Turning Film Challenges into Competitive Advantage
How Huhtamaki (Elif) Transformed Blown-Film Production with Nordson BKG® Melt Filtration Solutions
As sustainability targets push manufacturers to increase recycled content, maintaining consistent production quality becomes more complex. Huhtamaki’s Elif division, a global leader in sustainable flexible packaging, faced exactly this challenge. By partnering with Nordson Polymer Processing Systems and implementing BKG® continuous melt filtration, Elif successfully eliminated downtime, improved product quality, and boosted operational efficiency.
The Challenge: Recycling Without Compromise
Elif’s blown-film production line processes polypropylene (PP) and polyethylene (PE) at an output of 350 kg/h. As part of its commitment to sustainability, the company increased the proportion of recycled materials in its feedstock.
However, this shift introduced several operational hurdles. Their existing discontinuous melt filtration system struggled to handle the variability in recycled material purity, resulting in:
Key challenges included:
- Frequent downtime caused by discontinuous filtration interruptions
- High gel content in the final film, resulting in quality complaints
- Reduced operational efficiency and increased material waste
- Limited flexibility when processing varying input material qualities
These issues negatively impacted productivity, commercial performance, and Elif’s sustainability objectives.
The Solution: Continuous Melt Filtration with the BKG® HiCon™ K-SWE-HD/RS
To overcome these challenges, Elif partnered with Nordson Polymer Processing Systems to test a BKG® continuous melt filtration solution designed for demanding blown-film applications. The BKG® HiCon™ K SWE 125 HD/RS melt filter was installed downstream of a 90 mm extruder, operating at inlet pressures up to 550 bar and filtration fineness between 125–150 µm.
Why this solution was the perfect fit:
- True continuous filtration, eliminating process interruptions
- Stable melt pressure and temperature for consistent film quality
- Excellent handling of recycled materials, even with varying purity
- Reduced waste and improved overall line efficiency
- Proven performance in demanding blown film applications
At the heart of the system is advanced backflush technology, which enables uninterrupted screen cleaning, even during contamination peaks typical of recyclate processing.
The Results: Higher Revenue, Less Waste, Better Product Quality
Following a short trial period, the results were immediate and decisive. Elif moved forward with a full implementation after seeing significant improvements in performance and product quality.
Measured benefits achieved by the customer include:
- No unplanned downtime related to melt filtration
- A significant increase in sellable product due to uninterrupted operation
- Lower waste rates, improving material efficiency
- Higher film quality with dramatically fewer gels
- Enhanced operator safety through fully automated filter changes
- Improved commercial output, boosting overall line profitability
- Increased flexibility to process a wider range of recycled materials
Karim Saber, Global Senior Manager Extrusion & Recycling Operations at Elif, highlighted an important operational improvement:
“The introduction of the fully automated self cleaning filter greatly improved our operator safety. With the BKG® HiCon™ K-SWE-HD/RS, we were able to replace manual filter changes on a running machine - which previously posed high safety risks - with an automated, waste-free process requiring no operator intervention.”
Strengthening Sustainability and Profitability
By eliminating filtration-related stoppages and stabilizing the extrusion process, Elif achieved a powerful combination: improved environmental performance and stronger commercial outcomes.
The ability to process higher levels of recycled material without compromising quality or uptime is a major advantage in today’s market, where sustainability and efficiency must go hand in hand.
A Partnership That Delivers Results
Elif’s success underscores the value of advanced melt filtration technology when working with recycled materials. Nordson BKG® continues to support customers in overcoming production challenges while enabling more sustainable operations.
Frank Thomas, Manager Sales at Nordson BKG®, summarized the impact:
“This project clearly shows the value of continuous melt filtration when processing recycled materials. By combining automation, process stability, and robust filtration performance, we help customers like Elif achieve their sustainability goals while improving safety, efficiency, and profitability.”
Ready to Optimize Your Blown-Film Production?
Whether you're increasing recycled content or looking to improve productivity and product quality, continuous melt filtration can be a game-changer.
Talk to our experts today to learn how Nordson BKG® solutions can support your operation.
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