A medida que la atención global sobre la sustentabilidad continúa creciendo, los productores de películas de barrera deben concentrar los recursos en la entrega de productos que ayuden a reducir el desperdicio de alimentos y materiales.
Cree una película de barrera eficaz
Ahora más que nunca, es fundamental que las películas utilizadas en el envasado de alimentos proporcionen las cualidades superiores necesarias para prolongar la vida útil. Asegurarse de que estas películas puedan evitar que la humedad, el oxígeno o el olor arruinen rápidamente los artículos perecederos no es una tarea fácil, pero con el uso del equipo de extrusión adecuado, se vuelve mucho más fácil producir películas de barrera altamente efectivas.
The Foundation: EDI® Ultraflow™ Extrusion Dies
Multiflow™ 10 Die Manifold
US Patent 12,558,830Our Multiflow™ 10 manifold presents barrier film processors with many benefits in an industry-preferred die body design. The manifold is designed with a faster purging flow channel (when compared to competitive designs) to provide the lowest residence time in a straight backline manifold die.
By uniformly distributing layers across the width, the Multiflow™ 10 manifold also helps processors quickly refine their production process to increase the output of saleable film.
For Barrier Film Applications
The Multiflow™ 10 manifold features larger preland gaps and longer lip lands to prevent coextrusion instability. This means the desired layer-to-layer ratio remains virtually the same throughout the width of the film, giving barrier film producers reassurance that their product will perform as expected.
EDI® Lip Adjustment Systems
Nordson offers a variety of lip adjustment systems, from manual systems that enable direct coarse tuning for each set-up, to automatic systems that deliver fine adjustments in reduced time.
Where It Started: Manual Lip Adjustments
Manual lip adjustments enable operators to adjust the die lip by using hand-operated tools to tighten or loosen the bolts. This tried-and-true method has been used in the field for decades whenever coarse adjustments to the die’s lip gap are required.
Push-Only Lip Adjustments
A single thread allows for large movement per revolution (around 1mm/rev).
Differential Push-Only Lip Adjustments
The two-thread system enables finer movement per revolution (around 0.2mm/rev).
Differential Push-Pull Lip Adjustments
The two-thread system enables finer movement per revolution (around 0.2mm/rev) and the pull feature assists with lip opening in lower-pressure applications.
Stepping It Up: Autoflex™ VI-RE Systems
US Patent 10,518,459
The combination of the Autoflex™ VI-RE system and a computerized gauge monitor typically yields closed-loop control that reduces gauge variation to about half of the minimum achievable with manual systems.
The system:
- Provides a 43% increase in the stroke of the lip adjusting system, without adding to response time, enabling the system to correct a wider range of process variations, often without the need of manual intervention
- May be operated in convective or forced air cooling conditions
- Reduces downtime with a design that provides easy access to wearable parts during routine maintenance and cleaning
- Includes heater wiring routed directly into a junction box using a quick disconnect plug
- Features module sets, containing three or four adjustments each, allowing for easy access to wearable parts in a specific area of the system
- Is retrofittable to existing dies
The Future is Now: Prodigi™ Motorized Lip Actuator System
Patent Pending
Instead of using thermal bolts to control the lip adjustment, Prodigi™ relies on a series of motorized actuators, connected to the adjustment threads. These motorized actuators smoothly translate motor rotation into precise linear movement to locally open and close the lip. This is accomplished away from the hot die, at a user interface.
With this system, processors can:
- Increase their set-up speed by saving a gauge profile configuration, which may be simply relaunched for the next production cycle
- Gain additional stroke thanks to the motorized actuators, which can traverse the entire useful flexible lip travel range without the need for any manual intervention
- Achieve optimal repeatability, using the Prodigi™ system’s computer-based programming to save the exact location of each bolt during a production run
- Boost energy savings since the actuators operate at a significantly lower temperature than conventional auto bolt translator blocks and because the system uses little to no additional power after it achieves steady state operation
- Improve team safety by removing operators and technicians from the hot zone near the die surfaces and melt stream components
EDI® Coextrusion Technology
Coextrusion technology enables processors to further improve their end product by combining materials to add strength, durability, and protective properties. Our feedblocks combine polymers in a parallel path manner, achieving optimal layer ratio stability throughout a structure. Flexibility in the design means entrance locations can be customized, based on your line design and layout.
