RETROFIT SOLUTIONS

New Modules for Your Blown Film Lines

1. PROCONTROL TS operator console and OPTIFIL PLUS process automation, 2. Gravimetric resin metering and throughput control, 3. Plastifying units (extruders, screws, etc.), 4. MAXICONE dies, 5. MULTICOOL air rings to increase output in conjunction with patented gauge profil controllers (OPTIFIL P2K, P3K) , 6. VARIOCAGE film sizing unit, 7. Thickness gauges (contact, non-contact, traversing), 8. Haul-off units and appropriate components, 9. Winder add-ons

New Gravimetric Weighing System and Vacuum Feeders

Benefits

  • Constantly controlled mixing ratio and consistent material flow, eliminating disintegration
  • Constant resin supply for tight film width tolerances and optimal gauge profile
  • Patented integrated residual resin minimizer (resin feeding is automatically stopped according to entered order specifications) ensures short change times and notable resin savings
  • Centralized operation through integration with PROCONTROL TS
  • Multi-section screws minimize product change time and eliminate the need for changing metering screws
  • Metering hoppers can be operated also from the extruder

Retrofit Scope

  • High-precision continuous gravimetric metering and throughput control system for perfect mixing ratios
  • Retrofit capability for up to 7 components per extruder
  • Gravimetric system (module G) and/or vacuum feeders
  • Electrical equipment
  • PROCONTROL TS operation and control system (if applicable)
  • Technical documentation
  • Optional Extras: Powder metering capability, the metering unit designed for hightemperature applications

New gravimetric system (module G) and vacuum feeders can be retrofitted to all W&H blown film lines as well as extrusion equipment of other manufacturers.

Installation

Installation of gravimetric system and vacuum feeders, including all components, will be done by W&H service technicians.

Installation: approx. 1 – 2 days per gravimetric system and vacuum feeder (including training)

VAREX Extruders

Benefits

  • High melt output at a low temperature level
  • Optimal optical and mechanical product properties resulting from perfect melt quality
  • Universal HPS screw suitable for the whole range of marketable resins
  • Special grooved bush cooling concept
  • Modular easy-change capability for screws and barrels, e.g., to optimize melt quality
  • Castor mounted extruders ensuring ease of installation and retrofitting
  • Maximum wear protection through tungsten carbide coating of screw flights and feed barrel

Retrofit Scope

  • VAREX extruders from 50 mm to 135 mm (30 D)
  • Geared AC motor or gearless torque motor
  • Wear resistant screw
  • Quick resin drain capability
  • Heating with temperature probe
  • Electrical equipment
  • Integration with PROCONTROL TS
  • Technical documentation
  • Optional Extras: (High) temperature control unit for the grooved bush, Shut-off slide for PA/EVOH, Specially laid out dies for the retrofit, extruders, Corrosion resistant design, LT screw for increased output

VAREX retrofit extruders are available for all W&H lines as well as other systems.

Installation

Installation of extruders, including all components, will be done by W&H service technicians.

Installation: 1 – 2 days per extruder (including training)

New MAXICONE Die Heads and Dies

Benefits

  • Fewer dead zones within the melt flow system
  • Reduced melt volume as well as easy assembly and disassembly because of compact design
  • Excellent film quality
  • Notably reduced product change times
  • Flexible layer ratios
  • No seals (Teflon or the like) in the melt flow system
  • Customized die designs to suit specific applications
  • Pre-purchase testing of dies at W&H extrusion lab

Retrofit Scope

Superb film quality and minimum change times are the result of MAXICONE die heads and dies from W&H.

  • Die head for 1 – 11 layers and/or dies with diameters from 120 mm to 900 mm
  • Heating with temperature probe
  • Air distribution inside the die head
  • Die assemblies designed for minimum melt build-up
  • Internal bubble cooling
  • PROCONTROL TS operation and control concept
  • Electrical equipment
  • Technical documentation
  • Optional extras: MULTICOOL air ring, Die layout tailored to suit the extruder, Supporting cart, Gauge profile control, Corrosion resistant design

New MAXICONE die heads and dies can be retrofitted to all W&H blown film lines as well as other systems.

Installation

Die head installation, including all necessarycomponents, will be done by W&H service technicians.

Installation: approx. 5 days (including training)

MULTICOOL Air Ring

Increase your output and film quality by retrofitting W&H dies or MULTICOOL air rings, which are available for W&H and other dies. A new gauge profile controller is available as an additional option.

