Successful modernization of a cast film winder at Profol Harbke GmbH
Ensuring production and operator safety through innovative technical solutions
Comprehensive modernization after 23 years of operation
After more than 23 years of reliable operation, the cast film winder of the FILMEX extruder line with a 5-layer feedblock was modernized. The aim of the project was to ensure the high reliability and quality of the production processes in the long term while increasing operator safety through the use of modern technology. As part of the modernization, discontinued components were replaced in a targeted manner to ensure the long-term availability and functionality of the FILMATIC M winder. The measures included:
- Installation of new control cabinets,
- Replacement of the converter technology,
- Introduction of a modern user interface (HMI).
Particular emphasis was placed on maintaining the familiar operating structures in order to avoid a longer familiarization period for the operating personnel. A short training session was enough to enable a seamless transition during operation. This meant that production could continue without significant interruptions.
Control cabinet before
Control cabinet after
FILMEX winder before upgrade
FILMEX winder after upgrade
"We value the close and cooperative partnership with W&H. Thanks to their commitment, we were able to implement the modernization within the planned time frame and continue production without interruption."
Marco Dudda, Head of Production & Technology, Profol Harbke GmbH
Enhanced operator safety and maintained winding quality
One of the main objectives of the modernization was to increase operator safety, which was achieved by using modern technology and complying with current safety standards. At the same time, the excellent winding quality at a production speed of up to 200 meters per minute had to be maintained. The precise technical implementation has not only ensured the efficiency of the system for years to come, but also its performance. This ensures that production standards will continue to meet the highest requirements in the future.
Profols view on the project)
The close cooperation with Windmöller & Hölscher (W&H) was crucial to the success of this project. From the initial planning phase to the final commissioning, W&H provided technical expertise and comprehensive support. Particularly noteworthy is the intensive support provided during the implementation phase and the subsequent support after production resumed. Thanks to short response times and excellent project management, production could continue without significant downtime or delays.
Outlook: Further optimization measures
The modernization of the cast film winder was an important milestone. In the next step, Profol GmbH plans to replace the plasticizing sets of the four extruders. In addition, the temperature control of the chill roll and the cooling roll will be overhauled. These measures are intended to further optimize the existing quality and efficiency standards and to make the plant future-proof in the long term.
