TECHREport Nº31 / 01-2018

Editorial Karl Stöger Managing Hot News Director Dear Reader,

A year from now, SML will relocate to new office and factory buildings, which are currently under construc- tion in Redlham, about 12 km away from our current location . The move to invest in a completely new and much larger plant here in Upper underlines our strong commitment to the region as a prime industrial location as well as Leading edge to maintain the recognised quality technology associated with “Made in Austria”. And primarily this is because of the for hot-fill, highly qualified people that we are able to find and employ here. In ad- PET cups dition, the decision for this invest- ment demonstrates our belief in the continuing expansion of the plastics industries which we are serving. With the new premises we will dou- ble the size of our production areas, technological development centre and office space, and thus make Foamed PET sheet for cups for ourselves ready for future growth and technical advancement. hot-fill applications Although the rising amount of plas- tics in our waste streams is ques- tioned by various environmental Hot drinks and street food are often hot-fill commodities. As a consequence, this extremely positive result, the next protection organisations and NGOs sold in disposable cups and trays, a number of companies are attempting to objective is to render this development alike, I am of the opinion that, de- which must combine heat insulation solve this problem with an approach that suitable for industrial production. spite the justified critical voices, properties with minimum costs and involves the use of additives to increase plastics will long remain an indispen- low environmental impact. At present, heat stability. However, such additives are sible part of the packaging industry. these cups and trays are made from also expensive and must be employed in The rise in global consumption of differing materials such as cardboard high concentrations, which again leads to plastics products is enormous, as and rigid or foamed PS and PP. an uneconomical process. indicated by the annual growth rates However, as the highly popular PS in the polymer raw materials sector, is the object of ecological debate in The development of a PET cup amongst machine manufacturers a number of countries, alternatives for hot-fill applications and plastics processors. Nonethe- are necessary. Roughly a year ago, In July 2017, SML started testing a newly less, in the coming years it will be SML and a partner company started developed sheet line at its headquarters important that we develop and pro- a development project with the aim of in Lenzing, Austria. Amongst others, duce modern, recyclable packag- employing low-cost APET resin for the the aim was to manufacture a foamed ing. This must be manufactured with production of ecologically compatible, APET sheet for thermoformed cups that the help of sustainable processes foamed cups for hot-fill applications. would be suitable for hot-fill applications. and it is essential that disposal and The line is designed for the production recycling take place in a regulated The initial situation of 3-layer sheet and is equipped with manner in order to protect and pre- As a rule, PET is not employed in the two extruders with a maximum output serve our environment for coming production of containers for hot-fill of over 1 t/h. The sheet has an overall generations. applications. This is because APET cups density as low as 0.62 kg/dm³ and an lack dimensional stability when subject to A/B/A structure with a centre layer that is We at SML are convinced of the heat at the required temperatures. physically foamed. No special additives positive features that characterise are required to enhance the heat stability plastics and are equipping ourselves of the sheet, which is thus suitable for the The solution is a cup: for the future with our new factory in economic production of low-weight cups 02 SML bitWise – innovation Redlham. There, we will not only in- made of foamed sheet with good insulation properties. The sheet through digital business crease our production capacity, but That is suitable for hot-fill is thermoformed by SML’s project partner, competence also create additional jobs and con- which is a company that possesses tinue to fulfil our role as an important Produced from a standard APET resin advanced tooling and thermoforming and recycling material at low cost 03 SML produces partner to the plastics processing technology. separator films for industry. li-ion batteries Conversely, crystalline polyester (CPET) The cup in the photo has a foamed layer Yours sincerely, could easily meet this stipulation, as containing 40 per cent post-consumer it is employed to pack convenience bottle flakes and is able to retain its shape 04 A multifunctional cast foods, which are heated in ovens at even when being filled with boiling water. film line at ExxonMobil over 200°C. Unfortunately, CPET is At the same time, it can be held without in Shanghai expensive and therefore is not used for burning the fingers. Therefore, in view of

Extrusion lines – engineered to perform www.sml.at 01 TECHREport

the new bitWise platform is the unique modern, web-based user interface adapt- identification of every film and sheet roll ed to both desktops and mobile clients, bit Wise produced, which creates an audit trail that allows easy remote access and places the links all production parameters and re- right information at the user’s fingertips in lated data such as quality measurements. any location.

