CASE STUDY
Optimization of Multilayer Film Extrusion for Packaging Applications
With StrömungsRaum®, you ensure uniform layer thickness and optimal adhesion in multi-layer extrusion. Our simulation technology detects weak points early, reduces waste, and optimizes production costs—for the highest product quality and maximum efficiency in the packaging industry.
Challenge
In the packaging industry, multilayer films are increasingly used to combine functionalities such as barrier properties, flexibility, and protection against moisture or oxygen. These films consist of several layers of different polymers, each with unique material properties. One of the greatest challenges in the extrusion of such multilayer films is ensuring uniform layer thickness and perfect adhesion between the layers. Uneven flow distributions or faulty layer transitions can lead to quality defects such as cracks, delamination, or uneven film thicknesses, resulting in costly waste and product complaints.
Solution Approach
With StrömungsRaum®, the process behavior during multilayer extrusion can be precisely simulated. The simulation takes into account the different polymers and their specific flow properties, densities, and viscosities. StrömungsRaum enables the mapping of material flow in the tool channels for each layer and the precise analysis of the transitions between layers. Weaknesses such as uneven material distributions or undesired velocity differences in the layer structure are identified early. Engineers can go through multiple design iterations to achieve optimal flow conditions and produce a uniform, homogeneous film.
Benefits
Increase in Production Efficiency:
Uniform layer thicknesses and precise adhesion improve the stability of the films and reduce production waste.
Cost Reduction:
Less waste and more efficient development processes significantly reduce production costs.
Higher Product Quality:
Optimized adhesion and layer distribution lead to more durable, robust film products that meet the highest quality standards.
Faster Response to Market Requirements:
Manufacturers can flexibly respond to changing demands in markets such as food or pharmaceutical packaging through quicker adjustments and new material combinations.
"IANUS provides the ideal solution for process engineering optimization of our operations with the partner package. We do not need to license expensive software or hire simulation experts; instead, we address the challenges together with experienced engineers who understand our problems." - Thilo Rönspieß
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