BLOWN FILM COEXTRUSION LINES
The origins of a solid forward thinking company Ever since its establishment in 1947 by Luigi Bandera, it has proved to be a dynamic company focussed on innovation – the perfect ingredients for a pioneer of the extrusion line sector in Italy and worldwide. Today, Bandera designs and manufactures a complete range of extrusion lines based on two major applications: blown film, and sheet and foil with flat die technology.
Bandera Brand Value
RELIABILITY AND ORGANISATION
EXPERIENCE & INNOVATION
A family business, managed by skilled managers
R&D – ongoing investments
IN-DEPTH KNOWLEDGE OF EXTRUSION PROCESS
RELIABILITY
Sturdy and heavy-duty equipment
Over 66 years of in-house production and design expertise
TOP PERFORMANCE
Enhanced productivity and tolerances
CUSTOMISED DESIGN FLEXIBILITY
Turnkey customized complete extrusion lines
CUSTOMER ORIENTED
A customer service oriented company
COMPETITIVENESS AND COST EFFECTIVENESS
Consolidated standard production processes
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PROVEN PERFORMANCES
Over the years Bandera has earned a sound reputation worldwide thanks to its integrity and top quality standards
FullY fledged proven technologies
APPLIED INNOVATION
Preferred suppliers in the long term
Bandera – Excellence in Extrusion Bandera’s mission is to become the major European centre for excellence in extrusion. Focussed on manufacturing cutting-edge technological lines for plastics processing in blown film, sheet & foil and pipe extrusion, Bandera is pursuing to confirm its leading position for the future. Willing to enhance its international market position, Bandera’s corporate strategy concentrates on converging innovative extrusion line designing, engineering, manufacturing commissioning in its Italian headquarters, together with its customer service centre.
BANDERA IS FOCUSSED ON ESSENTIAL HIGH-TECH ASPECTS
Ensure minimised power consumption.
Design safe and reliable top performing extrusion lines compliant with the strictest safety standards.
Manufacture extrusion lines dedicated to finished products from latest innovative thermoplastics, thus favouring the use of recycled and/or biodegradable materials.
Promote technologies and processes aimed at consistent packaging weight reduction.
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Bandera production range - Blown film extrusion Adhering to strict compliance with accredited procedures and accuracy in selecting reliable and skilled European part suppliers, Bandera is focused on exclusive in-house manufacture of the basic equipment for its blown film extrusion lines - a reason for the company excellence in the field. Bandera is ranked among the few European and world manufacturers of extrusion machinery whose technological assets feature a knowhow combining synergies of rigid and flexible packaging fields with the experience acquired in direct production of blown film extrusion heads in small, medium and large sizes. BANDERA PRODUCTION RAnGE INCLUDES: Single-layer, three-layer and five-layer film coextrusion lines for technical packaging solutions Five-, seven- and nine-layer coextrusion lines for barrier film Three, - five and seven –layer coextrusion lines for the finest-quality agrifilm, up to 24m wide, processed with tailor-made coextrusion heads, of higher diameter than 2300mm. Bandera’s leadership in the field is acknowledged worldwide. Extrusion lines of the latest generation “hybrid flex”, capable of processing all biodegradable resins and HDPE to produce singleand three-layer biodegradable film Three-layer film coextrusion lines for heavy duty sacks (FFS- HDB) Three-layer coextrusion lines for high-thickness geomembrane,
for industrial and engineering waterproofing applications Bandera has recently enhanced the project “Smartflex plus”, aimed at manufacturiongf state-of-the-art film lines for competitive investment level, whilst maintaining high quality standard. Lines of the series “Smartflex plus” are astonishingly cost-effective, extremely reliable and ensure utmost versatility at reduced power consumption. After –sale technical assistance is well supported and prompt.
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Blown film extrusion lines for flexible packaging, converting and laminating The brand new 3-layer
series
Undoubtedly, film coextrusion represents the most consolidated technology for the production of standard multipurpose packaging solutions. Today, the three-layer coextrusion lines are the preferred option. The standard configuration comprises a mid high-capacity extruder, arranged with two smaller extruders intended for the outer layers. Bandera three-layer coextrusion lines combine top quality and quantity standards. Building on strong customisation, Bandera extrusion lines are characterised by production need orientation, top versatility and safety, combined with minimised power consumption.
