Colines has completed the installation of a new cast film line at LyondellBasell’s Cincinnati Technology Center in the United States. The line is a 9-layer AllRollex system designed primarily for the production of high-quality stretch film, while also providing a development platform for complex multilayer structures. With this investment, LyondellBasell expands its capabilities in film processing and application development in areas such as packaging and healthcare.
The newly installed line has been engineered for high-speed stretch film production and is intended to support both current development projects and future R&D activities. According to LyondellBasell, the configuration enables work on customer-specific formulations and film concepts. In parallel, the flexibility of the equipment allows it to be used beyond conventional stretch films, especially where barrier and lamination performance are required.
Flexible 9-layer configuration and broad thickness range
The AllRollex cast film line at the Cincinnati Technology Center is configured with nine extrusion layers. This multilayer design enables the production of advanced film structures, including stretch films and ethylene vinyl alcohol, EVOH, oxygen-barrier films. The machine can process a wide range of thicknesses, from 102 microns down to 10 microns, which covers typical ranges for both industrial stretch films and many specialty packaging and technical film applications.
A key feature of the line is its flexibility in terms of materials and structures. Interchangeable extruder screws allow the processing setup to be adapted to different polymers and formulations. Combined with advanced processing features, this enables the production of complex barrier and functional films, in addition to standard stretch film grades. The equipment design targets consistent thickness control and surface quality at high output rates, which is essential both for stretch wrap performance and for downstream processes such as lamination and printing.
To support subsequent converting steps, the line is equipped with dual-sided corona treatment. Treating both sides of the film surface improves adhesion for laminating adhesives, inks and coatings. This is relevant for multilayer packaging constructions where the cast film may serve as a core or outer layer that must bond reliably to other substrates and maintain performance across the supply chain.
Platform for packaging and healthcare film development
While the system is optimized for high-speed stretch film production, LyondellBasell positions the line as a broader development and testing platform. The capability to produce EVOH-based oxygen-barrier films and other complex multilayer structures makes it suitable for the development of food packaging films that require controlled gas permeability and product protection. The same set of features, including tight thickness control and dual-sided surface treatment, can be applied in healthcare and medical-related film applications, where precise properties and consistent quality are required.
Commenting on the new line, Mick Hundley, Cincinnati Technology Center site director at LyondellBasell, said: "This new cast film line is a testament to our unwavering commitment to innovation and collaboration. By enhancing our capabilities, we are better positioned to collaborate with our customers and deliver tailored solutions that meet their unique needs". The statement underlines the role of the installation as a customer-oriented R&D tool rather than solely a production asset.
From the machinery supplier’s perspective, the project reflects ongoing collaboration between Colines and LyondellBasell in film processing technology. The combination of interchangeable screws, multilayer die design and surface treatment options is intended to give LyondellBasell’s R&D teams freedom to test new resin systems, layer configurations and processing conditions on an industrially relevant platform.
A view of extrusion die and chill-roll on a Colines ALLRollEX cast stretch film line
Colines perspective on collaboration with LyondellBasell
Eraldo Peccetti, Executive President at Colines, commented on the installation: "We are proud to support LyondellBasell with this advanced cast film line, which fully reflects our shared commitment to innovation and customer-driven development. Collaborations like this allow us to bring our technology to the service of partners aiming to explore new structures, improve process efficiency, and accelerate time-to-market. We believe that this installation will open significant opportunities for LyondellBasell’s R&D activities and we are proud to contribute to this important step forward".
With this project, Colines provides LyondellBasell with a cast film line that combines high productivity for stretch film with development flexibility for multilayer barrier and specialty films. For the broader plastics and packaging industry, such installations contribute to faster testing of new material combinations and structures, potentially accelerating the introduction of new packaging and healthcare film solutions.
