Reifenhäuser

A large percentage of plastic waste is still landfilled or incinerated - partly because it is impossible or very difficult to recycle. These valuable resources are lost to the circular economy. Use our technologies and product solutions to design your films and nonwovens in a way that preserves raw materials for the circular economy and saves you material costs. Join us in creating best practices for fully recyclable products.

Manufacture monostructures

Films and nonwovens consisting of layers of the same material class can be recycled much more easily than products made from a mix of materials. We have developed technologies and product solutions to meet your functional and economic requirements. Our solutions also allow you to reduce the use of barrier materials so that they are easier to recycle.

Product examples

ALL-PE laminates
Packaging made of nonwoven-film composites
CPP packaging film
PP with stretched EVOH
Barrier MDO-PE with EVOH
PET thermoforming films
High barrier tubular film
Multi-cycle recycled heavy-duty sacks

Industrial solutions from Reifenhäuser

EVO Ultra Stretch stretching unit (blown film)
A stretch rate of up to 10 times gives PE films completely new mechanical properties to substitute PET and produce fully recyclable all-PE films.

EVO Ultra Flat film haul-off (blown film)
EVO Ultra Flat flattens PP blown film that tends to wrinkle due to its stiffness. It is so efficient that it can be laminated with a BOPP film instead of the usual PE film. The result is a monostructure suitable for producing fully recyclable retortable pouches, for example.
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MDO Stretching Unit (flat film)
Stretching film in the machine direction gives it new mechanical properties, allowing you to substitute raw materials that affect recyclability.

Reicofil RF5 BiCo Spunbond Line (nonwoven)
The lines produce extremely lightweight spunbonded nonwovens with the finest fibers, uniform opacity, and high strengths. This provides the necessary mechanical properties and a textile feel in fully recyclable film-nonwoven composite products.
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Value coating lines (flat film)
Value coating lines produce composites without solvents or adhesives for fully recyclable end-applications.
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Ensure traceability

A genuine circular economy for plastic packaging requires a traceability standard to acquire all recycling-related data from the production process in the form of a digital product passport. We are a member of the cross-industry consortium R-Cycle that is working on an open and globally applicable traceability standard.

Project examples

Crisp bag for the circular economy (Brückner)
Identifiable and fully recyclable All-PE pouches (Comexi / Reifenhäuser)
Digital Product Passports for smart Digital Watermark packaging in blow molding (Kautex Maschinenbau / Braskem / Morssinkhof / Kautex Textron)
How data increases the recyclability of food packaging (Greiner Packaging)
Digitally traceable mulch film for Chinese agriculture(Reifenhäuser / GIZ)
Recycling-friendly, traceable blow molded bottle made of sustainable materials (Kautex Maschinenbau / Braskem / Morssinkhof / Kautex Textron)
Sustainable PP drinking cups from "smart" turnkey line (Arburg)
Multi-cycle Recycled Heavy Duty Sacks (ExxonMobil / Reifenhäuser)
Traceable freezer bags (ExxonMobil / Reifenhäuser)

Industrial solutions from Reifenhäuser

Digital Product Passport for all film rolls (blown film)
The open standard R-Cycle stores the digital product passport containing all recycling-related product properties and data for Industry 4.0 applications to assess the recyclability of products more easily and permit transparent reporting.

Lever for improved recyclability

A successful circular economy requires easily recyclable packaging. How solutions from Reifenhäuser support this.

Read story

Monomaterial packaging: Pitfalls and solutions

Monomaterial composites are regarded as one of the keys to improving the recyclability of plastic packaging. Here's what producers should look out for.

Read story

Sustainable face masks: recyclable and climate-friendly

The Grabher Group has developed the world's first face mask made of 99.7% polypropylene using technology from Reifenhäuser and a low-emission feedstock from Borealis.

Read Story

In the future, it will be necessary to recycle significantly greater quantities of plastic into new products for the circular economy to function and to lower the carbon footprint of products made from films and nonwovens. Otherwise, at some point in time there will no longer be sufficient raw-material resources. The highly flexible extrusion lines and robust components help you to process a wide range of recycling raw materials reliably.

Increase the recyclate content

As a rule, it is not that simple for manufacturers to increase the percentage of recyclate content. One reason for this is the inhomogeneous material composition of recyclates and impurities that alter conditions in production. Our technologies and processes are optimized for processing high recyclate content and cater for fluctuating quality.

