At K 2025, Reifenhäuser Cast Sheet Coating, a line manufacturer specializing in flat film technology, will be demonstrating how film manufacturers can economically meet the requirements of the Packaging and Packaging Waste Regulation (PPWR) with regard to fully recyclable films and at the same time provide their customers with functional added value. Reifenhäuser's Cast MDO technology also enables the easy-tear function that is in great demand for consumer packaging and reduces the material costs of barrier films thanks to clever edge encapsulation.
With the PPWR coming into force in Europe, the demand for production technologies for recyclable mono-material solutions made of PP or PE is also growing in the cast sector. The answer is the same as in the blown film sector: MDO (Machine Direction Orientation) stretch units, which give the films extra stiffness, better optical properties and up to double barrier properties. PET films can therefore be replaced in composite materials in favor of a monomaterial solution.
Marcel Perrevort, CSO of the Reifenhäuser Group, explains: "We entered the cast MDO market at an early stage, which means that, in addition to the hardware, we have a firm knowledge of the process. Together with partners, we develop high-performance end products such as Cast All-PE stand-up pouches. As a line manufacturer, we always pursue one goal: to develop technology for recyclable films that are both functional and economical to produce. We will be showcasing the successful results at K 2025."
Clever features reduce manufacturing costs
Manufacturers who produce film for barrier packaging save material costs with MDO technology simply by stretching, because the process reinforces the EVOH barrier effect. The EVOH content can thus be reduced to less than five percent of the total weight of the packaging, which is a prerequisite for its recyclability and saves costs. Reifenhäuser cast systems also offer a further option for significantly reducing production costs: a particularly clever edge encapsulation process that eliminates the EVOH content in the film waste - without the need to invest in an additional extruder, which is necessary with other solutions. The encapsulation of the barrier layer is carried out directly in the coextrusion adapter. The result: the film edges and the resulting edge trim contain only low-cost raw material. This allows producers to save up to 150,000 euros per year on average.
Easy Tear: Pouches open exactly straight
The Reifenhäuser Cast MDO unit offers special added value for end customers thanks to the so-called Easy Tear effect: the packaging can be torn open in one direction exactly straight. It can then be closed using internal clips or zippers. Until now, packaging, such as stand-up pouches, was usually perforated in advance with a laser, which can have a negative effect on the structure of the packaging, the barrier effect and therefore the shelf life of the packaged product. With Reifenhäuser Cast MDO technology, this product property is achieved simply by stretching the film - without impairing other important film properties.
in the packaging. This means that the end product is fully recyclable
Reifenhäuser Cast MDO technology also available for retrofitting
The MDO technology from Reifenhäuser CSC is available for all in-house and almost all third-party cast systems. The unit can be ordered for new systems as well as retrofitted in the field as long as the width of the system does not exceed 3.60 meters.
"Reifenhäuser Cast MDO systems enable the production of recyclable packaging - with a barrier function if required - at low production costs. With Easy Tear, we also offer a clever technical solution that provides an attractive end customer benefit. At K, we will be using product samples to show what Cast MDO products can do for the circular economy and how their manufacture pays off for producers," says Marcel Perrevort.