Innovation around the product The use of a cutting-edge, special pur- With bitWise at the core of its digital pose, time series database ensures out- business strategy - maximising cus- through digital business standing performance and the highly effi- tomer business value by combining the cient storage of ever-larger data volumes. companys' extensive process and en- competence This facilitates data-driven decisions gineering competence with advanced based on vast amounts of data, which data analytics - SML has embarked on can even be gathered across numerous the exciting journey from hindsight, to With the launch of the new bitWise enabled initial customers to integrate extrusion lines and plants. Moreover, a insight and foresight. process data analytics and integration SML extrusion lines with custom MES framework, SML has embraced the po- and ERP applications. This not only How can we tential promised by the fourth industrial increases end-to-end process visibility, make it happen? revolution and the digital transforma- but also allows our customers to apply for tion, moved beyond the hype and is de- financial subsidies or tax benefits which What will Prescriptive happen? Analytics livering tangible customer value today. are currently granted for Industry 4.0 solutions in a number of countries. Using Why did Predictive The founding of a Digital Business flexible architecture and open standards it happen? Analytics Competence Center (DBCC) at SML such as OPC UA and REST-APIs What Diagnostic underlines the company’s commitment these types of integration now can be happened? Analytics to supplement its innovative, high- implemented far more quickly, enabling alue performance extrusion lines with digital specific national grant stipulations and V Descriptive Analytics solutions and services, and thus answer individual integration needs to be met with the increasing demand of customers for minimal effort on the part of the customer. data integration and data-driven product extensions. Product tracking Information Optimization The end-to-end tracking of products is Hindsight Insight Foresight The new bitWise platform provides a common requirement in many indus- concrete solutions and has already tries. Accordingly, another key feature of Difficulty

films possess good as a perfect hold point and a source of transparency and high stretching forces. In addition, the nip output high gloss, which rollers 1 and 4 prevent the entrainment result from the high of air between the roller surface and the increase degree of orienta- film, thus ensuring uniform heat transfer tion. This induces across the roller width and reduced neck- finely disperseding of the film in the stretching gap. The film crystallinity and design of the pull unit with one steel and a wavelength that one rubber stretching roller is identical to permits light per- that of the holdback unit, but in a mirror meation. image version. All the rollers are equipped with individual line drives. Eight rollers for the central Advantages of an inline adjust- orientation able stretching gap module with an The impact of the film orientation on the inline adjust- crystalline structure of the film is deter- able gap mined by the actual stretching speed, Orientation is car- which is an arithmetical number. This fig- ried out between the ure is calculated by dividing the stretching holdback and pull gap length with the residence time of the units, whereby the film. The shorter the stretching gap and the higher the line speed, the greater the actual stretching speed.

