Agricultural Film 2012

Agricultural Film 2012

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www.luigibandera.com

BANDERA ran the biggest five-layer blown film line in the

world for agriculture purposes at Ardeer plant, Scotland

Breaking news

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5-Layer Die Ø 2000 mm to produce up to 20 m open width

agrifilm

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Bandera Production Program -1

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Mono & Multilayer Complete Lines for Agrifilm & Geomembrane

Extrusion

Extruders up to TR 220 screw diameter

Extrusion Heads: 1, 3 & 5 layers

Take-off up to 8.000 mm width, with collapsing frame &

gusseting devices up to 20 m long

Winders: automatic type, up to 6.000 mm width, for small & big

rolls

Wide choice of Peripherals and Attachments

Bandera Production Program -2

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Bandera Single–Screw Extruders

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TYPE TR

85 TR 100 TR 120 TR 140 TR 160 TR 180 TR 200 TR 220

SCREW

DIAMETER mm 85 100 120 140 160 180 200 220

L/D RATIO 30 30 30 30 30 30 30 30

HEATING

ZONES n° 6 6 7 8 8 9 9 9

AC

MOTOR kw 132 160 250 315 400 500 560 710

OUTPUT

(LDPE 0.7) kg/h 300 400 550 700 850 1.150 1.400 1.800

3-Layer Agrifilm Lines: die diameter up to 2500 mm for 24 meters open width film. 5-Layer Agrifilm Lines: die diameter up to 2200 mm for 20 meters open width film.

Bandera Extrusion Heads

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Bandera Extrusion Hardware Solution (3-layer)

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Agrifilm Open Width (m) * Die Ø (mm) Coex 3-Layer Configuration Output (kg/h)

4 - 6 700 TR 100 + 2*TR 85 700

5 - 10 1.000 TR 120 + 2*TR 100 1.000

6 - 11 1.200 TR 140 + 2*TR 100 1.200

7 - 12 1.400 TR 140 + 2*TR 120 1.400

8 - 14 1.600 TR 160 + 2*TR 120 1.600

9 - 16 1.800 TR 180 + 2*TR 120 1.800

10 - 18 2.000 TR 180 + 2*TR 140 2.000

12 - 20 2.500 TR 200 + 2*TR 140 2.400

•for BUR between 1.6 to 2.7, running LDPE & LLDPE based blends recipes,

up to 220μ. Layers typical ratio 1:1:1 and 1:2:1

Bandera Extrusion Hardware Solution (5-layer)

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For BUR between 1.6 to 2.7, running LDPE & LLDPE based blends recipes, up to 220 μ.

% of each layer: up to 30%. Possibility to run barrier resins as PA and EVOH.

Fixed Take-Off Type, With Upper Nip Rollers working Width from 2.500 mm up to

8.000 mm

Collapsing Frame & Gusseting from 8 to 20 m long, motorized and with remote

control. Tilting system

Bandera Take - Off

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Bandera Take - Off

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Agrifilm

Open

Width (m)

Collapsing

Frame &

Gusseting

lenght (m)

Take-Off &

Winder Width

(mm) 4-fold rolls

Winder Width

(mm) 8-fold rolls

4 - 6 6 2.000 -

5 - 8 8 2.500 -

7 - 10 10 3.000 2.000

8 - 12 12 3.500 2.000

9 - 13 14 4.000 2.500

10 - 15 16 4.500 2.500

12 - 16 16 4.500 2.500

14 - 20 18 5.500 3.000

Automatic Surface and Axial Winders, mono & double station, working

width from 2.500 mm up to 6.000 mm, featuring 3”, 5” and 6” expansion

shafts, for big (jumbo) rolls (ASN Type).

Bandera Winders For Agrifilm -1

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Automatic Shaftless Winders, from 2.500 mm up to 5.000 mm for small

length rolls (New TA Type), up to 30 rolls changes per hour

Bandera Winders For Agrifilm -2

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Shaftless winder

for Ø 400 mm reels

(8 times C-Folded agrifilm)

Bandera Winders For Geomembranes

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Full- automatic Geomembrane winders. 7500 mm width

Bandera Peripherals & Attachments-1

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Typical agrifilm line Layout

Take off unit

Flattening

device

Calibrating

Basket

Blown film

die +

Extruders

‘C’ Folding unit

Double Station

Winder

New generations of Air control

Rings, designed for Agrifilm

production (high thickness,

low MFI grades, low BUR) with

Gauge Control Device built –in:

A) Manual Sector Flow Control with Flaps manually

adjusted by means of thread bolts for sector wise

manipulation of main cooling air volume

B) Fully motorized Sector Flow control for

Sector wise Manipulation of main cooling air

volume

Bandera Peripherals & Attachments -2

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Bandera Peripherals & Attachments -3 2500 mm: 3-layer Coextrusion Die for both agricultural & geomembrane applications

Bandera Peripherals & Attachments - 4

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“C”-Folder Device to fold the agrifilm 8 times (e.g. 16 m open width film to about 2 m C-folded finished rolls).