Ultraflow™ I-S Fixed Geometry Feedblock
Our fixed geometry feedblock is an industry-proven design, enhanced by collaboration of coextrusion expertise between our world-class design engineers and industry partners.
This feedblock offers processors:
- Controllable linear valves, which allow for highly precise layer ratio changes
- Exchangeable flow inserts and plugs, as well as flush inserts, which are used to change layer sequences
- Selector spool(s), which enable the layer sequences to be prearranged upstream of the combining point, all without removing the feedblock from the production line
- A split body design that minimizes physical space requirements and is easier to clean
Ultraflow™ V-TS Adjustable Geometry Feedblock
US Patent 10,442,126
The latest addition to our proven Ultraflow™ feedblock line, the V-TS, combines several innovative features to offer customers maximum adjustability and control of their layer ratios.
This feedblock offers processors:
- Large-diameter profiling actuators, which provide highly effective tuning lands, can be positioned at the combination point or significantly upstream to refine the layer distribution
- Controllable linear valves, which allow highly precise layer ratio changes
- A split body design that minimizes physical space requirements and is easier to clean
- “On-the-fly” layer ratio adjustability, which increases uptime and precision, allowing for greater end-product versatility
- Selector spool(s), which enable the layer sequences to be prearranged upstream of the combining point, all without removing the feedblock from the production line
Layer Multiplication Technology
US Patent 9,108,218
Layer Multiplication Technology (LMT) is a special tool that can be engineered to multiply some or all of the layers within the coextrusion “sandwich” provided by a feedblock.
Our streamlined design requires the smallest space envelope in the industry and provides the following benefits:
- Inserts that are easily changed, allowing for layer multiplication levels to be altered quickly
- No matter how many layers there are in a structure, the overall thickness is no greater than that of conventional coextrusion, and the structure contains the same amount of raw material
- When used for food packaging, the shelf life may be prolonged by reducing the Oxygen Transmission Rate (OTR) and total oxygen ingress over an extended period
- Barrier properties may be better maintained when packages are flexed since thinner EVOH layers tend to develop fewer pinholes
Other Optional Features & Equipment
Our goal is to ensure you have the tools needed to be successful. The following features are optional but certainly worth considering when trying to increase your operation's profitable output.
Deckling
Deckles are designed to vary the product width by blocking off portions of the die slot from both ends of the die. Options for barrier film applications vary, depending on the customer’s specific product and process needs.
Adjustable Edge Encapsulation Deckles
In coextruded cast films, such as barrier film, trimming edge bead wastes expensive polymer. A solution to this is to use a die that is equipped to “encapsulate” the film with a less costly resin that will make up the bulk of trim scrap. With this method, the less costly polymer is introduced at both edges of the film through manifolds located alongside the main manifold. The encapsulation manifolds are designed to generate a single uniform flow front as the film leaves the die. The edge material must be compatible with the polymer in the main structure in order to create a bond.
Adjustable or Fixed Internal Deckles
Internal deckle systems include fixed deckle blades and adjustable manifold deckling.
Die Insulation
Adding insulation can quickly benefit an organization. The insulation, made from inorganic materials, is sandwiched between stainless steel panels to optimize die temperature control, isolate the die from external drafts, and increase team safety.
Ultracart™ System
Enhance workplace safety with the added mobility of a cart, which allows an entire die to be wheeled from the processing line to a maintenance area. The Ultracart™ system streamlines the cleaning process by rotating the die halves for easy access to the flow surfaces.Additional Support Available from Nordson
Extrusion and fluid coating die systems are not only a strategic investment, but also a critical aspect in the overall success of your business. Nordson employs a team of field service technicians to offer processors and converters both on-site and remote technical support. The technical service team offers seven days a week scheduled or emergency call service and is based throughout the world to provide regional service and support.
Their services include:
Installation and Start-up Assistance
Our technicians are available to assist with startup, commissioning, and process optimization.
On-site Inspections and Repairs
Our team provides on-site inspections, repairs, and replacement of components and parts.
Operation and Maintenance Training
Profit from our experience and know-how in plastics processing by having our professionals train your staff. A team of Nordson experts tailors each program to fit your requirements. Training courses can be held at one of our technology centers or at your location.