Leading Cast Film Processor Adding Blown Film Capacity

Known primarily for its cast-film technology for producing nanolayer stretch film, Malpack in now venturing into blown film for the first time. In the months ahead, the Ajax, Ontario-based supplier of flexible packaging, which is part of the Trioworld Group, will install and commission a Varex II and Optimex II multilayer blown film line furnished by Windmoeller & Hoelscher. 

The first will be a five-layer Optimex II line, on which Malpack will produce stretch hood and shrink film. The second will be a seven-layer Varex II line mainly for agricultural film. Malpack has been providing agricultural film from a sister plant in Europe, notes Lynne Elliott, the company’s director of marketing and sustainability.

The seven-layer line will enable Malpack to produce high-performance agricultural films with enhanced strength, durability and precision essential for optimal film performance. Among other things, it features a system for injecting polyisobutylene into the melt stream and a winder with advanced automated loading and off-loading capabilities, keeping manual intervention to a minimum..

‘Meaningful Levels of PCR’

The line will produce structures primarily consisting of PE and ultimately what Malpack calls “meaningful levels of PCR.” Malpack officials add that the 7-layer technology will enable it to reduce film thickness up to 15% compared to 3- or- 5-layer films without compromising mechanical strength and durability.

Malpack says it is committed to using PCR in its film products through its Loop product lines, which contain at least 30% PCR. “As we unveil this new production line and advance our Loop initiative, we are not only enhancing our technological capabilities but also reinforcing our commitment to sustainability,” says Ricardo Cardoso, CEO of Malpack and president of Trioworld North America. “We are dedicated to creating a closed-loop system that minimizes waste and extends the life cycle of the materials that are used in our products, contributing to a more sustainable future for the industry.

“We are excited to collaborate with W&H and introduce this state-of-the-art production line,” he adds. “This expansion not only enhances our manufacturing capabilities but also reinforces our commitment to delivering industry-leading products.

A number of Malpack’s cast-film lines are also supplied by W&H. Notes Andrew Wheeler, president of W&H in North America, “W&H and Malpack have enjoyed a long-standing partnership and we’re excited to support their next phase of product development in North America. Our 7-layer technology is designed to achieve the highest standards of performance, and we are proud to see it applied by Malpack.”