Product examples

Food trays made of 100% PET
Flower pots
Trash bags
Mailing bags
Construction film
Freezer bags
FFS sacks
Carrier bags
Roofing membranes

Industrial solutions from Reifenhäuser

EVO Fusion blown film line (blown film)
The blown film line can be used to process inhomogeneous recyclates that otherwise can only be added to virgin material in small quantities.
Learn more

EFSA/FDA-compliant PET sheet line (flat film)
The line can be used to produce food-safe films from 100% recyclate without the need for expensive special equipment.
Learn more

EVO Ultra extruder (blown film)
With its adapted design, EVO Ultra extruders process many recyclates with the same reliability as any other raw material. The component combines maximum flexibility with high throughput.

Recycling extruder (nonwoven)
The recycling extruder feeds production rejects, such as edge trim stemming from nonwoven production, directly back to the production process to avoid scrap and make good use of rejects.

High-speed extruder (flat film)
The high-speed extruder is also capable of processing recyclates reliably due to good homogenization of the melt and its degassing performance that is excellent for extracting impurities.

RF5 BiCo spunbond line with twin-screw extruder technology (nonwoven)
Reicofil spunbond lines can easily produce nonwovens from recyclate. The line is therefore equipped with BiCo technology and a twin-screw extruder that gently processes PET and extracts impurities due to its excellent degassing performance.
Learn more

Process low-quality recyclates

Recyclates often contain foreign substances that make processing difficult or even prevent it completely. Our technologies even allow producers to process recycling material they had to dispose of at high cost in the past due to the high level of impurities.

Sources of raw materials

Stretched film
Packaging film
Agricultural film
PET/PE laminates
Printed film
Post-consumer recyclate from sorting fraction DKR-310 (German Plastic Recyclers, yellow sack)

Industrial solutions from Reifenhäuser

EVO Fusion blown film line (blown film)
The blown film line can process even highly contaminated recyclates. In addition, it can process fluff as well as granulate without having to first convert film scrap to granulate in an energy-intensive process. This means that even printed PET/PE film can be recycled into new blown film.
Learn more

Protect components from wear

Contaminants in recyclates accelerate wear in the plasticizing unit and contaminate line components faster than virgin material. That's why we developed special line components for processing recyclate so you can rely on stable process conditions.

Applications

All extrusion applications (e.g. film, blow molding, nonwovens, etc.)
Injection molding

Industrial solutions from Reifenhäuser

Line components for blown film production (blown film)
Even high-quality recyclates contaminate the die head, air ring, and other line components faster than virgin material. Special solutions from Reifenhäuser keep blown film lines operational for longer.
Learn more

Highly wear-resistant barrels and screws for the plasticizing unit
Processing recyclates is a stress test for the plasticizing unit. Our highly wear-resistant components achieve a long service life of the unit and a high quality of the products.
Learn more

Iron-based barrel wear protection
Due to a unique protective layer of extra dense ceramic phases, iron-based alloys from Reiloy deliver better wear protection for the same hardness at the best cost-benefit ratio on the market.
Learn more

Nickel-based barrel wear protection
Due to particularly large carbides, nickel-based alloys from Reiloy provide better wear protection than other alloys on the market, as well as the best cost-benefit ratio in the industry.
Learn more

Ensure quality control and traceability

Products made from recyclate must also meet all the necessary requirements of the later end product, especially if the materials are designed for food contact. Our digital solutions support producers with quality control and allow reliable traceability.

Industrial solutions from Reifenhäuser

R-Cycle
In the cross-industry consortium R-Cycle, we are working on an open and globally applicable traceability standard. It documents recycling-related properties and ingredients of plastic packaging in the production process digitally and automatically for use in the recycling process. This is intended to facilitate more precise sorting of plastic waste in order to produce high-quality recyclate and drive a functioning circular economy.
Learn more

c.Hub
This middleware connects lines and equipment made by various manufacturers, acquires all data in real time, and creates a uniform database at a central location. The c.Hub breaks down data silos and becomes a single point of truth. Transparency in production increases significantly.
Learn more

ExtrusionOS
ExtrusionOS processes the middleware database and uses custom industry applications to make production more transparent, render data traceable, and facilitate troubleshooting. The basic ExtrusionOS Core package for in-depth analysis applications is always supplied with the c.Hub middleware.

