Smurfit Westrock hosted a “Barrier Day Open House” on April 15 at its production facility in Ibi (Alicante), Spain, in collaboration with machine manufacturer Reifenhäuser Blown Film. The event brought together an international group of customers and industry experts who were able to see the latest generation of Reifenhäuser EVO Ultra Die Heads in a live production environment.
The key part of the presentation was a demonstration of output exceeding 1,000 kg/h for barrier applications. The manufacturer reported that films were produced with properties including profile accuracy better than ±3% (2σ) at a thickness of 70 µm. To maintain film tolerances even at very high throughput rates, the line combines the new EVO Ultra Die Head with the internal bubble cooling system EVO Cool and Kdesign cooling ring technology. In addition, the plant uses the Reifenhäuser Ultra Flat System, intended to ensure flat film for downstream processing.
“The results of the new EVO 7-layer blown film line with the EVO Ultra Die 7 have exceeded our expectations,” says Pascual Martínez Pérez, Managing Director of Smurfit Westrock Spain. “No other supplier achieves the nominal outputs we have achieved.”
With the commissioning of the new installation, Smurfit Westrock now operates a total of three Reifenhäuser blown film lines at this location, expanding capacity. According to information presented during the open house, the new generation of die heads is intended to set new productivity benchmarks without compromising process quality or stability.
Bernd Reifenhäuser, CEO of the Reifenhäuser Group, highlighted the role of cooperation: “The real competitive edge is about more than technology. It’s what we’ve built together over seven years, trust, partnership, and measurable results. Every major step we’ve taken in this partnership started with one question: What creates the greatest value for Smurfit Westrock? Today’s demonstration is a perfect example.”
Pascual Martínez Pérez, Managing Director of Smurfit Westrock Spain, and Bernd Reifenhäuser, CEO of the Reifenhäuser Group, reflect on seven years of a strong partnership and a total of three successfully installed Reifenhäuser lines in Ibi (Alicante).
On the new blown film line, which is scheduled to go into production at the beginning of 2026, Smurfit Westrock produces seven-layer barrier films. These materials are used, among other applications, for bag-in-box packaging. This solution consists of a sturdy cardboard box containing a plastic bag filled with liquid. As stated, a spout enables beverage dispensing and limits oxygen ingress, similar to the film’s oxygen barrier described as 100%.
The presentation also pointed to the flexibility of the new line. If required, production can be quickly switched from seven-layer film to five- or three-layer film. Despite the die head’s large geometry and high volume, short changeover times are intended to be enabled by a design focused on maintenance-friendly operation
The live demonstration was accompanied by a series of expert presentations on the production of barrier films and packaging. The talks addressed specific challenges of barrier applications and highlighted the advantages of the new Reifenhäuser Ultra Die Head generation.
The live demonstration at the open house event was accompanied by a series of expert presentations on the production of barrier films and packaging.