SML MDO Orientation creates the crystallinity of the oriented film in an exothermic process. technology with inline Heat is generated through the orientation triggered sliding of the crystalline lamel- adjustable gap geometry lae. This promotes uniform film orienta- tion, but the film will break if the critical limit of the stretching speed is exceeded. During the past four years SML has de- of 500 m/min. Film weights range from The best film properties can be ob- livered a range of new machine direc- 10 to 40 grams/m² and the introduction tained by means of a defined, optimum tion oriented (MDO) cast film lines with of the MDO unit with inline adjustable film stretching speed in the stretching an inline adjustable stretching gap. The gap is the main factor in an enormous gap. Various test runs in this field have new MDO is employed for both hygiene increase in output. proven that the required mechanical films produced according to the cold film properties (tenacity, elongation) stretch process and applications with High tensile PET adhesive tape and achievable film shrinkage values PET, PA, PP and PE films manufactured film produced using the new can be set at a slow line speed, which using hot stretching. MDO unit saves precious raw material. Subse- PET adhesive tape films can be manu- stretching gap is adjustable from 70mm quently, the line speed and output may factured with a thickness of 65 microns to 350mm. Gap adjustment is effected be increased by simultaneously varying Breathable film lines operating and a 2.5m film net width, which dem- smoothly and precisely by means of servo the gap length in order to maintain the with the new MDO unit show onstrates the capability of the new MDO positioning drives. The holdback unit be- established optimum stretching speed. enormous output increases to handle enormous stretching forces. fore the gap features a combination of one The underlying principle involves the SML offers cast film lines for LLDPE These films can be produced with an rubber and one steel stretching roller. En- use of the optimum stretching speed breathable films with a maximum roller output of 1,000 kg/h at a stretching ra- lacement around the two rollers amounts determined for each application during width of 4m and a top production speed tio of 1:4. The resultant adhesive tape to almost 360 degrees and serves both all stages of production. Extrusion lines – 02 engineered to perform www.sml.at TECHREport

SML machines produce separator films for Li-Ion Batteries

A lithium-ion battery cell consists of five main components formed by the casing, The separator an anode, a cathode, electrolyte and a separator. Separator films are one of the is a key com- most expensive and important parts of ponent in all the battery and for roughly eight years, Roll stack of cast film line for separator film SML has been delivering extrusion lines Li-ion batteries for their production. Top Cap Gasket equipped with a Vent roll stack with as PTC The separator – requirements many as ten rolls and applications and film thick- which the size of the pores is increased The separator is a key component in all Li- Cathode Tab ness is controlled by means of a higher temperature and a ion batteries, which are used in e-vehicles, Top Insulator Anode by an automatic slower strain rate. Finally, subsequent re- plug-in hybrids, consumer electronics, sta- regulation sys- laxation reduces the internal stress within tionary battery storage systems and power Separator tem. The final unit the film and processing is concluded with tools. It is located between the anode and in the line is the slitting to the required end film length. Steel Can cathode and separates them in order to winding station. control charging and discharging, and pre- Advantages of the dry process vent internal short circuits. Therefore, the The structure As compared to the wet version, SML’s dry separator plays a key role with regard to Cathode and orientation process offers far greater environmental battery performance, safety and reliability Anode Tab of the pre-film friendliness, as solvents are not required Bottom Insulator and has to meet very specific requirements: depends upon to excavate the low-molecular material, the processing which in the wet process is needed for Low weight there is the wet process and on the other, conditions and the characteristics of the pore generation. Moreover, apart from the High porosity for the excellent the dry process for which SML delivers its resin. In the course of the annealing pro- lower line expenditure, the dry process transmission of lithium ions extrusion lines. cess, the film is annealed at a temperature also offers the additional advantage of re- Uniform pore distribution and size slightly lower than the polymer's soften- duced raw material costs. Good mechanical properties In the dry process, the melted polymer is ing temperature with the aim of improving and chemical resistance first extruded as a uniaxially oriented film. its crystalline structure. During stretching, The separator films produced in the dry The casting line consists of an extrusion the annealed film is first deformed in the process can have one- or three-layers and A dry separator production unit with up to two extruders and a sin- machine direction by a cold stretch, which a PP or PE base. They possess oblong- process gle or multi-manifold die. Upon leaving creates the pore structure by stretching shaped pores and owing to their open and Two different methods are available for the die, the melt is stretched by a ratio of the film at a lower temperature with a fast- uniform structure are suitable for higher separator production. On the one hand, up to 1:100. For film annealing, the line is er strain rate. Hot stretching follows during power densities.

