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
ContentsContents
CurrentCurrent Trends and Trends and DemandsDemands
OurOur Superior Superior OffersOffers
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
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
CurrentCurrent Trends and Trends and DemandsDemands
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)
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:
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
OurOur Superior Superior OffersOffers
Future Challenges
Efficiency Flexibility
Total Energy Management
LIWIND
Direct Drives Extruders
Automatic Product Changes
Multipurpose Lines
LISIM®
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
Efficiency - LIWIND
(patents pending)
Mechatronic system withLinear motors for movementLinear motors for damping
Direct force transmissionNo wearNo backlash
Efficiency - Direct drives extruders
Energy Efficiency up by 5,5 %vs. motor-gearbox
No gearbox – less maintenance
Recent 10.0m BOPP Line:speeds beyond 400m/min, best film quality and film thickness profile
Efficiency – High Speed and Excellent Quality
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
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
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
Flexibility - LISIM® added value
Customized shrink properties
Superior barrier properties
Advanced sealing properties
Enhanced mechanicalproperties
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
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
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
Tests Along the Added Value Chain
Sensor TestPackagingLaminatingMetallizingFilm production
In Progress
AcceptationTest
Process ability
Process ability
OTR, WVTROptical Density
Optics Mechanics
Sealing
Mature Research & Development
Brückner Technology Center
Up to 7 layers with 6 extruders
Extension to sequential andsimultaneous operationby July 2006
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)
Vision without action is a daydream,
Action without vision is a nightmare !
Japanese Proverb
ThankThank YouYou!!