ExtrusionOS Production Compliance
Our EFSA-certified process produces food-safe film from recycled PET material. The Production Compliance application helps producers to monitor and document production processes and compliance with EFSA-related thresholds in a secure, real-time database.
Learn more

Increasing recyclate content: How to do it

Highly flexible extrusion lines and robust components from the Reifenhäuser Group help to resolve the conflict between sustainability and economic efficiency.

Read story

Interview: What you need to know about recyclate

It is not that simple to use recyclate in plastics extrusion. Our sustainability expert Dr. Tim Pohl rates the opportunities and obstacles.

Read story

Processing recyclate - Protecting components

Highly wear-resistant barrels and screws from Reifenhäuser Reiloy give the plasticizing unit a long service life and ensure high product quality.

Read story

How to lengthen cleaning intervals

Even high-quality recyclates contaminate line components faster than virgin material. Special solutions from Reifenhäuser keep blown film lines operational for longer.

Read story

Interview: Increasing the recycled content of plastic films

Why EVO Fusion twin-screw technology makes blown film producers less dependent on the input quality of recyclate.

Read story

Polifilm recycles adhesive-coated film

The Polifilm Group recycles scrap from the production of adhesive-coated films using EVO Fusion twin-screw technology and converts it into new film products.

Read story

In the future, it will be necessary to recycle significantly greater quantities of plastic into new products for the circular economy to function and to lower the carbon footprint of products made from films and nonwovens. Otherwise, at some point in time there will no longer be sufficient raw-material resources. The highly flexible extrusion lines and robust components help you to process a wide range of recycling raw materials reliably.

Increase the recyclate content

As a rule, it is not that simple for manufacturers to increase the percentage of recyclate content. One reason for this is the inhomogeneous material composition of recyclates and impurities that alter conditions in production. Our technologies and processes are optimized for processing high recyclate content and cater for fluctuating quality.

Product examples

Food trays made of 100% PET
Flower pots
Trash bags
Mailing bags
Construction film
Freezer bags
FFS sacks
Carrier bags
Roofing membranes

Industrial solutions from Reifenhäuser

EVO Fusion blown film line (blown film)
The blown film line can be used to process inhomogeneous recyclates that otherwise can only be added to virgin material in small quantities.
Learn more

EFSA/FDA-compliant PET sheet line (flat film)
The line can be used to produce food-safe films from 100% recyclate without the need for expensive special equipment.
Learn more

EVO Ultra extruder (blown film)
With its adapted design, EVO Ultra extruders process many recyclates with the same reliability as any other raw material. The component combines maximum flexibility with high throughput.

Recycling extruder (nonwoven)
The recycling extruder feeds production rejects, such as edge trim stemming from nonwoven production, directly back to the production process to avoid scrap and make good use of rejects.

High-speed extruder (flat film)
The high-speed extruder is also capable of processing recyclates reliably due to good homogenization of the melt and its degassing performance that is excellent for extracting impurities.

RF5 BiCo spunbond line with twin-screw extruder technology (nonwoven)
Reicofil spunbond lines can easily produce nonwovens from recyclate. The line is therefore equipped with BiCo technology and a twin-screw extruder that gently processes PET and extracts impurities due to its excellent degassing performance.
Learn more

Process low-quality recyclates

Recyclates often contain foreign substances that make processing difficult or even prevent it completely. Our technologies even allow producers to process recycling material they had to dispose of at high cost in the past due to the high level of impurities.

Sources of raw materials

Stretched film
Packaging film
Agricultural film
PET/PE laminates
Printed film
Post-consumer recyclate from sorting fraction DKR-310 (German Plastic Recyclers, yellow sack)

Industrial solutions from Reifenhäuser

EVO Fusion blown film line (blown film)
The blown film line can process even highly contaminated recyclates. In addition, it can process fluff as well as granulate without having to first convert film scrap to granulate in an energy-intensive process. This means that even printed PET/PE film can be recycled into new blown film.
Learn more

Protect components from wear

Contaminants in recyclates accelerate wear in the plasticizing unit and contaminate line components faster than virgin material. That's why we developed special line components for processing recyclate so you can rely on stable process conditions.