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Technical film The 5-layer APPLICATIONS
series
The 5-layer configuration is perfect for customers needing high production flexibility to process PE film as well as barrier film. The 5-layer Techno Flex plus extrusion line has been designed for the production of technical film with outstanding top quality mechanical properties. The 5-layer Techno Flex plus series production range is definitely wide, and comprises, among others: Film used in top performing converting lines Film with specific characteristics intended for industrial applications Barrier film intended for food as well as medical and pharmaceutical applications.
5-layer PE film recipes – an example 5-LAYER PE Functional layer PE Functional layer PE
5-layer barrier film recipes – an example 5-LAYER PE TIE PA/EVOH TIE PE Major advantages
Reduction of the thickness of the film Major flexibility Hourly production increased Ennobling of the formulations High quality film at competitive cost
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The brand new 7/9-layer
series
The 7/9-layer coextrusion lines are intended for customers manufacturing top-notch high-barrier technical film for food, medical, pharmaceutical and several mechanical (e.g. automotive) applications.
APPLICATIONS
The 7/9-layer films have a double and triple barrier, respectively, with an EVOH central layer combined with PA middle layers, thus offering a high performing barrier against gases and water vapour. Also, Bandera offers extrusion lines capable of ensuring minimised curling effect in cases of asymmetric film structures.
7-9-layer simmetrical recipes - an esample 7-LAYER PE TIE PA EVOH PA TIE PE
9-LAYER LLDPE LDPE TIE PA EVOH PA TIE LDPE LLDPE
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Blown film extrusion lines for FFS industrial bags HDB FLEX – the new series PROCESS MATERIALS HDPE LDPE LLDPE Mldpe PP
Industrial bag market growth is remarkable. Initial focussed on offering extrusion lines pursuing excellent mechanical characteristics, weldability, processability and printability, today the market trends require minimised film thickness aimed at maximising production capacity. Bandera has taken on this new challenge finding specific solutions to meet its customers’ needs, thus confirming – once again – its outstanding customer satisfaction orientation. Specifically, innovative solutions have been applied in each and every extrusion line section. The most outstanding ones are: Triple-flow cooling ring, which offers a strongly enhanced production capacity when combined with Bandera design extrusion heads Specific haul-off units with cutting-edge film cooling system for a better crease free film surface – a solution setting the pace of innovation in HDB film field Integrated thickness control Fully-automated winding station, either by contact or by axial winding
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Blown film extrusion lines for retail and industrial applications The brand new HYBRID FLEX series The brand new Hybrid flex range comprises single-layer extrusion lines and coextrusion lines for the production of HDPE and biodegradable/compostable resin blown film.
MAJOR ADVANTAGES
Pursuing on its commitment for environmental protection and power saving, and conforming with the latest European laws about retail materials, Bandera has designed a multi-material extrusion line. The brand new Hybrid flex extrusion lines can process:
Cost effectiveness
Compostable materials
Unrivalled flexibility in HDPE and bioresin film production “Made in Italy” - “Made in Bandera” User-friendly line management Sturdiness and performance
Biodegradable polymers HDPE LDPE The brand new Hybrid flex extrusion lines have been designed to ensure top performance regardless of extruded products. A standard Hybrid flex extrusion line configuration comprises the following: Dosing system for 4 materials Extruders with bimetallic barrel and no-wear coated screw Fixed extrusion head arranged with IBC system and high efficiency cooling ring Rotating haul-off unit, flatteners equipped with either hard wooden slats or aluminium rolls; rollers specifically designed for thin film processing Automatic single- or double-station winding unit, by contact Each extrusion line can be customised to meet the customer’s needs. Thanks to the consolidated partnership with the largest Italian bioresin and compostable resin producer, Bandera three-layer extrusion lines are accurately tested with different products.
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Multi-purpose extrusion lines for converting and flexible packaging film The new MAJOR ADVANTAGES Excellent mid- and long-term yield Optimised production regardless of process type Excellent cost effectiveness “Made in Italy” - “Made in Bandera” Unrivalled user-friendly line management
Winding unit series W 400, by contact
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series
Over the past two years, Bandera has launched its Smartflex project. Aimed at designing fully customer-need-oriented extrusion lines at a competitive price, the series pursues: PANTONE 2935 C | MACTAC 9839-22 PANTONE 431 C | MACTAC 9889-02
Quality Flexibility Top performance Reliability Low power consumption Low environmental impact The achieved cost savings do not come from component quality reduction indeed from series production. All general costs are split into a large number of lines thus generating an economy of scale at procurement stage.
