Maximum stable performance with EASY2 Run
Intelligent assistance systems raise blown film extrusion to a new level of automation - and create the basis for excellent printing and finishing results.
Article by: Ansgar Wessendorf, VerpackungsDruck & Converting, Issue 2/2026
Blow film extrusion is one of the most demanding processes in plastics processing. In almost no other process do thermal, rheological, and mechanical factors interact with such complexity. Among other factors, melt pressure, viscosity, cooling capacity, blow-up ratio, haul-off speed, and winding tension must be precisely coordinated within a narrow operating window. Even minimal deviations can immediately result in unstable frost lines, thickness profile errors, or optical and mechanical impairments defects in the film become apparent.
EASY2 Run is being successfully used on the state-of-the-art VAREX II blown film line at the Windmöller & Hölscher technical center in Lengerich
At the same time, market demands are increasing: multi-layer co-extrusion structures, high PCR content, sophisticated barrier layers, and tight thickness tolerances are making processes even more sensitive. For decades, the traditional response to this complexity was the empirical knowledge of experienced machine operators. But in times of a growing shortage of skilled workers, rising energy costs, and increasing demands for cost-effectiveness, this model is reaching its limits.
At K2025 in Düsseldorf, Windmöller & Hölscher (W&H) unveiled EASY2 Run, a new assistance system that fundamentally redefines process control in blown film extrusion: data-driven, adaptive, and consistently designed to deliver maximum yet stable system performance. This is not just about increasing throughput, but about achieving reproducible film quality as the foundation for the entire value chain - especially for printing and finishing. “Our goal was to make the enormous amount of data from modern blown film lines usable in such a way that the line can be operated at maximum output with consistently high quality at all times,” explains Fabian Herbort, Product Manager for Extrusion at W&H. “EASY2 Run does not blindly increase the system’s performance, but rather identifies unused performance reserves and offers operators the ability to exploit these through controlled adjustment of the operating point and to secure them on a permanent basis.”
EASY2 Run does not simply boost the performance of the blown film line; rather, it identifies unused performance reserves
From operator knowledge to data-driven process intelligence.
Modern blown film lines today collect an enormous amount of process data. More than 1,000 parameters influence output, product quality, and operational reliability. In practice, this complexity means that lines are often operated at a “safe margin” below their theoretically possible maximum capacity. Many lines run permanently below 80 percent of their potential capacity - not for technical reasons, but out of caution. Operating too close to the performance limit risks profile deviations or production stoppages, which can either lead to fluctuating and inadequate film quality or limit the overall efficiency of the system. The result is conservative settings with a corresponding loss of economic potential.
EASY2 Run continuously analyzes the real-time data available in the machine control system, evaluates the interactions between key process parameters, and clearly shows operators the plant’s untapped performance potential. In addition, it is possible to have the system automatically adjust to the operating point with maximum performance - taking into account the more than 1,000 parameters mentioned. The key factor here is not the short-term achievement of maximum performance, but its sustained, quality-assured stabilization.
The frost line as a sensitive indicator of quality
Its position influences the degree of crystallization, orientation, thickness profile, mechanical properties, and optical quality of the film. Even slight changes in melt temperature or in the intensity of internal and external cooling can shift the frost line. External environmental conditions, such as temperature fluctuations, can also be a negative influencing factor during operation; screw speeds and haul-off rates are adaptively adjusted. This marks a paradigm shift: the evaluation of critical process conditions is data-driven and thus objective and reproducible and not solely experience-driven and subjective.
High-quality film as the foundation for printing and finishing
However, the importance of a consistently produced, high-quality blown film does not end at the winder. On the contrary: it forms the indispensable foundation for all downstream processes - from printing, lamination, and coating to varnishing and roll finishing. A homogeneous thickness profile is crucial for consistent web tension during the printing process. Local thickness variations lead to uneven stretching under tensile stress, which significantly increases the risk of registration errors.
Especially in high-quality flexographic printing or with complex gravure designs featuring fine halftone gradations, even minimal deviations in the longitudinal or transverse profile can result in visible quality defects. Tight tolerances in the quality of the printing substrate significantly reduce these risks, ensured by a stable frost line and precise profile control. The film runs more smoothly through the printing press, register control operates consistently within defined tolerances, and waste is reduced.
Surface quality and flatness
In addition to the aforementioned advantages regarding dimensional stability during the printing and finishing processes - which result from the film’s uniform mechanical properties- this also ensures uniform and consistent corona or plasma pretreatment. During printing, this forms the basis for uniform ink adhesion and thus for uniform ink application and a consistently high-quality print image. The dimensional stability of the film is also crucial for lamination and further processing. Shrinkage stresses resulting from inhomogeneous cooling or uneven orientation can later lead to waviness, curling, or delamination. A precisely controlled frost line position ensures a uniform crystallization structure across the entire web width. This not only improves the mechanical properties but also enhances flatness during the printing and lamination processes - a key factor for high-performance systems operating at high web speeds.
Economic leverage along the value chain
Any quality defect that arises during extrusion multiplies its costs in subsequent processes. Waste in printing, machine downtime, or complaints due to visual defects result in significantly higher expenses than stable, reliable film production. In this respect, EASY2 Run is not only a tool for increasing output but also an economic lever along the entire value chain in packaging printing and converting. A consistently high-quality film increases overall equipment effectiveness not only in extrusion but also in downstream processing steps.