ing strength, but some customers are concerned about the use of ozone, which Adhesion can be harmful to humans. There- is what it is all about! fore, this solution requires an ef- One of the most important factors in For the coating of thick, bulky materials ficient extractor lamination or coating is the bonding such as needle felt or products that can system. between the extrusion layer and the contain moisture from upstream produc- substrate. As not every coating or lami- tion processes, e.g. woven fabrics, the Equally com- nating layer adheres to every substrate, incoming web can be preheated with hot mon is the use SML has placed a special focus on this rollers, hot air or infrared panels in order to of coextrusion area and has researched into the possi- both dissipate the moisture and improve by means of bilities for modification of both the sub- the penetration of the coating layer into the feedblock tech- strate and the coating material in order substrate. nology. In this to improve the bonding force, or even contact with the substrate surface. During process, tie layers such as EAA or EMA create adhesion where previously none In the case of combinations such as PE-LD this interval the melt can oxidise, which is create the missing link needed to bond two existed. and PET film, which do not adhere chemi- important for the creation of bonding forc- material types that are usually incompatible. cally, a water-based anchor coating can es. At higher line speeds the melt has in- Most tie layers are corrosive and therefore Substrate-related measures be employed with a primer station and this sufficient time to oxidise and therefore the corrosion-resistant equipment is essential in The most commonly used tool with regard method is frequently used for printed pro- die distance has to be adjusted by means order to prevent system damage. to the substrate is corona treatment. In ducts in the flexible packaging industry. of a vertical extruder carriage in order that principle, this involves a high voltage dis- the TIAG can be increased and the prob- SML is able to compare the various meth- charge via an electrode onto the substrate Improved bonding with the lem solved. ods on its demonstration line, and to- surface. The applied energy changes the extruded coating layer gether with its customers subsequently molecular structure of the surface and thus Time in air gap (TIAG) is a well-known pa- Another method of improving melt oxida- select the best possible solution for the increases its wettability. Flame treatment is rameter in the extrusion coating field. It tion is to blow ozone onto the extruded melt achievement of market-conform bonding similar, but in this case passes with a gas defines the period that elapses between curtain directly in front of the lamination nip. strength in the various extrusion coated burner activate the substrate surface. the exit of the polymer from the flat die and This is a very effective way of raising bond- and laminated products. www.sml.at Nº31 / 01-2018 03 TECHREport Karat invests in three more Multi-functional SML Austrofil Cast Film Line installed at ExxonMobil in Shanghai spinning lines

Through joint efforts, ExxonMobil and SML have been working on developing a new concept for a multi-functional cast film line, which has now been suc- cessfully implemented in Shanghai. The extremely versatile line will be intro- duced to the market prior to Chinaplas in April 2018.