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Automatic Reels Extraction device


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Device for Vineyard Film (agrifilm with different thickness at web edges and center)

Multicomponent Gravimetric Feeding & Dosing System

Bandera Blown film & Geo lines Locations

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Bandera Latest Main Installation -1

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Coex 5 layer line with

Ø 1400 mm die

For Agrifilm. Mexico

Coex 3 layer line with

Ø 2000 mm die

for geomembrane. Egypt

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Coex 5 layer Line with Ø 2000 mm die for

agrifilm (UK)

Coex 3 layer line with Ø 1600 mm

die for agrifilm


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1) Silage:

-Silo Bags

-Bale Wrapping (silo – Agristrech)

2) Mulching

3) Fumigation film

4) Low Tunnels

5) Greenhouses Cover Film

Agrifilms: Main Applications

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Temporary silos, liners for grain storage facilities, ground sheets,

bale covers

Silage of grass, corn: storage away from oxygen (PE film) to speed

up fermentation

Silage -1

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Silage -2 • Mainly: co-extrusion black / white layer (3 & 5

film)

Thickness: 80 ÷ 250 μ

Excellent physical mechanical performance

(tearing and perforation)

• Polymers:

LDPE + increasing use of LLDPE and

mLLDPE (Silo bags, up to 80%).

Also high % of reclaimed material.

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The first Silo Bags were introduced in North America in early 1990. Their primary function was the storage of hay and forage. During this decade, in Argentina, some manufacturers of plastic films for agriculture have extended the use of the Silo Bag to the storage of cereals, rice, soy and grain. Currently the Silo Bags are widely used in various countries beyond the American continent, among which particularly strong consumers are Australia, South Africa, Russia and Ukraine.

The Straight Story: Multilayered Film For Silo Bags-1

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The advantages of the Bags for Silo compared with the systems of traditional storage in metallic Silos are: ▪Least starting investment ▪Ideal also for small storages and for biological agriculture cereals ▪It allows an elevated hourly output both in entry and in extraction of the siled product ▪It doesn't need building authorizations ▪It doesn't need ant parasitical treatments ▪It requires low costs of cleaning and maintenance.

The Straight Story: Multilayered Film For Silo Bags-2

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Inside the bag for silo a low fermentation (anaerobic) is produced by natural way that leads to the formation of CO2 and lactic acid, which inhibit the growth of mould and parasites. Generally a perfect maintenance up to 18 / 24 months can be reached for the product siled inside the Bag for Silo. Bandera is world leader company in Design & Manufacturing of Equipment for the production of coextruded 3 layers film for Bag for Silo. Bandera has recently introduced the 5 layers technology for the production of film for Silo Bag, in the most common and commercial sizes, that is 9, 10, 12 & 14 feet.

The straight story: multilayer film for silo bags-3

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The Straight Story: Multilayer Film For Silo Bags-4

The application to produce this film with 5 layers technology arises from the following

demands:

▪ Reduction of the total thickness of the film, retaining the original mechanical features

▪ Reduction of the cost of formulation thanks to the possibility of using different resins

or of lower cost

▪ Possibility to use resins with barrier feature (polyamide and EVOH type) to lengthen

the period of maintenance of the ensiled products, over 18 months

▪ Possibility to encapsulate additives and more expensive dyes (or with tendency to the

degradation) on the middle layers to increase the duration of the Bag for Silo once

placed on the field.

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Wrapping silage of hay:

storage away from oxygen in wrapped bales

using a stretchable film

Films:

Thin films 15 ÷ 23 µ (3 & 5 layer film)

Duration: 1 or more years (with barrier PA)

Good abuse property Sticky properties

Polymers:

LLDPE (C8) + tackifier agent (6% PIB)

EVA (%VA>18%); also VLLDPE as tackifier.

Liquid PIB injection from back of the screw

Developments:

EVA: reduction of the PIB content

down gauging + puncture resistance.