Applications

All extrusion applications (e.g. film, blow molding, nonwovens, etc.)
Injection molding

Industrial solutions from Reifenhäuser

Line components for blown film production (blown film)
Even high-quality recyclates contaminate the die head, air ring, and other line components faster than virgin material. Special solutions from Reifenhäuser keep blown film lines operational for longer.
Learn more

Highly wear-resistant barrels and screws for the plasticizing unit
Processing recyclates is a stress test for the plasticizing unit. Our highly wear-resistant components achieve a long service life of the unit and a high quality of the products.
Learn more

Iron-based barrel wear protection
Due to a unique protective layer of extra dense ceramic phases, iron-based alloys from Reiloy deliver better wear protection for the same hardness at the best cost-benefit ratio on the market.
Learn more

Nickel-based barrel wear protection
Due to particularly large carbides, nickel-based alloys from Reiloy provide better wear protection than other alloys on the market, as well as the best cost-benefit ratio in the industry.
Learn more

Ensure quality control and traceability

Products made from recyclate must also meet all the necessary requirements of the later end product, especially if the materials are designed for food contact. Our digital solutions support producers with quality control and allow reliable traceability.

Industrial solutions from Reifenhäuser

R-Cycle
In the cross-industry consortium R-Cycle, we are working on an open and globally applicable traceability standard. It documents recycling-related properties and ingredients of plastic packaging in the production process digitally and automatically for use in the recycling process. This is intended to facilitate more precise sorting of plastic waste in order to produce high-quality recyclate and drive a functioning circular economy.
Learn more

c.Hub
This middleware connects lines and equipment made by various manufacturers, acquires all data in real time, and creates a uniform database at a central location. The c.Hub breaks down data silos and becomes a single point of truth. Transparency in production increases significantly.
Learn more

ExtrusionOS
ExtrusionOS processes the middleware database and uses custom industry applications to make production more transparent, render data traceable, and facilitate troubleshooting. The basic ExtrusionOS Core package for in-depth analysis applications is always supplied with the c.Hub middleware.

ExtrusionOS Production Compliance
Our EFSA-certified process produces food-safe film from recycled PET material. The Production Compliance application helps producers to monitor and document production processes and compliance with EFSA-related thresholds in a secure, real-time database.
Learn more

Increasing recyclate content: How to do it

Highly flexible extrusion lines and robust components from the Reifenhäuser Group help to resolve the conflict between sustainability and economic efficiency.

Read story

Interview: What you need to know about recyclate

It is not that simple to use recyclate in plastics extrusion. Our sustainability expert Dr. Tim Pohl rates the opportunities and obstacles.

Read story

Processing recyclate - Protecting components

Highly wear-resistant barrels and screws from Reifenhäuser Reiloy give the plasticizing unit a long service life and ensure high product quality.

Read story

How to lengthen cleaning intervals

Even high-quality recyclates contaminate line components faster than virgin material. Special solutions from Reifenhäuser keep blown film lines operational for longer.

Read story

Interview: Increasing the recycled content of plastic films

Why EVO Fusion twin-screw technology makes blown film producers less dependent on the input quality of recyclate.

Read story

Polifilm recycles adhesive-coated film

The Polifilm Group recycles scrap from the production of adhesive-coated films using EVO Fusion twin-screw technology and converts it into new film products.

Read story

If materials become thinner, they consume fewer resources in production and therefore reduce emissions and the amount of scrap. At the same time, however, the materials must meet the functional requirements of the downstream application. Our clever technologies are the basis for reducing material use, while maintaining or even improving functionality.

Use less material while retaining the same functionality

Every gram of basis weight saved in films and nonwovens reduces the carbon footprint of the product. Our customized technologies help you to produce thinner materials, save raw materials, and still meet the demands of the end product.