The Smartflex range comprises two configurations: Smartflex 16
Smartflex 22
Useful width
1600 mm
2200 mm
Extruder configuration
1 x 65 ø mm 2 x 50 ø mm
1 x 75 ø mm 2 x 65 ø mm
Extrusion head range
180÷350 mm
300÷500 mm
Haul-off unit
Oscillating 1800 mm
Oscillating 2400 mm
Winding unit
By contact Open width: 1800
By contact Open width: 2400
Bandera Smartflex projects include standardised extrusion lines fully arranged to be implemented according to customers’ requirements. Smartflex extrusion line production includes: Packaging film (food and non-food film) Thermoretractable film Lamination film Stretch hood film PROCESS MATERIALS
LDPE LLDPE mLDPE EVA MDPE HDPE PP
Standard Smartflex 22 layout
11900
FORNIRE FOTO
L . BANDE R A
SEZ.2
SEZ.1
±0.0
14800
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New extrusion lines for the production of agrifilm Bandera is a pace setter in agrifilm extrusion lines. AGRIFILM APPLICATIONS Greenhouse film Thermal film Diffusive film Photoselective film Fumigation film Mini tunnel film Silo film Mulching film
Today, agrifilm production is predominantly obtained by multi-layer coextrusion lines while single-layer film application is increasingly intended for a limited and low target market. Nowadays, three-layer coextrusion lines are preferred as they satisfy the current requirements for agrifilm. Nonetheless, future trends are toward 5-layer line configuration ( with the possibilities to have 7-layer configuration). The multi-layer film ensures an enhanced management of raw process materials and optimised additive distribution in every layer, thus increasing film physical and mechanical properties as well as light and heat transmission: as a consequence, the film life cycle is increased.
Solar film
Bandera agrifilm coextrusion line flexibility and versatility is increasingly appreciated by customers, considering that, generally, agrifilm is a seasonal product. With the same coextrusion head and minimised set-up times, Bandera coextrusion lines can produce agrifilm as well as thicker film (e.g. waterproofing geomembrane): a valuable chance to have an all-yearround profitable coextrusion line, regardless of agrifilm seasonality.
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The classical configuration of agricultural systems are: Coextrusion line
Extrusion head
Open width
3-layer
Up to 2300mm
Up to 24m
5-layer
Up to 2200 mm
Up to 22m
7-layer
Up to 2000 mm
Up to 18/20 mt
Bandera coextrusion lines are equipped with cutting-edge peripheral and ancillary systems, whose control and display functions are integrated into the Bandera line supervision system in order to ensure automated line operation: Haul-off units, up to 8500mm open width Power-driven gusseting units C- and V- folders for easy reel stocking and handling Winders up to 5500mm, available in gap winding mode
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Complete extrusion lines for geomembrane Geomembrane is the most peculiar product in the tubular blown film sector, with unique characteristics. WATERPROOFING GEOMEMBRANE INTENDED FOR
Landfills Tunnels Collection tanks Water basins Irrigation channels Extraction mines Motorways Strengthening works at river and marine water flows Dam protections Fish farming
Geomembrane target market growth is ongoing, especially in emerging economies where rapid development has increased the demand for geomembrane. Bandera offer comprises complete extrusion lines with up to 1200kg/h production capacity, with film thickness up to 3 mm. 3-LAYER GEOMEMBRANE EXTRUSION LINE STANDARD CONFIGURATION Dosing system The standard configuration comprises a high-capacity extruder
for the inner layer and two smaller extruders intended for the outer layers, arranged with bimetallic barrels and no-wear coated screws Coextrusion head (die up to 2300mm) equipped with internal
THICKNESS RANGE
bubble cooling system (IBC)
Min thickness: 0.5 mm Max thickness: 3 mm
Fixed haul-off unit, suitably designed for production needs
USEFUL WIDTH
extraction and reel downloading
Useful width: from 6 ÷ 8 m PROCESS MATERIALS HDPE Black(carbon black)/white Masterbatch
Fully-automated winders, 8m width, with automatic shaft
Geomembrane can be textured on one or both sides; a plain strip can be obtained to ease welding. This product can also be processed with 5 –layer extrusion head for the production of Agrifilm. Bandera geomembrane extrusion lines can be customised according to Bandera customer’s needs.