EASY2 Run Overview
Source: Verpackungsdruck & Converting Magazine
“EASY2 Run combines extrusion, quality, and cost-effectiveness - laying the foundation for excellence in packaging printing and converting right from the extrusion stage.”
– Fabian Herbort, Product Manager, Extrusion, at W&H –
At the heart of the control strategy lies one of the most critical parameters in blown film extrusion: the frost line. It marks the point in the formed polymer bubble where the melt solidifies and takes on its final shape
Full transparency regarding performance reserves
A key feature of EASY2 Run is the clear visualization of performance reserves. Mechanical limitations, thermal process limits, and quality-related indicators such as profile and frost line are consolidated and presented in an easy-to-understand format.
The machine operator is shown how far the system is from the maximum stable operating point and which reserves can be safely activated. A single push of a button is all it takes to switch to the optimized performance range. The system coordinates all control loops autonomously. For the operator, this does not mean a loss of control over the extrusion process, but rather high-level decision support.
Real-world applications show performance gains of up to 20 percent, and in some cases even more. For operators, this means a significant increase in throughput while maintaining the same quality, as well as a significant reduction in costs. “Many systems have significantly more technical potential than is utilized in day-to-day operations,” says Fabian Herbort. “With EASY2 Run, we make these performance reserves transparent and enable them to be tapped in a controlled manner at the push of a button -including continuous monitoring of quality-relevant parameters. For us, EASY2 Run is not merely a performance tool, but a stability tool. We provide the operator with full transparency regarding the physical and process-related limits of the system - while simultaneously ensuring that these limits can be safely utilized. This builds confidence in higher performance.”
Available for: OPTIMEX II and VAREX II
EASY2 Run is available for the current W&H blown film lines, OPTIMEX II and VAREX II, and can also be integrated into existing W&H lines as a retrofit solution under certain conditions. The OPTIMEX II stands for industrial efficiency. Designed for the cost-effective production of three- and five-layer PE films, it combines high output with stable, reproducible processes. Proven technologies such as the MAXICONE die head, a motorized ARCTIS II cooling ring, and modern profile control systems form the foundation. Its clear, standardized configuration makes it particularly attractive for high-volume producers focused on laminating films and stretch hoods. In contrast, the VAREX II represents a modular high-end platform. With structures of up to eleven layers, working widths of up to 3600 mm, and optional integration of machine-directional orientation (MDO), it opens up a wide range of applications - from sophisticated barrier structures to specialized technical films. While the OPTIMEX II stands for focused efficiency, the VAREX II embodies maximum flexibility and innovation. EASY2 Run delivers its full potential on both platforms -tailored to the respective production philosophy.
Support Concept for Digital Extrusion
EASY2 Run is part of W&H’s comprehensive automation strategy. When combined with EASY2 Change and TURBOSTART, it creates a seamless support system that covers the entire production cycle of blown film extrusion.
- EASY2 Change optimizes product and format changes. The system guides the operator through product and recipe changes in a structured manner and automatically adjusts the relevant machine parameters. Changeover times are reduced, sources of error are minimized, and reproducibility is improved.
- TURBOSTART automates start-up and shutdown procedures. Screw speed, cooling ring, take-off, winder, and other machine parameters are coordinated and controlled, reducing complex start-up processes to just a few guided steps. This significantly increases process reliability, especially during frequent production changes. In addition, this allows for a reduction in the number of operators required during the startup process, meaning that even a single operator can safely start up a blown film line.
All systems are based on a similar data and hardware infrastructure. Sensors for temperature, pressure, output, and speed, cameras for frost line and bubble detection, and modern HMI visualizations form the technological foundation.
Support, not substitution
Despite its high level of automation, EASY2 Run is not intended to replace qualified personnel. Rather, the system acts as a “co-pilot.” It makes complex interrelationships transparent, reduces the cognitive load on the operator, and enables even less experienced employees to operate systems safely within the optimal performance range. Experienced plant operators benefit from the reduced workload during routine operations and can focus more on process analysis and continuous improvement. The machine thus becomes a learning, adaptive system that intelligently connects operators and automation.
Conclusion: Quality starts with the extrusion process
The demands of modern packaging printing can only be met if the foundation is right. Registration accuracy, brilliant print images, secure lamination, and efficient post-processing require a dimensionally stable, homogeneous, and reproducibly manufactured film. With EASY2 Run, blown film extrusion evolves from reactive process management to proactive performance optimization. Maximum productivity and the highest film quality are no longer seen as opposites, but as two sides of the same coin. For the packaging printing industry, this sends a clear message: anyone who wants to achieve top performance in printing must rely on intelligent, data-driven process control right from the extrusion stage. EASY2 Run provides a crucial technological building block for this and marks another step toward fully digitized, self-optimizing film production. “Anyone who wants to remain competitive today must understand and keep an eye on the entire value chain,” concludes Fabian Herbort. “EASY2 Run combines extrusion, quality, and cost-effectiveness thereby laying the foundation for excellence in packaging printing and converting right from the extrusion stage.”
EASY2 Run is available for W&H blown film lines OPTIMEX II and VAREX II and can also be integrated into existing W&H lines as a retrofit solution under certain conditions.
“Our goal was to make the enormous amount of data generated by modern blown film lines usable in such a way that the line can be operated at maximum output with consistently high quality at all times.”
– Fabian Herbort –