Product examples

Nonwoven-film pouches
Diapers (8 g/m² nonwoven)
Medical protective clothing made of nonwoven (35 g/m² nonwoven)
Medical protective clothing made of nonwoven-film composite (Ultrathin Coating)
Consumer goods, such as margarine lids and cream cheese lids (200 µm PP thermoforming film)
35 µm stretched CPP film
Blown film barrier pouch (stretched EVOH film)

Industrial solutions from Reifenhäuser

RF5 Spunbond line (nonwoven)
Reicofil spunbond technology has made it possible to continuously reduce the necessary grammage of nonwovens, without sacrificing functionality. The latest RF5 technology can produce highly functional nonwovens of only 8 g/m²: nonwovens with the lowest material usage on the market.
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Ultrathin Coating process (flat film)
The Ultrathin Coating process is used to produce extremely thin nonwoven-film composites without the need for adhesives. Compared to the usual process, this process requires 28% less material and reduces costs by up to 34%.
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EVO Ultra Stretch stretching unit (blown film)
The stretching unit stretches blown film up to 10 times - and roughly doubles the barrier effect of the EVOH. This achieves material savings, while maintaining the same functionality

EVO Ultra Flat film haul-off (blown film)
The EVO Ultra Flat unit produces blown film of superior flatness. Since flat blown films can be laminated better with other films, EVO Ultra Flat reduces the amount of adhesive required. Less camber also minimizes the edge trim needed.
Learn more

Value sheet line (flat film)
Value sheet lines achieve tighter tolerances in the production of films due to the integrated Value Ultra Polishing Stack and much faster start-up and changeover times reduce scrap. Production is highly energy-efficient.

MDO Stretching Unit (flat film)
The stretching unit is used to stretch flat film. Since this significantly improves the mechanical properties of the film, the same functionality is achieved with less material. It is therefore possible to produce thinner film.

PAM coextrusion adapters
The coextrusion adapter Pro with PAM option (Precise, Autonomous, Mechatronic) is the resource-saving solution for multilayer films. The coextrusion adapter allows precise profiling of individual layers. This helps manufacturers to control the use of raw materials with pinpoint accuracy and avoid waste.
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Downgauging Saving costs, producing more sustainably

If manufacturers reduce the grammage of nonwovens and films, not only will they save raw material costs - they will also improve their carbon footprint.

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Plastics produced from crops such as sugar cane or corn is considered climate-friendly. Demand for these types of raw material is growing. Use our technologies to process biopolymers from renewable raw materials for a wide range of applications.

Process PLA, PHB and Co.

When an extrusion line is designed, it is normally irrelevant whether the common polymers PP and PE are produced from fossil or sustainable raw materials. In addition, there are always new polymers, such as PLA or PHB, that require suitably adapted components in an extrusion line.

Product examples

Diapers
Hard packaging
Carrier bags
Undershirt bags

Industrial solutions from Reifenhäuser

Value sheet line PLA (flat film)
The polishing stack processes both PLA and PET reliably and give producers the flexibility they need on the market.
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EVO Ultra Flat Plus film haul-off (blown film)
In general, blown films made from bio-based raw materials are very soft. Light stretching with EVO Ultra Flat Plus gives these films the necessary stiffness for converting them into products, such as shipping bags.

EVO Ultra extruder (blown film)
EVO Ultra extruders can be used to process bio-compounds gently at low extrusion temperatures.

RF5 Spunbond line with BiCo technology (nonwoven)
Reicofil spunbond lines make it easy to produce nonwovens with ultra-fine fibers and high mechanical properties made from PLA. The line is equipped with BiCo technology to achieve optimum bonding of the nonwoven.
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PAM coextrusion adapters
The coextrusion adapter Pro with PAM option (Precise, Autonomous, Mechatronic) adjusts the layers of raw materials flexibly and precisely as well as their distribution within a flat film. This makes it easier to process alternative raw materials, for example PLA.
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Scrap always occurs in the manufacture of plastic products, e.g. from start-up rolls, edge trim, and cleaning processes. Our efficient technologies help to reduce this production waste or recycle it in practical ways.

Use optimized technology

High plant availability, speed, and precision: Our line technology helps to maximize productivity and to use only as much material as absolutely necessary - for greater resource efficiency.

Industrial solutions from Reifenhäuser

PAM coextrusion adapters
The fully automatic adjustment options of the coextrusion adapter Pro with PAM option (Precise, Autonomous, Mechatronic) shortens start-up and changeover times and minimizes layer tolerances. This reduces the production of rejects and material waste.
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PAM dies
Reifenhäuser PAM dies operate with precise, autonomous, and mechatronic adjustment. This minimizes operator errors, reduces start-up and product changeover times, and reduces scrap to a minimum.

