Range of machine with higher speeds and output, new technologies, were introduced at K2010. Global demand for flexible packaging will increase by 3.5% from 16 mln tons in 2008 to nearly 19.5 mln tons in 2013. Researchers predict the fastest growth to occur in the developing regions of Asia, Latin America, East Europe. Machinery manufacturers have contributed to this growth by designing cutting-edge, high-quality equipment that meets the needs of these emerging markets in terms of price, performance and function. KM-Berstorff introduced QuickSwitch extrusion system, which makes it possible to change polyolefin pipe diameter and wall thickness within minutes on the fly. The complete extrusion line changes automatically to the new dimensions at the touch of a button, reducing the waste normally produced during changeovers. Because it’s a modification of the previous design - the die is adjustable, while the pin is fixed, the die can be retrofitted to conventional standard pipe heads. Windmöller & Hölscher presented Varex blown film lines, one Filmex Cast extrusion line, and its latest in extrusion technology - the Aquarex, Optimex and MDO (Machine Direction Orientation) lines. The Optime is an economical, high-output, 3-layer blown film line that complements the established Varex range. It combines the latest in extrusion technology with a defined line specification for producing top-quality films for a wide range of applications, including packaging, carrier bags, laminating and shrink or stretch hoods. Available widths are: 1300 mm, 1600 mm and 1800 mm layflats, as well as 2200 mm and 2600 mm side-gussetted layflat. The unit also includes the Maxicone C die, which has already proved successful with the company's Varex blown film line. Its low melt volume and short melt path are instrumental for yielding the best film quality and rapid changeovers. Layer ratios range from 1:1:1 up to 1:6:1, offering a unique range of flexibility. Newly developed low-temperature barrier screws also allow high output rates. Latest generation water-cooled frequency converters of the extruder drives keep the temperatures inside the switch cabinets at an acceptable level - even at high ambient temperatures. The film sizing cage moves its arms concentrically to the bubble for more accurate sizing of the bubble. Aside from the very tight width tolerances, the film is also characterized by its perfect thickness profile featuring extremely low tolerances, achieved by a capacitive thickness measuring system. Its sensor is continuously circulating the bubble, transmitting relevant data to the proven Optil P2K gauge control. The Aquarex is a new branch of the W&H blown film line family that literally turns extrusion up-side down. The Aquarex "up-side-down wet“ blows film downwards and uses water instead of air to quench the bubble. The result is soft film with high clarity and gloss, and exceptional puncture and tear-resistance, that can be used for barrier films and medical applications. Peak performance combined with energy efficiency in profile extrusion has been introduced by Battenfeld-Cincinnati. The new twinEX extruder is another generation of successful twin screw extruders. Three decades ago an output of 100 kg/hr in standard single strand production was leading technology, the new twinEX 93-34D sets the new standard with production capacity up to 420 kg/hr. They are available in four sizes from 78 to 135 mm, require approximately 15% less specific energy input with a simultaneous increase in output compared to other counter rotating twin screw extruders. This is achieved by an elongation of the processing unit to 34 L/D combined with a reduction of heat dissipation. Key design features include a fully insulated barrel, the intelligent APC barrel air cooling units (Air Power Cooling), Intracool screw tempering system and optimized screw geometries. The Reifenhauser Kiefel Extrusion Evolution 9 layer extrusion line is designed to handle a wide range of film recipes, resin structures and layer thickness ratios commonly used in the food and medical packaging industry. The system's centrepiece is its extruder/blown film die-head combination. The new EVOLUTION extruder excels through its great flexibility in the processing of polyolefins and barrier raw materials such as EVOH, PA and PETG, and it has an extremely wide throughput range at very low melt temperatures. The blown film die-head is designed for trouble-free production with a wide variety of recipes commonly used in the industry today. The rheological and thermal design of the die-head permits manufacturers to consistently produce films with minimized individual layer thickness with highly accurate thickness ratios of the individual layers. The ideal surface texture and geometry of the melt channels allow for quick product changes and very short raw-material dwell times. The film cooling unit has been redesigned and adapted to the particular characteristics of barrier film requirements. This permits barrier films to be run at throughput rates that were only possible with polyolefins until now. KraussMaffei Berstorff showcased technology for producing pipe up to 95 in. diam. A series of single-screw extruders in 105, 125, and 150 mm diam. all have 36:1 LD. The extruder features a barrier screw for low and uniform melt temperature. In the pipe head, specially engineered for extra-large diameters, the melt is gently predistributed via multiple holes to produce an ideal circular cross section before it reaches the spiral channels. The die set can be manually pre-adjusted. A number of heating-oil circuits and segmented heater bands support accurate wall-thickness control. The new head reportedly also results in pipe with much improved inner surface. Cincinnati Milacron Extrusion Systems introduced a new grooved feed single screw extruder featuring high torque and high throughput rates for polyolefin pipe. The GPAK 90-36 extruder has a screw diameter of 90 mm and 36:1 L/D ratio for optimum processing length. It has a workhorse 300 kW (400 HP) motor and drive system, and a Koellmann double reduction gear reducer. Other features include a special barrier screw design, and a Mosaic microprocessor control with 381 mm (15 inch) color LCD touch screen. Maximum throughput of the GPAK90-36 ranges from 800-950 kg/hr when running high-density polyethylene, and 550-660 kg/hr when running polypropylene. The complete GPAK grooved feed single screw line includes six models (45 mm, 60 mm, 75 mm, 90 mm; 120 mm and 150 mm). Each model is available with L/D options of 36:1 and 30:1, to allow for customization and a precise fit to match customer requirements. Three new high-speed stretching lines and their capabilities were featured by Brückner Maschinenbau. Its’ 8.7m wide biaxially oriented polypropylene (BOPP) line, which was delivered to a customer in June is said to offer a 20% higher output than comparable units while churning out web at 525 mtr/min with a capacity of 47,000 tpa. A second, even larger BOPP line (10.4m wide, 525 mtr/min, and 56,000tpa) is claimed to generate less scrap and edge trim. The company says that with such high-speed lines, the specific investment is reduced by each kilogram output by up to 30% if one compares a 4.2 or 6.7m wide line with a new 10.4m wide unit. A third line featured in talks at the stand will be an 8.7m wide unit with 525 mtr/min and capacity of 32,000 tpa BOPET. This features a twin-screw extruder with degassing to eliminate costly predrying They feature the company’s Heat Recovery System to redirect waste heat back into the unit and thereby save power, and direct drives in components to avoid losses in the motors and belts.