PA/EVOH: barrier effect against oxidation

of outside layers of the bale

Bale Wrapping

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LDPE film: conservation soil moisture & water management + reduction of weed

growing & thermal (transparent films) Raise

soil temp. For better and earlier crops

Films:

Black 60-90 µm films: wine yards, trees

Black 15-50 µm films: strawberries, cucumbers

Coloured films special requirement (virus control)

Transparent 15-50 µm films: salads, ...

12 µm "photo-degradable" films : corn, cotton

3 & 5 layer film for longer life

Polymers:

Thick films: LDPE + carbon black

Thin films: LDPE + LLDPE (> 40 %) blends

EVA for thermal and special applications

Mulching

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Developments:

More LLDPE down-gauging

Playing with layers: different materials properties (WV barrier, mechanical,

colour…).

Use of biodegradable & compostable resins for environment protection.

Mulching

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Reduction in the use of fumigants such as methyl bromide by try to brake the

emissions during the treatment and keep more active gas in the soil using plastic films

more gastight VIF / TIF films

3 & 5 layer film, with PA or EVOH barrier layers for gas low-permeability

Film for soil fumigation

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The VIF (with PA) / TIF films (with EVOH) are the best way : -to reduce Methyl Bromide emissions in the atmosphere (and the amount to be used by the farmer) -to improve efficiency of the treatment (same surface with less Methyl Bromide)

Film for soil fumigation

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PE/PA/PE 30 micron

film

Permeability to

Methyl Bromide

0.18 g/m2/h

PE/tie/PA or EVOH

/tie/PE 25 micron

film

Permeability to

Methyl Bromide <

0.07 g/m2/h

3-Layer 5-layer

Protection against wind, rain, thermal variations.

Crop Protection Greenhouse Effect.

Earlier crops. Late Crops

Films:

Thickness: 30 - 100 µ

Duration: 1 year

Standard transparent films: salad, ...

Transparent thermal films: strawberry, ...

Light diffusion thermal films: melons, ...

Low (walk-in) tunnels

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Low (walk-in) Tunnels

Polymers:

LDPE or coext LDPE/LLDPE

EVA (14 % or 18 %) for thermal

films EVA + charge for light

diffusion films

Developments:

More and more coextrusion with LLDPE

(down gauging, down to 30 µ...)

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Greenhouses: 3 ÷ 12 meters wide tunnels

Protection against wind, rain, temperature

control. Crop protection Greenhouse effect.

Earlier harvests and higher yields

Films:

Thickness: 120 to 220 µm

Duration: 2 to 4 seasons

Actually 1 & 3 layer film, but strong

trend to 5-layer

Polymers:

LDPE, LLDPE, mLLDPE

EVA + charge + anti-UV additives

PA for barrier and mechanical properties

Greenhouses cover Film

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Developments:

Virgin resins + UV master batches

Substitution of quencher-nickel by HALS

HALS resistant to pesticides

5-Layer photo selective films for Diseases

Reduction (Anti-Insect / Anti-Virus Film)

Playing with additives in the inner layers,

to keep film properties for longer periods


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LDPE & EVA Blends recipes


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FUNCTIONAL FEATURES MOST

REQUIRED BY THE USER ARE:

-Elasticity and good resistance to tensile stress,

tear and perforation

-Transparency for sunlight in the visible light

range especially in PAR

(photosynthetic activity range 400-700 nm)

-Ability to retain heat inside the greenhouse

during night time

-Long lasting mechanical properties and

transparency

Direct light thermic film

Diffused light thermic film (sunny

areas - 145kLy)

EVA (VA >10%)

Width up to 14 m

Thickness from 120 to 250 micron

Mainly multilayer VA: 3-5% / VA 18-22% /

VA 3-5%

EVA (VA: 3-5%)

Width up to 16m

Thickness from 150 to 250 micron

Mainly multilayer VA:3-5% / VA 3-5 +

mineral fillers % / VA3-5%

Greenhouse cover Film

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-4 fold film installation

procedure

-8 fold film installation

procedure

Typical folding procedures

Demand for agricultural film in Europe

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45% Silage film

31% Greenhouse film

24% Mulch film

550.000 ton

consumed in 2011

in Europe

(source Ami Plastics)

Costruzioni Meccaniche Luigi Bandera Spa

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Corso Sempione 120,

21052 Busto Arsizio (VA) – Italy

Tel. +39.(0)331.398.111

Fax +39.(0)331.680.206

Website: www.luigibandera.com

Email: [email protected]

Diego Castiglioni, Technical Manager: [email protected]

Paolo Ceol, Product Manager: [email protected]

http://www.luigibandera.com/

mailto:[email protected]

mailto:[email protected]

Agricultural Film 2012

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Transcript of Agricultural Film 2012