Benefits

  • Easy to retrofit to W&H and other dies (both stationary and rotating)
  • Flexible use of different air ring inserts (single lip, dual lip, etc.)
  • Up to 50 per cent increase in output
  • Increased profitability as a result of major resin savings
  • Consistently tight gauge tolerances, saleable production shortly after line start-up or after product changeover
  • Service-friendly technology
  • Air ring height adjustment to ease cleaning and optimize production

Retrofit Scope

MULTICOOL Package 1 (does not include gauge profile controller)

  • MULTICOOL air ring
  • Manual
  • Available Options: Fans, Air ring height adjustmen

MULTICOOL Package 2 (includes gauge profile controller)

  • Package 1 Delivery Scope
  • Gauge profile controller
  • PROCONTROL® TS process automation
  • Preassembled cable
  • Thickness gauge
  • Oscillating assembly
  • Availabe options: Fans, Air ring height adjustment

Installation

Installation of MULTICOOL retrofit packages, including all components, will be done by W&H service technicians.

Installation: approx. 5 days (including training)

VARIOCAGE

Improve film width tolerances with optimal calibration that saves trim and satisfies your customers with its operating properties – all with the non-contact NOSTIC cage.

Benefits

  • Optimal bubble support with minimal width variation achieved with 15 optimally placed guides
  • Mechanical parts of adjustment unit are protected from dirt and paraffin buildup, large dust particles and contact
  • Wear-resistant and low-maintenance CFK (carbon fiber) rollers with no effect on the film surface
  • Non-contact Nostic segments for special applications with constant width tolerances
  • Film sizing system integrated in control unit of blown film line

Retrofit scope

  • VARIOCAGE
  • Guiding segments
  • Electrical components
  • PROCONTOL TS-operating concept
  • Technical documentation
  • Optional equipment: CFK (carbon fiber) rollers, Teflon rolls, or NOSTIC non-contact air Segments, Monomer exhaust, Ultrasonic bubble control

The VARIOCAGE film calibration unit ensures tight tolerences.

Installation


The film calibration unit and components are assembled by W&H service technicians.

Installation: approx. 2 days (incl. training)

PROFILE BOOSTER

Increases the effective up-time of your blown film line through intelligent die and/or air ring control at line start, ensuring fast saleable quality production and short job change times.

Benefits

  • Optimized line start-up resulting in notably reduced start-up waste (up to 60%)
  • Fast saleable quality production resulting in reduced job change times
  • Increased effective up-time of the extrusion line
  • Automatic activation after EASY CHANGE (automatic size change capability is available only for W&H lines)
  • Can be retrofitted to W&H VAREX blown film lines, including older ones, as well as systems of other manufacturers.

Retrofit Scope

  • Software package
  • Thickness gauge modification
  • Wiring and documentation

PROFILE BOOSTER helps you reach the desired gauge profile, and with it saleable production, faster.

Installation

Adaptation of existing control system and change of hardware components (if necessary) will be done by W&H service technicians.

Installation: approx. 1.5 days (including training)

MMC Retrofit

Get ready for the future and boost your blown film production by retrofitting state-of-the-art MMC* control technology.

Benefits

  • State-of-the-art B&R control and CAN bus technology
  • Long-time spare parts availability
  • Reproducible process data
  • Increased effective up-time
  • Planning reliability
  • Overall line monitoring and control
  • Touchscreen technology
  • Graphic representation
  • Increased ease of operation

Retrofit Scope

  • PROCONTROL TS process automation
  • B&R control
  • Gravimetric system upgrade (if applicable)
  • Electrical cabinets, connecting parts and cables
  • Manual

Installation


Retrofitting of control hardware and of appropriate operator control elements will be done by W&H service technicians.

*) MMC stands for Siemens Multi Micro Computer

RMOS-IPC Retrofit

Replacement of previous RMOS-IPC hardware with the latest Windows APC 620 technology.

Benefits

  • Long-time spare parts availability
  • The latest CAN bus technology
  • Reproducible process data
  • Increased machine up-time
  • Planning reliability
  • Overall line monitoring
  • Touchscreen technology
  • Graphic representation
  • Easy operation

Retrofit Scope

  • 17" TFT touchscreen color monitor
  • Windows operator interface
  • Industry PC APC 620 and function keys
  • Touchpad keyboard
  • Printer
  • Manual

Installation


Retrofitting of components and replacement of the appropriate elements will be done by W&H service technicians.

