RETROFIT SOLUTIONS

Benefits

• Operator independent consistent production, no room for errors or to forget anything
• 100% Reproducibility of air ring settings
• Number of necessary klicks, the time needed as well as the waste created during a product change is heavily reduced
• Integration of company- and product specific checkpoints

Retrofit Scope

• Two camera-based system integrating bubble stability, bubble shape and frostline detection
• Motorized, encoder controlled and recipe integrated ARCTIS II Air Ring
• Intuitive dashboard software
• Plug & Play installation (< 3 days)

Benefits

• 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

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

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 120 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

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

Retrofit Scope

• 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: ARCTIS air ring, Die layout tailored to suit the extruder, Supporting cart, Gauge profile control, Corrosion resistant design

Benefits

• Up to 60% increase in output
• Easy to retrofit to W&H and other manufacturers equiments
• Flexible use of different air ring inserts
• 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

ARCTIS Package 1 (does not include gauge profile controller)

• ARCTIS air ring
• Manual
• Available Options: Fans, Air ring height adjustment

ARCTIS Package 2 (includes gauge profile controller)

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

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

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
• 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

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
• Technical documentation

Benefits

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

• Touchscreen technology
• Graphic representation

• Easy operation

Retrofit Scope

• PROCONTROL TS process automation
• B&R Control
• Gravimetric system upgrade (if applicable)
• Electrical cabinets, connection parts and cables
• Technical documentation

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 RUBY 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

• RUBY- software package
• Machine software update

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

Benefits

• improved film properties
• Enhanced tensile strength and stiffness
• Better shrink properties
• Increased gloss and transparency
• Saves resources
• Optimizes films for specific uses

Retrofit Scope

• Complete MDO unit, with 8-14 controlled rollers (depending on final application)
• Corresponding Temperature Control Units (TCU)
• Automation to reduce neck-in
• Fully integrated in existing line automation
• Piping, cabling, necessary adaption work
• Technical documentation

Benefits

• 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

• 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

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