The film specialist Allvac has modernised its production, relying not only on the latest technology but also on renewable energy. The company has invested a total of over ten million euros at its headquarters in Waltenhofen.
Two new so-called cast-coex extrusion lines for film production, an automatic packing line and a new ERP system ensure optimised processes. The energy for the new systems and the office building comes, among other things, from a photovoltaic system on the company premises. With over 6,000 modules, the PV system at Allvac one of the largest rooftop solar systems in Bavaria. It supplies 2.3 million kWh of electricity per year and covers the film manufacturer's entire electricity requirements on sunny days.
Film production is an energy-intensive process. Allvac's aim is therefore not only to produce the films, but also to also their production at the site sustainable design.
„We have made ourselves fit for a sustainable future and have invested a lot of time, energy and money in our green modernisation over the past two years.“
Dr Andreas S. Gasse, Managing Director of allvac Folien GmbH
„As a film specialist based in the Allgäu region, we are deeply rooted in the region and are aware of our responsibility towards the environment. I am therefore particularly pleased that we are significantly reducing our carbon footprint thanks to the PV system. We are continuously modernising our production and develop films that are 100 per cent recyclable are“, adds allvac owner Hans Bresele.
Modern production facilities for recyclable films
Allvac has also made a major investment in production: Two new eleven-layer cast coextrusion lines ensure particularly efficient, economical and sustainable film production. Each of the two systems produces around 1.5 tonnes of film per hour and works with ten per cent less waste (edge trims) than was the case with the old systems. Allvac feeds the edge trimmings that are still produced back into the extrusion process and thus carries out internal recycling directly during production.
Another sustainability advantage of the new systems is that they can be used to produce recyclable films, some of which can be 100 per cent recycled. One such film is the allflex SR. It is a fully recyclable multilayer PA/PE film and was developed by Allvac.
„We wouldn't have been able to produce recyclable films like the allflex SR on our old systems. This requires state-of-the-art technology like the one we are now using.‚
Thomas Herbst, Sales Manager
Special feature: Ionomer films
Allvac also uses the new eleven-layer cast coex extrusion lines to produce so-called ionomer films, which are used for packaging cooked ham, for example. „The production of such ionomer films is a difficult process, not everyone can do it. There are very few manufacturers across Europe, who do this - Allvac is one of them,“ Herbst continues.
The modernised and efficient production is followed by equally modern and efficient packaging of the film rolls for further transport. The automatic packing line at allvac packs 120 small film rolls per hour. This corresponds to around ten Euro pallets of film rolls. „Compared to pure manpower, packaging is now twice as fast,“ explains Dr Gasse. „What's more, the automatic packing line is an enormous Relief for our employees, as the handling of heavy rolls is almost completely eliminated. Thanks to the automatic packing line, the distances travelled by forklift trucks have also been reduced by around 90 percent, which also reduces the risk of accidents,“ continues Dr Gasse.
In the course of the modernisation, allvac Folien GmbH their interfaces have also been brought together and fully networked, by means of a new ERP system. ERP (Enterprise Resource Planning) links production and the individual departments at Allvac. This streamlines and simplifies internal processes. For example, stock levels can be queried even more quickly for customers.
SourceAllvac : Allvac