Installation: approx. 1 day (including training)

ISP Retrofit

The Information System Production (ISP) is a software package that allows you to keep track of your film production and to have the process data of your W&H blown film lines recorded and printed out.

Benefits

  • Decentralized monitoring of order, production, machine and winder data
  • Client-Server technology is a convenient tool for quality assurance and allows the collected data to be accessed on all connected computers for the purpose of production data acquisition, job costing, statistical process control, etc. …
  • Similar layout of ISP and PROCONTROL TS screens for visualisation of data
  • Split screen for viewing the data of current jobs and previously run jobs
  • Easy to use without special training

Retrofit Scope

  • ISP software package
  • Machine software update

Requirements
PC with Hardware and Software Configuration based on W&H specifications to be interfaced with the IPC and, if applicable, with customer network via LAN. Update of existing software in the PROCONTROL TS operator console and installation of software on existing computer will be done by W&H service technicians

ISP Retrofit

nstallation: approx. 1 day (including training)

Module XTENSION

This module allows for easy integration of customer supplied components such as vacuum feeders, gravimetric systems, chillers, draws, winders, etc. … into VAREX blown film extrusion lines.

Benefits

  • Display of all parameters and operation of the VAREX line and customer supplied
    components via the PROCONTROL TS operator column
  • Provision of up to six B&R control modules for interfacing with non-W&H components
  • Display of up to 32 trends per control module for quality control during production.
  • For rapid product change, 32 receipes can be stored in each module and retrieved
  • 48 detailed alarm messages per control module ensuring overall line monitoring and control, and quick troubleshooting.

Retrofit scope

  • Control system
  • Software

The XTENSION module retrofitted into the PROCONTROL TS operator column gives simple and safe operation of customer supplied components integrated into a W&H VAREX blown film extrusion line.

Installation


For electric interfacing of customer supplied components with the PROCONTROL TS column, B&R control modules will be provided and installed. Installation of the necessary software will be done by W&H service technicians.

Installation: approx. 1 day (including training)

Retrofit solutions for blown- and cast film lines

FILMATIC-Winders

Easy processing with a smart design: With a film winder from W&H's comprehensive FILMATIC range, you can offer perfect, straight-edged rolls from start to finish.

Benefits

  • Extension of blown film product line
  • Optimal winding quality, perfect for subsequent processing
  • Improved handling with the new roll handling system
  • Integrated control system
  • Easy to use technology
  • Safety features and equipment

Retrofit Scope

  • Winders with center drive and gap winding
  • Treater systems
  • Spreader roll systems
  • Edge Trim and bleed trim removal system
  • Center Drive
  • Deionization units to prevent static buildup
  • Newest generation of winding shafts
  • Roll handling system (crane and shaft extractor for winding shafts)
  • Safety package

Installation

Filmatic winders and components are assembled and installed by W&H service technicians

Installation including training: approx. 5 days (depending on requirements)

Retrofit Solutions for Cast Film Lines

FILMEX Extruders

Upgrade your cast film line by retrofitting high performance FILMEX extruders with SMB (Smooth Barrier) screws and crosshole mixing sections.

Benefits

Replacing extruders or retrofitting cast film lines with new FILMEX extruders from W&H provides a variety of benefits.
Here are just a few of them:

  • Flexibility with resin types and a broad throughput range
  • Optimum optical and mechanical product properties through perfect melt quality
  • Enhanced efficiency through high specific output
  • Excellent wear resistance guarantees extraordinary longevity

Retrofit Scope

  • Extruders from 50 mm to 180 mm (30D) mounted on base frame, pre-wired and ready for connection
  • SMB extruder screw with
    • performance and flow optimized barrier zone for universal application, including LDPE / (m-) LLDPE, PP, PA, EVOH, EVA, PS, and PET
    • feed-effective spiral shear section and highly efficient crosshole mixing section
    • maximum wear resistance through tungsten carbide coating of screw flights
  • AC gear motor or gearless torque motor
  • Hopper section with temperature controlled smooth feed bush
  • Bimetal feed barrel with tungsten carbide based wear protection
  • Electric heating and air cooling
  • One or two melt pressure probes and one melt temperature probe
  • Screw extractor

FILMEX extruders can be retrofitted on all cast film lines, including W&H and others.

Installation

Installation of extruders including all components either by W&H service technicians or by customer.

Installation: approx. 1- 2 days per extruder (including training)

More ways to improve the performance of your lines

Optimum output and quality in the long term

Our DIE CLEANING SERVICE makes it possible to run a used die with the output capacity and quality of a new one.

Learn more

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