

2.500

10 - 15

16

4.500

2.500

12 - 16

16

4.500

2.500

14 - 20

18

5.500

3.000

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Bandera Winders For Agrifilm -1 Automatic Surface and Axial Winders, mono & double station, working width from 2.500 mm up to 6.000 mm, featuring 3”, 5” and 6” expansion shafts, for big (jumbo) rolls (ASN Type).

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Bandera Winders For Agrifilm -2 Automatic Shaftless Winders, from 2.500 mm up to 5.000 mm for small length rolls (New TA Type), up to 30 rolls changes per hour

Shaftless winder for Ă˜ 400 mm reels (8 times C-Folded agrifilm) 13

Bandera Winders For Geomembranes Full- automatic Geomembrane winders. 7500 mm width

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Bandera Peripherals & Attachments-1 Take off unit ‘C’ Folding unit Flattening device

Calibrating Basket

Double Station Winder

Blown film die + Extruders Typical agrifilm line Layout

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Bandera Peripherals & Attachments -2 New generations of Air control Rings, designed for Agrifilm production (high thickness, low MFI grades, low BUR) with Gauge Control Device built –in: A) Manual Sector Flow Control with Flaps manually adjusted by means of thread bolts for sector wise manipulation of main cooling air volume

B) Fully motorized Sector Flow control for Sector wise Manipulation of main cooling air volume

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Bandera Peripherals & Attachments -3 2500 mm: 3-layer Coextrusion Die for both agricultural & geomembrane applications

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Bandera Peripherals & Attachments - 4 “C�-Folder Device to fold the agrifilm 8 times (e.g. 16 m open width film to about 2 m C-folded finished rolls).

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Bandera Peripherals & Attachments -5 Automatic Reels Extraction device

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Bandera Peripherals & Attachments -6 Device for Vineyard Film (agrifilm with different thickness at web edges and center)

Multicomponent Gravimetric Feeding & Dosing System

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Bandera Blown film & Geo lines Locations

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Bandera Latest Main Installation -1 Coex 5 layer line with Ă˜ 1400 mm die For Agrifilm. Mexico

Coex 3 layer line with Ă˜ 2000 mm die for geomembrane. Egypt 22

Bandera Latest Main Installation -2 Coex 5 layer Line with Ă˜ 2000 mm die for agrifilm (UK)

Coex 3 layer line with Ă˜ 1600 mm die for agrifilm

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Bandera Latest Main Installation -3

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Agrifilms: Main Applications 1) Silage: -Silo Bags -Bale Wrapping (silo – Agristrech) 2) Mulching 3) Fumigation film 4) Low Tunnels 5) Greenhouses Cover Film 25

Silage -1 Temporary silos, liners for grain storage facilities, ground sheets, bale covers Silage of grass, corn: storage away from oxygen (PE film) to speed up fermentation

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Silage -2 • Mainly: co-extrusion black / white layer (3 & 5 film) Thickness: 80 ÷ 250 μ Excellent physical mechanical performance (tearing and perforation)

• Polymers: LDPE + increasing use of LLDPE and mLLDPE (Silo bags, up to 80%).

Also high % of reclaimed material.

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The Straight Story: Multilayered Film For Silo Bags-1 The first Silo Bags were introduced in North America in early 1990. Their primary function was the storage of hay and forage.

During this decade, in Argentina, some manufacturers of plastic films for agriculture have extended the use of the Silo Bag to the storage of cereals, rice, soy and grain.

Currently the Silo Bags are widely used in various countries beyond the American continent, among which particularly strong consumers are Australia, South Africa, Russia and Ukraine.

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The Straight Story: Multilayered Film For Silo Bags-2 The advantages of the Bags for Silo compared with the systems of traditional storage in metallic Silos are: ▪Least starting investment ▪Ideal also for small storages and for biological agriculture cereals ▪It allows an elevated hourly output both in entry and in extraction of the siled product ▪It doesn't need building authorizations ▪It doesn't need ant parasitical treatments ▪It requires low costs of cleaning and maintenance.

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The straight story: multilayer film for silo bags-3 Inside the bag for silo a low fermentation (anaerobic) is produced by natural way that leads to the formation of CO2 and lactic acid, which inhibit the growth of mould and parasites.

Generally a perfect maintenance up to 18 / 24 months can be reached for the product siled inside the Bag for Silo.

Bandera is world leader company in Design & Manufacturing of Equipment for the production of coextruded 3 layers film for Bag for Silo.

Bandera has recently introduced the 5 layers technology for the production of film for Silo Bag, in the most common and commercial sizes, that is 9, 10, 12 & 14 feet.

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The Straight Story: Multilayer Film For Silo Bags-4 The application to produce this film with 5 layers technology arises from the following demands: ▪ Reduction of the total thickness of the film, retaining the original mechanical features ▪ Reduction of the cost of formulation thanks to the possibility of using different resins or of lower cost ▪ Possibility to use resins with barrier feature (polyamide and EVOH type) to lengthen the period of maintenance of the ensiled products, over 18 months ▪ Possibility to encapsulate additives and more expensive dyes (or with tendency to the degradation) on the middle layers to increase the duration of the Bag for Silo once placed on the field.

