At Chinaplas 2026 in Shanghai, the Reifenhäuser Group is set to present its latest generations of extrusion lines, Evo Gen3 for blown film and Everex for cast flat film. The display is expected to include solutions aimed at high output and the highest possible level of automation. Additional booth highlights include blown film cooling technologies from subsidiary Kdesign and examples of fully recyclable monomaterial films intended for packaging applications.
The announcement emphasizes that the new lines are designed with converters’ staffing constraints in mind and the need to maintain stable product quality and process efficiency. In practice, this is intended to translate into a greater use of operator assistance systems, expanded automation functions and solutions supporting faster changeovers. Reifenhäuser also points to the importance of a control architecture that enables connectivity, use of process data and automation, including the integration of AI-based tools.
Evo Gen3, output increase up to 1,050 kg/h
The new generation of Evo Gen3 blown film lines is stated to reach an output of up to 1,050 kg/h with a 350 mm die diameter. According to the manufacturer, this is around 30% more than previous solutions. The output increase is attributed to the combination of the new Evo Ultra Die Heads with Ultra Cool Gen3 cooling rings.
The Evo Ultra Die Heads are said to be available in three variants: a 3- and 5-layer variant aimed at maximum throughput and fast product changeovers, a 7-layer variant optimized for barrier films, and a 9-layer variant intended to deliver the highest film quality in complex products.
Reifenhäuser also highlights usability and ease of operation. The use of assistance systems and the new HMI called “Evo OS 3” is intended to enable fast achievement of target process parameters even for less experienced operators.
Features mentioned include the Auto Flat System, which is described as enabling, for the first time, measurement of film flatness and its automatic optimization. According to the manufacturer, this improves downstream processing and influences material consumption. The ReStart Assistant is intended to reduce downtime during material changes. The company also points to a new control architecture designed to support connectivity, data utilization and automation, including AI integration.
Powerful, smart and digital, Evo Gen3 is a new generation of blown film lines delivering a record output of 1,050 kg/h with a 350 mm die diameter.
Everex, automation of core processes on a flat film line
The new generation of Everex flat film lines for cast and sheet applications is described as being designed for comprehensive automation. According to the preview, core processes are to run automatically, from the co-extrusion adapter and die through width adjustment to the winder. In the manufacturer’s view, this is important given the shortage of skilled workers.
The central element is said to be the enhanced PAM 2.0 system, which is intended to fully automate width adjustment. The manufacturer states that recipes can be reliably recalled and that product changeovers can be completed faster and more consistently in under 80 minutes, while achieving higher quality and less startup waste.
Automated width adjustment is said to include edge pinning, a vacuum box, and pre- and final trimming, improving film quality and process stability. The solution is also stated to be integrable into existing systems, including those from other manufacturers.
In addition, a new edge encapsulation system is described as reducing the use of expensive barrier materials, as these do not end up in edge trim waste. The manufacturer states that this can deliver savings of up to EUR 150,000 annually.
The announcement also covers the Everex Hybrid polishing stack unit, which is intended to increase flexibility for film thicknesses from 150 to 2,500 µm. It is stated that with standard polishing stacks, PP films generally could not be produced thinner than about 380 µm without an additional air slot die, which in turn limited line productivity. According to the manufacturer, Everex Hybrid is intended to provide greater flexibility and material savings through down-gauging while maintaining fully reproducible quality through mechatronic control.
The new generation of Reifenhäuser Everex flat film lines is expected to offer automation features that simplify operation and support long-term profitability.
Monomaterial films and packaging application examples
Reifenhäuser Blown Film reports process-stable production of a 14 µm MDO-PE film, presented at the trade fair as a market-ready All-PE Pouch (stand-up pouch). The technology used is Evo Ultra Stretch, a patented MDO unit positioned directly at the take-off of the blown film line and intended to stretch the film from its first heating stage.
The manufacturer states that Evo Ultra Stretch provides additional benefits when Evoh is used in barrier films. The stretching process is said to enhance the barrier effect of this raw material, allowing its share to be reduced. According to the announcement, this lowers production costs to a level competitive with conventional films, which is indicated as a decisive factor for market acceptance.
The Reifenhäuser Group’s flat film experts are set to show, among other items, a Cast All-PP stand-up pouch with a high oxygen barrier. It is stated that, in addition to high recyclability, the solution provides functionality through an Easy-Tear effect, allowing the packaging to be torn open in one direction and resealed using internal clips or zippers.
According to the manufacturer, such features in stand-up pouches have typically been achieved through laser perforation, which can negatively affect the packaging structure and barrier performance and therefore the shelf life of the packed product. With Reifenhäuser’s Cast MDO technology, the Easy-Tear property is stated to be achieved solely through film stretching, without compromising other key film properties.
Cast All-PP stand-up pouches are intended to be both highly recyclable and functional thanks to the Easy-Tear effect.
Kdesign and blown film cooling technologies
Kdesign, a company specializing in cooling, measurement and calibration systems for blown film lines, is also set to be present at the Reifenhäuser Group booth. Solutions mentioned include the Karat cooling ring, which, according to the manufacturer, sets the standard in cooling performance, minimization of tolerances and ease of operation.
The announcement states that the Karat cooling ring enables output increases of up to 50% versus mid-range components and up to 25% versus competing high-end solutions, while maintaining very good profile tolerances and high film quality.
