Agriculture Film Production Methods

1. Agriculture Film ProductionMethods

2. Film Production Methods Cast film Blown film • low tensile force in the longitudinal direction (molecular arrangement) • Irregular stretching@70%  thinner and thicker bands • unstable elasticity  irregular overlap • adhesive force through contact • perfect regulation of film thickness • high tensile force in the longitudinal direction (molecular arrangement) • Regular stretching@70%  equal distribution of the thickness • stable elasticity  perfect overlap • glue is inside the film 90% of allagriculture stretch wrap

3. Howdoesblownextrusionwork? The oscillating haul-off evens out the thickness profile from the die and environmental conditions to produce reels with a very flat profile and even weight distribution across the winder. Guide rollers maintain even film tension and web flatness Thickness measuring head measures and controls the film thickness Sizing cage controls the bubble size and maintains bubble stability Secondary nip rollers maintain film tension from the main nip rollers to the winding drum to produce reels of even tension. Extruder melts the polyethylene granules Die transforms the plug of melt leaving the extruder into a thin cylinder which is blasted with chilled air from the air-ring. The air-ring is segmented and works in conjunction with the thickness measuring head to minimise the film thickness variation around the bubble.

4. Benefits of multi-layer extrusion • Options to place different polymers into the areas they are needed most • Options to produce a film with two different surface layers • Options to avoid blending different raw materials • Ability to produce a film with less variation • Disadavantage: the more layers, the higher the residence time, which can cause oxydation Traditional 3 layers Multi layer technology Temperature Reduction Temperature Reduction Tear Resistance Mechanical Strength Puncture Resistance Elasticity UV Protection from Sunlight UV Protection from Sunlight

5. Blown Extrusion at RPC bpi RPC-BPI has 5 , 7 and 9 layer extrusion technologies • Some extrusion lines also have a “Machine Direction Orienter” (MDO) unit • This unit orients film in a longitudinal direction • Film becomes thinner while: • increasing the tensile force, • decreasing the OTR (oxygen transmission rate) • maintaining a good strength

6. Making a solid & reliable film is all about finding the right balances Optimal tack level Optimal impact strength Optimal tear resistance Optimal elasticity Optimal tightening force

7. Optimal Tack Level • Polybale combines: • the right type of tackifer • the right amount of tackifier • the right anti-slip surface Lower tack level Too much tackifier Higher tack level Incorrect adhesion between layers Oxygen can enter between layers Deposits on the pre-stretch rollers which affect the stretch level. Causes tearing problems when wrapping at higher ambient temperature

8. Optimal Tack Level • Polybale combines: • the right type of tackifer • the right amount of tackifier • the right anti-slip surface Lower tack level Too much tackifier Higher tack level Dust and moisture affect the cling in a negative way

9. Impact strength Higher - impact strength- Too High Lower impact strength • Film can be damaged / punctured during wrapping or storage •  oxygen can enter the bale The film does not cut correctly at the end of the wrapping process When the impact strength is too high it has a negative effect on other mechanical baling parameters

10. Optimal Tear Resistance Lower tear resistance Too high tear resistance • Film is sensitive to tearing • during wrapping / stretching • or handling •  oxygen can enter the bale When tear resistance is too high it has a negative influence on other mechanical baling parameters

11. Optimal Elasticity • Stiffer film • Will break easier during both wrapping and cutting at the end of a wrapping cycle. • In particular this occurs frequently if certainly by wrapping square bales. More elastic film Can be too soft Can have problems in warm conditions Can create unequal film stretching

12. Tightening Force • Tightening force = the residual force of the film after stretching to 70% Polybale has an optimum tightening force. Higher tightening force Lower tightening force Greater risk of film breaking • no sufficient adhesion between the layers around the bale • oxygen can enter between the layers • contributes less to the compactness of the bale

13. Making a solid & reliable film is all about finding the right balances Optimal tack level Optimal impact strength Optimal tear resistance Optimal elasticity Optimal tightening force

14. Making a solid & reliable film is all about finding the right balances • Next to those mechanical factors, • Polybale also provides the correct values for: • UV Stability • Neck-in • Opacity • Thickness variation • Oxygen Transmition Rate (OTR)

15. The 5 star wrapping film for silage bales

16. Product Overview 25µm Universal

17. 25µm Universal Problem free wrapping... Stemmy forage Heavy bales Square bales Continuous wrapping ...unterallenUmständen Wet/Dry Day/Night All wrapper types Perfect overlap

18. 25µm Universal Technical Specification • Available in 4 colours: White-Green-Olive-Black • UV protection suitable to the sales region • Product ranges may vary depending on the sales region

19. Product Overview 22µm Value

20. 22µm Value 22µm – Best used for round bales • 10% Extra length • Up to 3 more blaes per roll • Reduces waste by up to 10% • Saves time – less roll changes • Saves money – more bales per roll 1 2 3 Um 10%

21. 22µm Value TechnischeSpezifikationen • Available in green • UV protection suitable to the sales region

22. Product Overview 20µm ProTechnology

23. 20µm Pro Technologie 1950m roll length450m extra = 30% more Wrap more with less Higher tightening force Excellent tack properties Minimal oxygen transmission rate

24. 20µm ProTechnology Sleeve Packaging More metres/roll More bales/roll High speed wrapping Saves time optimal Price-performance ratio More compact bales Higher holding power More dense film Saves waste Sleeve packaging Thinner film Less film to recycle

25. 20µm Pro Technology Technical Specification • Available in green • UV protection suitable to the sales region

26. Product Matrix

27. Product Overview Mantelfolie

28. Mantle film: The Advantages Easier to recycle Made of the same material as stretch film Time & cost savings. Improved hygiene. Easier to remove from the bale Improved fermentation / less waste Full bale cover Better silage quality. Increased production. Better oxygen barrier Reduces costs. Reduces downtime. Strong film properties Solid/dense bales More wrapped bales of standard film

29. Mantle film: the advantages

30. Mantle film: Technical Specification 1380 mm 16 µm Bales of 115-135 cm 1280 mm 16 µm Bales of 115-135 cm 1280 mm 20 µm Bales of 125-135 cm Shoulder to shoulder - 2000 m Over the shoulder - 2000 m UV protected - 1650 m

31. Mantle film: Measurement elongation % on the bale This 100 mm distance is roughly reduced after this small piece of foil has been cut out 100mm = 1,10 = 10% stretch 91mm

32. Mantle film: Measurement elongation % on the bale Transfer a bale wrapped in mantel film to the changing table. For a measurement, the bale should be wound once with at least 6-8 layers of bale wrap Mark 2 horizontal lines at a distance of 100 mm (= D1) in the middle of the bale away from the end of the film Cut out a piece of the bale wrap (all layers) around the two horizontal lines Let the cut piece of bale wrap rest for at least 3 minutes In the meantime, wrap the bale with stretch film Measure the distance in mm between the two lines (= D2) The elongation % is calculated as follows: D1/D2 = 1,XX mit XX = stretch % • Example 1: 100mm/95mm = 1.05 => 5% stretch • Example 2: 100mm/91mm = 1.10 => 10% stretch

33. Overview of combination Film & Film for grass

34. Thank you