Value sheet line (flat film)
Value sheet lines produce thermoforming films with high material efficiency. The integrated mechatronic polishing stack minimizes tolerances and shortens changeover times.
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EVO Ultra Flat film haul-off (blown film)
The EVO Ultra Flat unit produces blown film of superior flatness with less camber and curling. This reduces the necessary edge trim and the consumption of adhesive and ink during conversion.
Learn more

Recycling extruder (nonwoven)
The recycling extruder feeds production rejects, such as edge trim stemming from nonwoven production, directly back to the production process to avoid scrap and make good use of rejects.

Support operating staff

In addition to sophisticated line technology, line operators also impact the material efficiency of a production facility. Appropriate training courses as well as support from digital systems optimize line conditions more quickly and prevent errors, increase line availability, and minimize material waste.

Industrial solutions from Reifenhäuser

c.Hub
The open data connectivity platform c.Hub connects equipment in production irrespective of manufacturer, acquires data in real time, and, since it represents a single point of truth, creates the necessary transparency in production to improve OEE.
Learn more

ExtrusionOS Machine Health
ExtrusionOS Machine Health is a supplementary package that helps producers to detect, store, and track the condition of all connected equipment. Based on this knowledge, producers can adjust their equipment optimally and optimize processes sustainably along the entire production chain.

ExtrusionOS Defect Analytics
This software bundle provides producers with an immediate overview of when and where defects occur on a roll during production. They can monitor their KPIs live, analyze their data, identify defect patterns, and optimize processes to reduce scrap efficiently.

Digital assistance systems
High levels of line automation and digital solutions, such as assisted start-ups or assisted product changeovers, increase line availability and production regardless of operator skills.

AR:DEL Training
Modern and interactive learning methods turn staff into extrusion experts so they can help to exploit productivity potential to the full and increase efficiency in production.
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Extrude barrier films more efficiently

The Coextrusion adapter Pro simplifies this task for line operators and improves overall line efficiency.

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Well-trained staff are a productivity booster

Reifenhäuser has set up an academy to ensure a high level of qualification through basic and advanced training courses.

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The energy required to manufacture plastic products is by no means a trivial matter. Depending on line efficiency, the energy requirement raises the carbon footprint of products or helps to reduce it. Our special line features help you to save energy in production.

Use energy-efficient line technology

There are many ways to improve the energy efficiency of your production, from clever solutions for cooling and heating to the insulation of components and complete energy concepts.

Industrial solutions from Reifenhäuser

EVO Ultra Cool 2.0 cooling system (blown film)
Unlike competitive technologies, the Reifenhäuser cooling system works without heating cartridges and this drastically reduces energy consumption and costs.
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EVO Ultra Stretch stretching unit (blown film)
The stretching unit is highly energy-efficient and stretches blown film from initial heat. This is made possible by its unique position directly in the line haul-off.

EVO Ultra Flat film haul-off (blown film)
Other flatness systems on the market are positioned upstream of the winder. Ultra Flat is positioned directly behind the two-roll haul-off. Only this unique and patented position permits energy-efficient stretching from first heat.
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RF5 Spunbond line (nonwoven)
With an energy requirement of 1 to 1.2 kilowatt hours per kilogram of nonwoven produced, Reicofil RF5 technology manages the conversion from raw material to nonwoven with greater energy efficiency than any other technology on the market.
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PAM dies
Reifenhäuser PAM dies are fitted with precise, autonomous, and mechatronic adjustment without heat expansion bolts to avoid energy-intensive and unnecessary heating of bolts and surrounding area.

BLUE EXTRUSION package (nonwoven)
Reifenhäuser supports producers with special energy-saving measures for more sustainable production. The packages include the use of climate-friendly energy for line temperature control, insulation of line components, and complete energy concepts, taking into account the mass and energy balance of production facilities.

Reduce the carbon footprint with energy concept

A customized BLUE EXTRUSION package from Reifenhäuser Reicofil reduces energy demand at Fitesa's northernmost nonwoven plant.

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Calculate carbon footprint in plastics extrusion

Do you know the carbon footprint of your produced films and nonwovens? Every new Reifenhäuser line ensures transparency and provides indications for lower-emission production.

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How to save energy with the PAM option

Automatic dies constantly readjust themselves during the production. For this purpose, the mechatronic automation option PAM consumes significantly less power than dies that are adjusted with thermal expansion bolts.

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