A decade of growing together: Polybol and W&H's successful partnership
For the past decade, Polybol and Windmöller & Hölscher (W&H) have cultivated a dynamic partnership marked by continuous growth and innovation. Polybol has invested in a range of state-of-the-art machinery from W&H across all divisions: Extrusion, Printing and Converting.
This collaboration highlights the significant advantage that W&H offers as system supplier – everything from a single source. This partnership, alongside Polybol’s constant investment in R&D and development with over 25% of its workforce in full-ride college scholarships has been instrumental in developing over 100 new client relationships in the last 18 months.
Background
Polybol S.A.S., a Colombian company is a subsidiary of the Globalpak Group, a leading packaging industrial conglomerate with sales in over 35 countries and a full-scale packaging offering. Polybol, a leading name in industrial packaging with close to five decades of expertise, embarked on a transformative journey with W&H to modernize and expand its production capabilities. Polybol, recognized for its innovative approach and commitment to sustainability, sought to upgrade its equipment to stay competitive in the rapidly evolving market of valve PE bags and industrial films. The company produces low melt, Tyvek, foil bags and other complex packaging structures.
The challenge
Polybol's existing production lines, comprising older AD PLASTIC SP and SL machines and three Kiefel 3-layer extruders, were becoming less efficient, leading to high waste and production costs. Additionally, the two presses were no longer meeting the quality demands. To address these challenges, Polybol needed a comprehensive overhaul of their production facilities, including state-of-the-art machinery and infrastructure upgrades.
The solution
W&H provided a multi-phase solution that began with the installation of the MIRAFLEX AM in 2014. Over the next decade, Polybol's production capabilities were significantly enhanced through the addition of advanced machinery, including the VAREX II 5-layer extruder and the high-speed MIRAFLEX II 8M and 2 other MIRAFLEX presses. The final phase included the installation of the OPTIMEX II 5-layer machine with 2 die heads and the AD PLASTIC 2, optimizing their production for various film types and stretching capabilities.
Infrastructure and innovation
“The project demanded extensive infrastructure upgrades. Polybol reconstructed their extrusion hall, implemented silos for improved process control, and established temperature-controlled production areas to improve quality and product consistency. These upgrades were crucial for maximizing the efficiency and longevity of the new machinery”, says Diego Amaya, Regional Sales Manager at W&H.
Results and benefits
- Improved quality and efficiency: The new equipment reduced waste, increased product quality, and streamlined production processes.
- Innovative solutions: The OPTIMEX II's flexibility with 2 die-heads and the retrofitted Miraflex AL with inline slitting and microperforation units provided Polybol with a competitive edge in specialized products.
- Sustainability: Polybol's commitment to sustainable practices was bolstered by the new machinery's efficiency and reduced environmental impact.
Successful collaboration between Polybol and W&H (from left): Maria Castelar, Eduardo Arrieta, Diego Amaya, Marvin Williams, Iule Lacerda, Orlando Insignares, Carlos Albornoz, Artajerjes Valdelamar.
Collaboration and training
The success of this project hinged on the close collaboration between Polybol and W&H. Continuous training sessions in Lengerich and Cartagena, regular visits by W&H technicians, and joint development of solutions ensured seamless integration and optimal performance of the new machinery.
Mauricio Bernal, Polybol's Production Manager, highlighted the exceptional teamwork and support from W&H: “The partnership with Windmöller & Hölscher has been instrumental in our growth. Their innovative solutions and dedicated support have significantly enhanced our production capabilities.”
Future prospects
"We are very satisfied with the services and solutions provided by W&H. We particularly appreciate exclusive products such as POLYTEX and AD PLASTIC 2 sift proof, which have made a significant contribution to our operations”, says Bernal. The company is considering additional investments in another AD PLASTIC 2, a new extrusion line, in-house MDO capabilities, retrofit solutions, and long-term service contracts.
Conclusion
The decade-long collaboration between Polybol and Windmöller & Hölscher has been a resounding success, marked by significant technological advancements, operational efficiency, and enhanced product quality. Polybol's strategic investments and W&H's cutting-edge solutions have positioned them as leaders in the industrial packaging industry, ready to meet future challenges and opportunities.
From left: Jimmy Ruiz, Maria Castelar, Iule Lacerda
