BOPP film manufacturer Treofan is investing around €30 million in the construction of a new production line at its largest manufacturing and innovation site, Neunkirchen in the German state of Saarland. The 8.7-meter line has been specially designed for Treofan by Andritz for production of a highly differentiated portfolio of top-quality packaging and label films. It will allow the company to manufacture films with a wide range of thicknesses and densities. Starting from mid-2015, Treofan aims for the plant to produce an annual quantity of around a billion square meters of film. 
The innovative concept with five-layer extrusion allows the production of films with a great variety of properties and makes it possible to structure films with exact precision. This means special functionalities can be integrated directly into the film, leading to greater sustainability and efficiency for converters and brand owners – for instance, by eliminating the need for certain laminations. The ability to quickly switch between products will boost flexibility in manufacturing. Provisions for a possible extension of the plant and the addition of further process innovations and new products, including outside the food industry, are already built into the design. 
Integrated Concept 
“Together with Andritz, we have jointly developed a sophisticated overall concept spanning everything from raw material supply to a differentiated film portfolio. The design also includes close integration with our innovation center on the same site,” says Treofan CEO Peter Vanacker. “This approach ensures short distances between product development – including joint development with partners – and the end product. And it drives quality and efficiency. All of this will ultimately benefit our customers.” 
Neunkirchen was chosen for this major investment partly because its central European location allows for rapid continent-wide delivery. The local team is also highly experienced. “The Neunkirchen team has near-unrivalled expertise in complex production processes and the corresponding industrial processes,” explains Vanacker. 
Significant Energy Savings 
Besides quality, reliability and flexibility, the new asset provides a quantum leap in terms of energy-efficiency. Specific energy consumption, measured in kWh per kg of manufactured film, will be at least 20 percent below the existing local assets. 
Production Continues as Normal
Construction work on the new building is set to begin this spring, and the equipment will be installed starting at the end of 2014. As the new line will occupy its own building, production at existing assets will continue without interruption, ensuring reliable deliveries on customer orders in the meantime. 
“The new production line is another step – and certainly not the last – in implementing our growth strategy of manufacturing sophisticated, complex film solutions characterized by innovation, quality and efficiency,” says Vanacker.