The signs are green: the film specialist allvac has modernized its production and is not only relying on the latest technology, but also on renewable energy. To this end, allvac has invested a total of over ten million euros at its headquarters in Waltenhofen, Bavaria. Two new so-called cast-coex extrusion lines for film production, an automatic packing line and a new ERP system ensure optimized processes. The energy for the new systems and the office building comes, among other things, from a photovoltaic (PV) system on the company premises. With over 6,000 modules, the PV system at allvac is 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.
"We have made ourselves fit for a sustainable future and have invested a lot of time, energy and money in our green modernization over the past two years," emphasizes 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 CO2 footprint thanks to the PV system. We are continuously modernizing our production and developing films that are 100% recyclable," adds allvac owner Hans Bresele.
2,500 tons less CO2
With 15,000 square meters and 6,151 modules, the PV system at the allvac site is one of the largest rooftop solar systems in Bavaria. It generates 2.3 million kWh of electricity per year, which flows into both production and the office and administration building at allvac. With the large-scale PV system, the film manufacturer saves around 2,500 tons of CO2 per year, which is the equivalent of 200,000 newly planted trees.
Film production is an energy-intensive process. The aim of allvac is therefore to make not only the films but also their production at the site sustainable. The solar system helps here. "On sunny days, the PV system covers 100 percent of our own electricity requirements. Sometimes it also produces more electricity than we consume, which we then feed into the grid," explains Dr. Gasse.
Modern production facilities for recyclable films
Allvac has also made a major investment in production: two new eleven-layer cast-coex extrusion lines ensure particularly efficient, economical and sustainable film production. Each of the two lines produces around 1.5 tons of film per hour and works with ten percent less waste (edge trimmings) than was the case with the old lines. Allvac feeds the edge trimmings that continue to be produced back into the extrusion process and thus carries out internal recycling directly during production.
Another sustainability benefit of the new systems is that they can be used to produce recyclable films, some of which are 100% recyclable. One such film is the allflex SR. It is a fully recyclable multilayer PA/PE film and was developed by allvac. "We would not have been able to produce recyclable films like allflex SR on our old lines. This requires state-of-the-art technology like the one we are now using," explains Sales Manager Thomas Herbst.
Special feature: Ionomer films
On the new eleven-layer cast coex extrusion lines, allvac also produces 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 only very few manufacturers in Europe who do this - allvac is one of them," Herbst continues.
Automatic packing line
The modernized and efficient production is followed by an equally modern and efficient packaging of the film rolls for further transport. The automatic packing line at allvac packs 120 small rolls of film 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. "In addition, the automatic packing line is a huge relief for our employees, as handling the heavy rolls is almost completely eliminated. Thanks to the automatic packing line, forklift truck travel distances have also been reduced by around 90 percent, which also reduces the risk of accidents," Dr. Gasse continues.
Optimally linked thanks to new ERP system
As part of the modernization, allvac Folien GmbH has also merged and fully networked its interfaces using 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.
About allvac:
The production of thermoformable barrier films based on polyethylene and polyamide is the core competence of allvac. These composite films are used in particular for packaging perishable foodstuffs. From development to extrusion and packaging, the Allgäu-based family business covers the entire process chain, allowing customers to benefit from maximum flexibility and speed. Thermoformable barrier films are produced using two different processes: Blown film extrusion, which is used to produce up to 18-layer laminated films, and cast film extrusion, in which eleven-layer laminated films are cooled on a chill roll. The question of which process to use depends on the end application and the required film properties.
Press contact:
allvac Folien GmbH
Thomas Herbst
Dieselstr. 7
87448 Waltenhofen
Tel.: +49 (0) 831 - 960 282-0
E-Mail: thomas.herbst(at)allvac.de
www.allvac.de