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BENCHMARK FOR PRODUCTIVITY AND FLEXIBILITY: FILM STRETCHING LINES FROM DORNIER

Current mega trends include DORNIER films

Lindauer DORNIER GmbH has been developing and producing film stretching lines since 1955. Today, they represent about a third of all film stretching lines installed worldwide. Film stretching lines are designed for specific applications, so the machinery equipment can sometimes vary widely. But all DORNIER machines and systems have two features in common: exceptional quality and reliability.

Digitalisation

This mega trend, launched by the introduction of the iPhone, continues to boost sales of optically highly pure film. It is produced worldwide on DORNIER lines and can be found in flat screens on which Netflix, Amazon and Co. are streamed, as well as in the displays of tablets and smartphones.

Energy revolution & electrical mobility

Battery separator film is also produced on DORNIER film stretching lines. It separates cathode and anode in batteries from photovoltaic systems, electric car batteries and smartphone batteries.

Flexible packaging

Another trend is “flexible packaging”. Here, food and liquids are packaged or filled precisely and resealable according to their shape and volume. This significantly reduces the amount of film used and protects the food providing freshness of the product.

High quality film production with DORNIER lines

  • Planning, design and manufacturing from a single source
  • Quality “Made in Germany”
  • Individual components or complete film production lines according to customer requirements
  • A modular machine concept
  • Integrated, customised control system
  • Worldwide on-site service
  • A maximum of economical efficiency
News
08/26/2024

New melt filter insert from DORNIER improves melt filtration

The optimised melt filter increases filter service life by approx. 20 % and the throughput by approx. 5 %.

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News
07/26/2024

Higher productivity and film quality thanks to clever preheating

Retrofittable preheating unit for corona station removes unwanted moisture.

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Film stretching lines brochure

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"Made in Germany": Film stretching lines by DORNIER

All DORNIER film stretching lines and their components are produced and preassembled at the Esseratsweiler production site on the shores of Lake Constance, with a more than 50 % vertical range of production.

The high production speed of DORNIER lines, combined with the consistently high availability, ensures maximum productivity. With their legendary process reliability, the lines produce fast and efficiently – ensuring customers full satisfaction.

COMPACT AND ROBUST DESIGN: THE CASTING UNIT

Dosing and drying (unit)

In DORNIER film stretching lines, the granulate conveying system with dosing scales and mixing devices is arranged in such way to ensure highest dosing accuracy also allowing inline flake recycling.

High throughput consistency: the extrusion systems

Extrusion lines from DORNIER are available as single extruders with melt pump or as cascade systems. Customers appreciate the very high throughput consistency, temperature uniformity and low viscosity reduction. The extruders are equipped with electric or oil heating and air cooling; they are available in combination with filter systems, melt pump, melt line and die. Filters for cleaning the polymer melt are available as single filters. Twin screw extruders can also be used for extrusion to ensure maximum flexibility in case of raw material changes.

Robust and vibration-free: the casting units

DORNIER manufactures casting units for the production of polyester film. The largest casting roll supplied so far has a diameter of 2,000 mm and a width of 3,500 mm. The casting units are optionally equipped with a second cooling or take-off roller; this allows free access to the die. Their robust and stable design prevents vibrations and thus unwanted thickness fluctuations. DORNIER casting rolls have stable die frames and rollers are driven by torque drives. The melt is applied to the casting roll with operator-friendly and automatically pinning systems.

SUPERIOR FILM QUALITY AT HIGHEST LINE SPEED: THE LONGI­TUDINAL STRETCHING MACHINE

Highest film quality: the longitudinal stretching machine

The longitudinal stretching machines (MDO – Machine Direction Orienter) are extremely robust, easy to maintain and convince with maximum line speed. The MDO stretches polyester, polypropylene and polyamide films as well as special materials with superior quality. A longitudinal stretch comprises heating, stretching and cooling zones. The first two zones are heated with thermal oil, hot water or steam; cooling is carried out with water or thermal oil. Direct drives (e. g. torque) for highest speed and torque accuracy are being used.

Accurate thickness profile: the thickness gauge stations

DORNIER systems are equipped with two thickness gauge stations for high-precision control of the thickness profile; one is located after the casting unit, the other shortly before the edge trimming of the final film before winding. All common measuring systems can be used.

Quick roller exchange: the inline coater

Coaters are available for single side or double side coatings. In both cases, the web flow is different. Easy access to the coating stations is provided via operating corridors. A drawer system ensures the quick exchange of the coating rollers (also available as an upgrade for retrofitting).

EXCEPTIONALLY RELIABLE: THE CLIP MADE BY DORNIER

Stable, robust and flexible

For more than 60 years: The well-proven clips from DORNIER with exclusive roller bearings reliably grip film even with the smallest material thickness and transport it safely and efficiently through the transverse stretching machine.

