Significantly lower energy consumption and maximized film quality as key benefits
Manucor S.p.A. (part of Plastchim-T Group) operates the BOPP packaging line ZEN in Sessa Aurunca, Italy, which produces speciality products such as label films. Building on an drives upgrade 2023, the next step towards energy-saving film production to ensure competitiveness was recently taken.
Innovative engineering enhances product quality and reduces energy usage
To ensure stable production with high film output, Manucor invested in a twin-screw extruder to replace the three old HEX extruders of the biax line (two melting and one metering extruder). The advantages of a modern Brückner twin screw extrusion, in addition to reducing the energy consumption, are best melting quality, high flexibility and no necessary pre-drying in the raw material supply. Furthermore, the compact machine design - one extruder requires less space than three - is easy to maintain and can be adapted for different production setups that enable output ranges up to 9,200kg/h for PP film.
Manucor’s requirement to carry out the upgrade in four weeks during the Christmas period resulted in a sophisticated schedule in order to be able to restart the production line as quickly as possible after the holidays. In addition to removing the old equipment (raw material tower, dryer and three extruders), the scope of the upgrade for the Brückner Servtec team primarily comprised assembly preparations as well as monitoring the construction progress, since the Manucor personnel installed the new twin-screw extruder independently during the Christmas period.
The Brückner Servtec experts returned for further assembly work and checks, in order to prepare the check-up and line re-start together with the Manucor team, which took place on time and immediately delivered saleable film after the first cut.
Long-standing partnership drives record-time revamp
‘This fast progress was only possible due the long-standing, good relationship with Manucor and the installation companies (electrical and mechanical) we have, as they know our processes and provide us with straightforward support for any issues that arise. Thanks to this and the incredible commitment of everyone involved, the requested very short downtime was met and the system was back in production on the first day after four weeks.’, emphasizes Joachim Weese, project manager at Brückner Servtec.
Manucor’s COO, Luigi Antonio Martinese, was extremely satisfied with the achievements after the successful start-up: ‘The BIG revamping performed in Manucor ZEN line has been completed without any major technical problem; very positive is the fact that the line has been put in operation in only 4 weeks despite the Christmas and year end period! The result of less energy consumption compared to what was original installed - has been achieved, and on top the fact that the line has been restarted in very positive and stable conditions.’
Together with Brückner Servtec, Manucor has taken a major step towards energy-efficient and competitive film production, and has paved the way for future optimizations of their film stretching line.