“This new machine at our Shanghai Tech- nology Center (STC) is an important global asset for the development of advanced cast film formulations based on our broad portfolio of performance polymers,” said Dirk Michiels, global polymer technology manager, ExxonMobil. “Moreover, we can The machine’s key specifications test our materials under real production are as follows: conditions at the same speeds as those used for customer lines.” five extruders in sizes from 60 to 90mm gross output of up to 1,300 kg/h A special feature is the machine direction SML and the Ukrainian yarn and car- A single machine, multiple orientation unit (MDO), which can be oper- pet producer Karat launched their suc- a 7-layer variable geometry feed block applications ated in-line for breathable hygiene, MOPP cessful partnership in 2012. Now, six The challenge facing SML was clear, as a mechanical line speed of 650 m/min and in-line, pre-stretch films. An additional years later, Karat is operating five SML single machine had to be capable of man- unwinding unit on top of the MDO provides machines at its plant in Ukraine and final net film width of 1,000mm ufacturing products for all the relevant cast off-line testing from roll to roll. three more are to be delivered this year. film applications such as: stretch wrap film, CPP films, breathable and embossed hy- Most importantly, despite the complexity of SML is very proud to have been selected In recent years Karat has become a well- giene films, protective and elastic films, as the entire line, the machine is simple to op- to accompany ExxonMobil on its path into established yarn and carpet producer in well as mono-oriented films. Accordingly, erate and all relevant components are easy the future and to be represented in the the world market and therefore the com- the machine’s 1,500mm roll width is de- to access. Different web paths through the Shanghai Technology Center with this mul- pany requires more capacity. Accordingly, signed for quick product changes, testing machine, combined with variable operation tifunctional cast film line. “The ExxonMobil three new SML Austrofil machines, con- without an excessive use of raw materials, modes, allow efficient changes from one STC Open House during Chinaplas 2018 sisting of two BCF and one FDY, will be and the up scaling of test results to larger solution to another. Additionally, ancillary will provide a unique opportunity to present installed in a new Karat production hall production lines. functions such as material pre-drying, coro- our latest cast film technology to the mar- during the current year. na treatment and melt embossing are incor- ket,” said Martin Kaltenecker, senior sales porated to increase the line’s product range. manager, SML. SML technology for high-quality yarns Addresses SML’s BCF technology enables the pro- duction of top quality yarns in a high- SML - Head Office speed process. The yarns possess ex- Bundesstrasse 1a SML’s new headquarters A-4860 Lenzing, Austria tremely high crimp, which is a major factor Phone: +43-7672-912-0 in achieving material savings. Accordingly, E-mail: [email protected] are under way! Karat’s success in over 30 markets such www.sml.at as the USA, Japan, China, India, Europe, SML started the construction of com- During the past 22 years, the demand and the CIS countries demonstrates the SML - Machinery Far East Sdn Bhd pletely new buildings to move the whole for SML machinery has grown steadily fact that the products from SML lines are (1029958-P) company to Redlham, . and company CEO, Karl Stöger, explains: just what customers are seeking. 1201 Block B, Menara Amcorp “The infrastructure of our cur- No.18 Jalan Persiaran Barat rent facility does not match This year, the Ukrainian company has 46050 Petaling Jaya our anticipated further expan- again shown its faith in SML’s spinning Selangor, Malaysia sion and therefore we have technology and is investing in its first Aus- Phone: +60-3-7955-9098 E-mail: [email protected] decided to create a base for trofil FDY line. Small wonder, if one con- future enlargement and tech- siders the fact that with this technology, SML - Moscow Office nological progress through SML has led the way in the high-tenacity Ogorodny proezd, 5 the building of a new head- polypropylene yarn segment for more Building 6, office 504 quarters in Redlham.” than twenty years. 127254 Moscow, Russia Phone: +7-495-618-8007 E-mail: [email protected]

SML - Beijing Office Events 2018 Unit 1410, Landmark Tower No. 8 North Dongsanhuan Road Event Location Booth No. Date Chaoyang 100004 Beijing, P.R. of China Phone: +86-10-6590-0946 Chinaplas Shanghai, China 2C59 April, 24 - 27 E-mail: [email protected] NPE Orlando, USA W6185 May, 7 - 11 SML - North America Service Inc. Suite 204 EXPO PLAST PERU Lima, Peru 100 May, 23 - 26 85 Eastern Avenue Gloucester MA 01930 Plast Milan Milano, Italy Hall 15/C71 May, 29 – June 1 USA Phone: +1-978-281-0560 ICE South East Asia Bangkok, Thailand 450 September, 5 - 7 E-mail: [email protected] Plastics & Rubber Indonesia Jakarta, Indonesia B-5517 November, 14 - 17

IMPRINT Publisher: SML, Bundesstrasse 1a, A-4860 Lenzing, AUSTRIA, Extrusion lines – Phone: +43 7672-912-0, Fax: +43 7672-912-9, E-mail: [email protected] Editor–in-chief: Bettina KREUZER Marketing Assistant, E-mail: [email protected] 04 engineered to perform © Date: 18.04.2018 www.sml.at