A new BOPP film line just launched by Bulgarian flexible packaging producer Plastchim-T has already broken international speed and output records.
The 10.4m wide film stretching line exceeded its capacity speed mark of 600m/min for the first time ever, while the equipment also surpassed the film orienting hourly production record of 7,600 kgs/hr, according to its German supplier Brückner Maschinenbau.
Besides this, added Brückner, the high speed line chalked up another record with its specific energy consumption per kilogram of film produced achieving the lowest level ever measured.
When Tervel, Bulgaria-based Plastchim-T ordered the big new production unit in 2016, it was billed as a world beater in size and speed. But the family owned company had expected the Brückner line only to top its capacity limits in the future.
“Our new Brückner plant was intended as an investment for the future. We had planned to realise speeds of 600m/min sometime in the next two years. But our team and the specialists from Brückner have reached this milestone in much less time.
“Of course, we are pleased about that – not for the sake of speed, but because of the associated unique energy and production efficiency of the system,” commented Plastchim-T’s owner Aydan Faik.
His new line should later also be capable of producing quality special foils, like those for metallisation, at top speeds of more than 500m/min.
Plastchim-T operates two divisions with film producing at its Black Sea coastal plant of Aksakovo and its flexible packaging manufacturing carried out at the firm’s main facility at Tervel to the northwest. The two plants cover an area of 150,000m2.
The company already runs other Brückner lines with working widths of between 4.2m and 10.4m which allows it to react flexibly to changing market requirements. That means it can offer different film types in smaller or larger quantities even with short delivery times.
Meanwhile, Plastchim-T is planning other expansion projects at its Aksakovo film processing site. In March, the firm agreed EU and national Bulgarian grant aid worth almost €1m for a new capacity expansion and energy efficiency scheme there.
This €2m project will include the introduction of low-energy, high output PP production with the installation of two new PP extruders with combined capacity of 760 kg/hour. In addition, Plastchim-T will replace an existing water cooler with new air-cooled equipment with built in free-cooling system used for cooling finished film.
It will also install a residual heat recovery system to capture heat generated from compressor cooling to warm a raw materials warehouse.
Plastchim-T, which employs a total workforce of 1,000, also has capacity to turn out up to 6,000 tpa of cast PP films, 2,500 tpa of polyethylene film and 10,000 tpa of woven PP packaging products. It makes flexible intermediate bulk containers (FIBC), bags and flextainers.