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Bale Wrapping Wrapping silage of hay: storage away from oxygen in wrapped bales using a stretchable film Films: Thin films 15 á 23 ¾ (3 & 5 layer film) Duration: 1 or more years (with barrier PA) Good abuse property Sticky properties Polymers: LLDPE (C8) + tackifier agent (6% PIB) EVA (%VA>18%); also VLLDPE as tackifier.

Liquid PIB injection from back of the screw Developments: EVA: reduction of the PIB content down gauging + puncture resistance.

PA/EVOH: barrier effect against oxidation of outside layers of the bale

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Mulching LDPE film: conservation soil moisture & water management + reduction of weed growing & thermal (transparent films) Raise soil temp. For better and earlier crops Films: Black 60-90 µm films: wine yards, trees Black 15-50 µm films: strawberries, cucumbers Coloured films special requirement (virus control) Transparent 15-50 µm films: salads, ...

12 µm "photo-degradable" films : corn, cotton 3 & 5 layer film for longer life Polymers: Thick films: LDPE + carbon black Thin films: LDPE + LLDPE (> 40 %) blends EVA for thermal and special applications 33

Mulching Developments:

More LLDPE ďƒ° down-gauging Playing with layers: different materials properties (WV barrier, mechanical, colour‌).

Use of biodegradable & compostable resins for environment protection.

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Film for soil fumigation Reduction in the use of fumigants such as methyl bromide by try to brake the emissions during the treatment and keep more active gas in the soil using plastic films more gastight VIF / TIF films 3 & 5 layer film, with PA or EVOH barrier layers for gas low-permeability

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Film for soil fumigation The VIF (with PA) / TIF films (with EVOH) are the best way : -to reduce Methyl Bromide emissions in the atmosphere (and the amount to be used by the farmer) -to improve efficiency of the treatment (same surface with less Methyl Bromide) 3-Layer

5-layer

PE/PA/PE 30 micron film Permeability to Methyl Bromide 0.18 g/m2/h

PE/tie/PA or EVOH /tie/PE 25 micron film Permeability to Methyl Bromide < 0.07 g/m2/h

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Low (walk-in) tunnels Protection against wind, rain, thermal variations.

Crop Protection Greenhouse Effect.

Earlier crops. Late Crops

Films: Thickness: 30 - 100 Âľ Duration: 1 year Standard transparent films: salad, ...

Transparent thermal films: strawberry, ...

Light diffusion thermal films: melons, ...

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Low (walk-in) Tunnels Polymers: LDPE or coext LDPE/LLDPE EVA (14 % or 18 %) for thermal films EVA + charge for light diffusion films

Developments: More and more coextrusion with LLDPE (down gauging, down to 30 Âľ...)

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Greenhouses cover Film Greenhouses: 3 á 12 meters wide tunnels Protection against wind, rain, temperature control. Crop protection Greenhouse effect.

Earlier harvests and higher yields Films: Thickness: 120 to 220 Âľm Duration: 2 to 4 seasons Actually 1 & 3 layer film, but strong trend to 5-layer Polymers: LDPE, LLDPE, mLLDPE EVA + charge + anti-UV additives PA for barrier and mechanical properties

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Greenhouses cover Film Developments: Virgin resins + UV master batches Substitution of quencher-nickel by HALS HALS resistant to pesticides 5-Layer photo selective films for Diseases Reduction (Anti-Insect / Anti-Virus Film) Playing with additives in the inner layers, to keep film properties for longer periods

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Greenhouses cover Film LDPE & EVA Blends recipes FUNCTIONAL FEATURES MOST REQUIRED BY THE USER ARE: -Elasticity and good resistance to tensile stress, tear and perforation -Transparency for sunlight in the visible light range especially in PAR (photosynthetic activity range 400-700 nm)

-Ability to retain heat inside the greenhouse during night time -Long lasting mechanical properties and transparency

Direct light thermic film EVA (VA >10%)

Width up to 14 m Thickness from 120 to 250 micron Mainly multilayer VA: 3-5% / VA 18-22% / VA 3-5%

Diffused light thermic film (sunny areas - 145kLy) EVA (VA: 3-5%) Width up to 16m Thickness from 150 to 250 micron Mainly multilayer VA:3-5% / VA 3-5 + mineral fillers % / VA3-5%

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Greenhouse cover Film Typical folding procedures -4 fold film installation procedure

-8 fold film installation procedure

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Demand for agricultural film in Europe 45% Silage film 31% Greenhouse film 24% Mulch film 550.000 ton consumed in 2011 in Europe (source Ami Plastics)

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Costruzioni Meccaniche Luigi Bandera Spa Corso Sempione 120, 21052 Busto Arsizio (VA) â&#x20AC;&#x201C; Italy Tel. +39.(0)331.398.111 Fax +39.(0)331.680.206 Website: www.luigibandera.com Email: lbandera@lbandera.com

Diego Castiglioni, Technical Manager: diego@lbandera.com Paolo Ceol, Product Manager: p.ceol@lbandera.com 44