Among extrusion technologies to be displayed by Reinfenhäuser at the forthcoming K 2022 show in Düsseldorf, Germany, from October 19-26, is the new Reicofil Reico*Star line, engineered to produce high-performance composites of nonwovens and films.

These are used in packaging applications such as sacks or so-called ‘big bags’ for free-flowing bulk materials like cement, grain or animal feed, as well as medical packaging.

The chief advantages of combining film and nonwoven  production in a single line are that the resulting monomaterial products can be fully recyclable and a 25% reduction in raw materials can also be achieved. At the same time, compared to paper-film composites, the barrier effect against moisture and air permeability is increased by the nonwoven to enable air-conveyed filling.

In medical packaging, the material combination also enables the steam sterilization of fully packaged products.

The manufacturing process combines the Reicofil RF5 BiCo spunbond line with an extrusion coating line from sister company Reifenhäuser Cast Sheet Coating. Starlinger, a market leader in machine and process technology for woven plastic sacks, was also involved in the development of the Reico*Star.

“With this line and the process behind it, we have shown that nonwoven/film composites are a sustainable and economical alternative to paper-film composites,” said Dr Andreas Rösner, who is responsible for strategic product development at Reifenhäuser Reicofil. “They also offer a better moisture barrier and a higher-quality feel. There is enormous potential for companies to participate in the growing demand for fully recyclable packaging products with this new hybrid line.”

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