bopp film lines in 2010 – what does the market demand? film lines in 2010 – what does the market...
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BOPP film lines in 2010 –What does the market demand?
Markus GschwandtnerBrückner Group
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ContentsContents
CurrentCurrent Trends and Trends and DemandsDemands
OurOur Superior Superior OffersOffers
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BOPP: Demand vs Production - World
0
500.000
1.000.000
1.500.000
2.000.000
2.500.000
3.000.000
3.500.000
4.000.000
4.500.000
5.000.000
5.500.000
6.000.000
6.500.000
7.000.000
7.500.000
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Tons
/ Ye
ar
Demand Actual: CAGR 1998-2004 of 10,2% p.a.Demand Projection on CAGR 7 % p.a.Demand Projection on CAGR 5,5 % p.a.Demand Projection on CAGR 4 % p.a.Production
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Total New BOPP Capacity in 2006: 194,000 tpaTotal New Number of Lines: 7Market Share Brückner: > 50 %
Additional BOPP Capacity in 2006 - Sold by Brückner
Americas
30,000 tpa
Europe
48,000 tpa
Asia
87,000 tpa
BOPET & others world wide 48,000 tpa
India
29,000 tpa
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CurrentCurrent Trends and Trends and DemandsDemands
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Premium Segment:
● Small lots● High prices
Average Segment: (Low speed, 3 layer)● Getting smaller and smaller
Discount Segment:
● Big volume● Little margins
Current Consumer Buying Behaviour
100%
1973 1981 1986 1990 2010Source: DPF
Flexibility
Efficiency
Premium Segment
Average Segment
Discount Segment
(up to 6.6m, Multi layer, LISIM®)
(8, 10, 12 m)
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Demands from Converters` EyesMultifunctional films as a replacement for laminate structures
Substrate to print on
WVTR Barrier
OTR Barrier
Sealing layer
Puncture resistance
Aroma protection
Multifunctional BOPP films
Source:
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Market Needs = Our Challenges
Replacement of aluminium foil
Replacement of paper
Replacement of PVDC coated films
Down gauging
Replacement of lamination steps
Replacement of PVC sleeves
Market Needs Our Challenges
Ultra-high barrier film BOPP met
White opaque film with high modulus
Co-extruded EVOH based barrier film
Thin films with high mech. properties
Multifunctional co-extruded films
MD shrinkable labels
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OurOur Superior Superior OffersOffers
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Future Challenges
Efficiency Flexibility
Total Energy Management
LIWIND
Direct Drives Extruders
Automatic Product Changes
Multipurpose Lines
LISIM®
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Efficiency - Total energy management
Oven heat recovery systemfor energy savings > 30%TDO exhaust air amountcontrol by condensatesensor
Twin screw extrusion for less energy consumptionWater cooled motors –saving air condition power
Electrical energy management systemRegenerating energy for line drive system
Stand-alone power stationfired by gas for electrical &thermal energysavings up to 1 Mio € / a @ 3 MW
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Efficiency - LIWIND
(patents pending)
Mechatronic system withLinear motors for movementLinear motors for damping
Direct force transmissionNo wearNo backlash
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Efficiency - Direct drives extruders
Energy Efficiency up by 5,5 %vs. motor-gearbox
No gearbox – less maintenance
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Recent 10.0m BOPP Line:speeds beyond 400m/min, best film quality and film thickness profile
Efficiency – High Speed and Excellent Quality
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Flexibility - Automatic product changes
Drastically reduced changeover time Highly flexible extrusion systems and resin feedingAccurate level control of the day silosFully automated product change procedure
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Flexibility - Multipurpose lines
Additional Investment for Multi-Purpose Preparation
Dedicated BOPP Line, i.e. 5-layer, 6.6 m width
Synthetic Paper
Barrier (EVOH) BOPE BOPLA OPET-G OPS
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Flexibility - Simultaneous Stretching
• Proven technologysince 1996
• No wear & tear• MD stretching ratio 10• Speed up to 450m/min• Width up to 7.2 m• Technology Centre /
Pilot line forUpscaling, New productsand Pre-marketing
SimultaneousStretching
Tenter Frame
Double Bubble
FixedStretching Ratio
Flexible Stretching Ratio
Pantograph
Spindle
LISIM®
MESIM
References:3x BOPET2x BOPP2x Pilot lines 1x Optical Films
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Flexibility - LISIM® added value
Customized shrink properties
Superior barrier properties
Advanced sealing properties
Enhanced mechanicalproperties
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Film-ProductionSequential &
Simultaneous
MetallizationSiOx
LaminationPrint
Adhesive
Packaging End userPackaging propertiese.g. haptics
Joint Project Along the Value Chain to Enhance Packing Properties at Reduced Costs
Project coordination
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Used Systems for Packaging Trials
New film laminates show equal or even better barrier properties
Current Standard Future Potential
Peanuts80 µm Film CompoundBOPET 12µm // BOPPmet 15µm // PE-LD 50 µm
38 µm Film CompoundBOPET 7µm // BOPPmet 18µm / PE-LLD 12µm
Chips
27 µm Film CompoundBOPPmet 15µm // BOPP 12 µm
40 µm Film CompoundBOPPmet 20 µm // BOPP 20 µm
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Example for Substituted Film Laminate 80µ -> 38µmApplication: Peanuts
BOPET,12µm, Reversed Print
BOPP, 15µm, metal.Lamination
PE-LD, 50µm
Lamination
BOPET,7µm Reversed Print
Lamination
BOPPmet,18µm,PE-LLD 12µm
Duplex Compound1 Laminating Step
Triplex Compound2 Laminating Steps
Remark
38 µm80 µmGauge
PET 7 µm // BOPPmet 18 µm / PE-LLD 12 µm
PET 12µm // BOPPmet 15µm // PE-LD 50µm
Material
Future PotentialActual Standard
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Tests Along the Added Value Chain
Sensor TestPackagingLaminatingMetallizingFilm production
In Progress
AcceptationTest
Process ability
Process ability
OTR, WVTROptical Density
Optics Mechanics
Sealing
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Mature Research & Development
Brückner Technology Center
Up to 7 layers with 6 extruders
Extension to sequential andsimultaneous operationby July 2006
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Expansion of LISIM® Pilot Line – Your Benefits
Simultaneous AND sequential mode available, easy switchable !Additional highly flexible MDO with multi-gap stretching New IPC system for vital information concerning machine parametersAdvanced Manufacturing Management System (MMS)
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Vision without action is a daydream,
Action without vision is a nightmare !
Japanese Proverb
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ThankThank YouYou!!