Uninterrupted clip guiding

DORNIER transverse stretching machines have a clip guiding system that guides the film from the inlet to the outlet without interruption. Depending on the application, different types of clips are available. The returning chain track can be arranged inside or outside the oven, depending on the film type produced.

One espresso cup lubricant per day

The entire clip guiding system needs an amount of lubricant as small as about 50 cm³ per day, which is less than the content of a cup of espresso. This saves costs and ensures the highest standards of cleanliness und film quality.

Significantly less wear and tear

High production speeds lead to high wear? Not at DORNIER. The patented, spring-loaded clip guide system in
the chain reversing heads of the transverse stretching machine significantly reduces wear.

High dimensional stability: MD-Relax

The MD-Relax system for the transverse stretching machine is based on a variable clip pitch ensuring a very high dimensional stability by controlled inline relaxation of the film in machine direction. There is no need for additional offline post-treatment. Films from DORNIER film production lines are therefore ideal starting materials for applications with high heat exposure, such as film for photovoltaics cells, displays or rechargeable batteries.
 

 

 

HIGHEST TEMPERATURE ACCURACY, LOWEST ENERGY CONSUMPTION: THE OVEN

Benchmark since years: the transverse stretching machine

DORNIER’s Transverse Direction Orienter (TDO) machines are highly efficient and maintenance-friendly. They run reliably even at production speeds of 600 m/min. Their closed design and intelligent air guiding ensure minimum energy consumption and excellent heat transfer. Thus, the temperature is optimally distributed and the air velocity is kept constant in machine and transverse direction.

The TDOs consist of heating and stretching zones as well as wide crystallization, tempering and cooling zones. The zones that can be heated either using thermal oil, gas, electricity or steam are available with lengths of 3,050 mm, 4,575 mm and 6,100 mm. Depending on film type and thickness, the ovens can be equipped with different chain track systems. The maximum stretching width of a TDO is more than 12,000 mm. Another special feature of the DORNIER TDO is the special monorail clip guide system, which is mounted floating in the oven.

Intelligent use of waste heat

The patented and intelligent airing system leads exhaust air into the following oven zone. Heat is thus used optimally and primary energy is saved. An additional, external heat recovery system provides further energy
saving potential.

OPERATOR­FRIENDLY AND VIBRATION­FREE: THE TAKE­UP TRANSFER UNIT

Stable and vibration-free: the take-up transfer unit

The take-up transfer units (TUT) are extremely stable and therefore vibration-free. A simple roll exchange to the
top is easily possible. All rollers of the take-up transfer unit (guide, cooling, corona and rubberized nip rollers)
are individually driven by direct drives (torque). Take-up transfer units of the polyester, polypropylene and
polyamide plants are equipped with corona treatment stations. A flame treatment station can be provided for
BOPP film. If required, rollers can also be internally cooled. The roll diameter depends on the width of the film.
The film is fed manually on the operating side through an threading gap. DORNIER has already supplied
take-off devices for end film widths of up to 10,600 mm. All rollers are built with a carbon fiber roller body core.

This provides high stability at lowest power requirement.

Functionality: The take up and transfer unit pulls the film out of the TDO with controlled tension. The first roller
is a measuring roller which controls the film tension between the TDO and the take-off device. The film is then
cooled by cooling rollers and passes through the second thickness gauge station, which controls the thickness
profile via control of the die lip gap at the casting unit. Following this the film is being trimmed on both sides;
the edge strips are recycled in a grinder.

Full width, fully automatic: the winder

At the end of the manufacturing process, the film is wound in full width onto an automatic turret winder
(diameter up to 1,400 mm). The winder features an ergonomic design and short roll exchange cycles.

COMPLEX TECHNOLOGY, SIMPLE HANDLING: INTELLIGENT CONTROL TECHNOLOGY

Integrated and customised: the control system

DORNIER supplies tailor-made, integrated control system based on the Siemens SIMATIC S7 PLC and state-of-the-art bus systems for all systems and plants. Visualization is carried out via Siemens WINCC. The latest multi-motor drive systems (AC synchronous motors with frequency control) are installed. Components provided by the customer, purchased components or auxilliary equipment can also be integrated. The connection to frequency process control systems is prepared as standard.

Downstream plant components

The type and configuration of downstream plant components depends on the product portfolio and the degree of automation. Slitters (cutting machines) are used for cutting films, which are oriented to the rolls delivered from the winder. Further optional system components that can be integrated into the control system: Film grinders, regranulating plants and flake handling systems.

Smart film production: digitalisation of DORNIER quality

Worldwide 24/7 availability of spare parts, high process reliability of the systems and optimum maintenance intervals thanks to intelligent monitoring and production adaptation – the smart mechanical engineering of the future is already standard today in DORNIER film stretching lines. This allows customers to design their manufacturing processes and sequences individually and flexibly.
 

 

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