Retrofit: Win-win for KABLONEX
The advantages of retrofitting vintage machines are obvious. Whenever we talk to our customers about retrofitting, we get a big smile - there are hardly any disadvantages. But as always, it's better to prove than to tell, so we're very pleased that KABLONEX allowed us to tell their retrofit story.
KABLONEX saw great potential in retrofitting an old blown film extrusion machine to save energy, increase productivity and improve melt quality. The machine in question was a non-W&H machine with an old Mono 120 extruder. Due to its age, it had become very noisy, had very poor melt quality and (very) high power consumption (during heating: 244 kW, during production: 95 kW). Due to the very limited space in the existing production area, a flexible design of the new components was crucial. After a detailed analysis of the status quo and a comparison of objectives, the following measure was planned
- New 90.30D stand-alone extruder with control and operator panel
Expectations were high from the start, but after a problem-free installation and a quick and easy start-up after the retrofit, the results were very convincing:
- Energy consumption reduced by 36% (during heating: 155 kW, during production: 62 kW)
- Energy savings of €62,000 per year
- 20% increase in output (limited by die head back pressure)
- Better melt quality compared to the old extruder
- Silent production
In addition to the hard facts, the qualitative aspects were also convincing Oskar Nawrocki, CEO at KABLONEX summarizes it as follows: "Finally, you can't hear in the production hall whether the mono line is working or not. The new stand-alone extruder makes it easier to start up, and this has significantly improved the safety of operation". This retrofit, like many others, demonstrates the benefits of retrofitting. Sustainable use of material and financial resources, as well as
- More output, less waste
- Quality improvement
- Sustainability: energy optimization, use of existing floor space
- Diversification: producing new (sustainable) products
- Improved reliability
- Improved safety
- Cost and time benefits
As the results speak for themselves, KABLONEX is already interested in further retrofits. The next project is already underway: The conversion of a 5-layer non-W&H machine into a 7-layer barrier.
New Extruder after retrofit
Old non-W&H Extruder before retrofit
Operator panel for new stand-alone extruder
About KABLONEX
KABLONEX is a family company founded in 1971. A lot has changed since then: technologies, the market, the needs of its customers. However, time has proven to be their ally. The small company that KABLONEX was more than 40 years ago is now a well-established company in the film packaging market with a modern machinery park that employs more than 120 people. Currently, KABLONEX processes more than 1,500 tons of polyethylene per month and is constantly expanding its production capacity.
KABLONEX and W&H have a long and trustful relationship. After the first purchases in 2013, the company now owns a total of eight machines from all machine types (extrusion, printing, converting). KABLONEX owns 4 high-performance blown film extrusion machines (1 x 5-layer VAREX II, 3x 5-layer OPTIMEX), 2 x modern flexo printing presses NOVOFLEX and MIRAFLEX II, one In-line printer FLEXA II and a POLYTEX converting machine.