Page 23 - Packaging News May-June 2021

May-June 2021 | www.packagingnews.com.au | CONVERTING UPDATE
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LEFT & BELOW: IPG’s new seven- layer extruder is a game-changer.
Layers of local innovation
Integrated Packaging Group – a Pro-Pac Group company – has installed and commissioned a seven- layer co-extrusion line for flexibles at its reservoir site in Melbourne, Victoria. PKN reports on the scope and execution of the project.
INTEGRATED Packaging Group (IPG), one of Australia’s largest manu- facturers of flexible packaging products for a diverse range of customers, is seeing market demand shift towards more sus- tainable packaging film solu-
tions. Its multi-million dollar invest- ment in this world-class blown extrusion line from Italian company Macchi is evidence, the company says, of its commitment to find more sustainable solutions for the environ- ment and its customers. Importantly, it means the delivery of global solu- tions, locally.
Andrew Harris, executive GM for IPG Flexibles explains, “The invest- ment in the seven-layer co-extrusion line is a significant step forward in our ability to continue to exceed ser- vice expectations. The operational efficiency that this technology brings to the group creates the opportunity to focus on innovation and growth for our customers.”
Not only did the project require an extensive overhaul of the plant – including raising the roof by 2.5m to accommodate the height of the extruder, and upgrading all provi- sioning services – the installation of
this machinery was not short on com- plexity, largely stemming from the unpredictable nature of the global pandemic.
“Typically the vendor would sup- port such an installation onsite, but with the machine’s manufacturer Macchi S.P.A based in Italy, and travel to Melbourne impossible, other solutions had to be found for the com- plex assembly and commissioning,” operations GM for Pro-Pac Group, Dominic Adams tells PKN.
The Melbourne-based IPG engineer- ing team connecting virtually with the Macchi technicians in Italy, and with the help of AR and VR technology were able to bring the line to life.
“This was an incredibly challeng- ing project to embark on in the midst of a pandemic,” Adams says.
“This really stretched the techni- cal and engineering teams who per- formed magnificently in the face of multiple challenges.”
Harris echoes the praise for every- one involved, and says, “Pre- production testing is now underway to ensure finished product quality and performance is in line with our customers’ expectations, with signif- icantly positive results so far.”
RECYCLED RESIN IN THE MIX
The seven-layer co-extruder allows IPG to increase the technical com- plexity of the film’s components, enabling innovation with different resin blends for increased end product recyclability and performance.
“We can add a different resin mix to each layer of the film, which means customers can expect a product of superior quality and performance, engineered precisely to suit its spe- cific application,” Harris explains.
“This innovative technology also improves our ability to include recy- cled resin mixes in the film we man- ufacture, without impacting on prod- uct performance.”
Among other benefits of the new extrusion machine is automatic gauge control technology, ensuring it pro- duces consistency in the specified film thickness across the length and width of its rolls – reducing suscepti- bility to tearing and split edges.
The additional capability adds around 4000 tonnes per annum to IPG’s existing 50,000 tonne per annum extrusion capacity, and com- plements the company’s extensive fleet of extrusion, print, lamination and conversion machinery. ■