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Automatic winding units Bandera winding units are definitely worth detailing. Fully automatic and equipped with safety devices. Winding cycle control by touch screen user interface connected with central PLC. Winders are offered in three operating modes: By contact (peripheral winding), single- and double-station configuration; film tension control by top sensitivity load cells By contact and with shaft axial control, single- and double-station configuration. Two winding modes are available: - by contact - by axial control on winding shaft axis, - a.c. servomotors Top quality winders featuring the following operation modes:
- by contact - with axial control arranged on winding shaft axis by AC servomotor - with gap control - combined winding, with control arranged on winding shaft axis and by contact on the rubberized pressure roller - by counter-rotation - shaft accelerator. Larger pressure roller size allow for top-quality faultless reels, whose diameter can exceed 1500 mm.
W 400 series: Contact mode Contact mode combined with axial control
Top ESR 9000 series
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Winding units for agricultural film and geomembrane As far as agrifilm is concerned, Bandera winding unit range comprises single- and double-station versions: Useful width from 2500 to 5000 mm Fully automated for jumbo reels Shaftless to wind agrifilm on cardboard and PVC cores
Bandera offers geomembrane automatic winding units with automatic steel shaft extraction and reel download.
Geomembrane automatic winding unit
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Made in “Bandera” – a synonym for quality In-house manufacture of the most critical and complex extrusion components: Screws: they are designed on the basis of process material
rheological characteristics in collaboration with raw material producers. Extrusion heads: conceived with the support of the most up to
date and precise design systems, taking into account customers’ process material rheological characteristics. Bandera offers its customers the widest range on the market, with dies from 30 to 2300 mm. Bandera extrusion heads ensure top quality products and minimised melt residence time inside the extrusion head, thus allowing accurate temperature control and offering the chance to process the most thermosensitive materials. Cooling rings: cutting-hedge double-flow cooling rings for
extremely accurate bubble stability control and top performance with minimised thickness tolerances. They ensure trouble-free integration into top-quality automated thickness control systems. Cutting-edge haul-off units, either oscillating or fixed: designed
and manufactured in compliance with product requirements and line production range. Useful widths comprised between 800 mm (for the production of industrial heavy bags) and a 8500 mm (for the production of agrifilm and geomembrane).
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RECLAIMING OF EXISTING MACHINES AND REVAMPING OF COMPLETE EXTRUSION LINES
OVER 24-MONTH WARRANTY UPON REQUEST
CUSTOMIsED ON-SITE TRAINING FOR NEW APPLICATIONS
EXPRESS CUSTOMER SERVICE SUPPORTED BY BANDERA STAFF UNRIVALLED EXPERTISE IN PROCESS MECHANICS/ ELECTRONICS
4 SERVICE CENTERS FOR A WORLDWIDE ASSISTANCE
COST EFFECTIVE SPARE PARTS PACKAGES
SCHEDULED INTERVENTIONS FOR EXTRAORDINARY MAINTENANCE
Why choose Bandera as a technological partner? Over the past years Bandera has strengthened its leading position in its reference markets worldwide of packaging film, agrifilm and waterproofing geomembrane sectors. Among its customers Bandera lists major packaging item suppliers of food industries, and major agrifilm and geomembrane producers. Why choose Bandera? Unrivalled expertise in manufacturing complete blown film extrusion lines Worldwide appreciation Pace-setting know-how from the collaboration of leading packaging companies and expertise in small-, medium-
and large-sized blown film extrusion heads manufacturing
Wide extrusion head range, from 30mm to 2300mm Extended expertise in winding units Its rooted collaboration with tested reliable sub-suppliers Timely and efficient aftersales service ISO 9001:2000 certification
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R&D A new Research & Development area is going to be fully operational by 2014 to test complete extrusion lines
Comin
g
Soon
Facts & figures: latest turnovers
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briefinglab.com
PLASTICS MACHINERY EXTRUSION TECHNOLOGY SINCE 1947
For details about Bandera technology, visit us at luigibandera.it
FOIL SHEET
EXTRUDERS
PIPE COATING EXTRUDERS
GRANULATION
REV2/FILM/EN/09/13
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Costruzioni Meccaniche Luigi Bandera SpA Corso Sempione, 120 - I-21052 Busto Arsizio (VA) Italy t +39 0331 398111 - f +39 0331 680206 lbandera@lbandera.com - luigibandera.com You can download this document for your own mobile use and in the interest of the environment
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Technical specifications provided for illustrative purpose only and subject to change without prior notice.