MALAYSIA - With the installation of two VAREX(r) Blown Film Lines and one ASTRAFLEX(r) Central Impression (C.I.) flexographic press, leading Malaysian flexible packaging manufacturer Great Wall Plastic Industry Bhd has taken another step towards its objective aimed at increasing its production capacity and enhancing product quality.

The investment decision by the management board of Great Wall Plastic, reinforces the company's business strategy to focus on superb quality products. The new equipment has been put into operation in the company's Rawang facilities.

According to General Manager - Manufacturing, Mr. P.K. Wong, the crucial factor in the decision to invest in new W&H equipment was the higher efficiency as compared to existing equipment. "The automation level of the W&H machines, combined with reduced manual settings and adjustments, and, not least, the superior overall productivity will definitely generate higher cost advantages for us," says.

The two new Varex Blown Film Extrusion Lines are designed for the production of single-layer films. One of the lines features a 120.30D extruder and can handle film widths of up to 3300 mm double-flat. Optimal consistent film quality is ensured by the automatic gauge profile control system Optifil P. Other features include gravimetric metering, side gusset forming for the manufacture of shrink hoods and a Filmatic K dual winder. Output rates are in the order of 400 kg/h.

"The HPS barrier screw allows for the processing of LDPE, LLDPE, EVA, metallocenes or HDPE, without changing the screw or the die," says David Lim, Executive Director and Member of the Board, emphasizing the flexibility and variability of the new equipment adding, "Since the Varex is equipped with a special side gusset former, we are now in a position to produce side gusseted tubing using the oscillating haul-off, a prerequisite for perfect quality film rolls made possible, because the side gusseting system incorporates automatic gusset offset capability."

The other Varex line, again a single-layer unit, has a 70.30D extruder and can handle film widths up to 1600 mm double-flat and is designated for the production of high-quality laminating films.  Depending on resins used and on order or product specification, the line can achieve outputs of approx. 180 kg/h.

"By adding the two new lines to our existing equipment, Great Wall is now operating a total of four Varex W&H blown film lines, including a 3-layer extrusion line, in an air conditioned clean room environment," reports David Lim proudly. "This high-tech equipment will definitely give us a competitive edge and we feel, in fact, well prepared for the agreed tax harmonization among South East Asiatic countries (NAFTA)."

By the same token, Great Wall invested in a new central impression flexographic printing machine Astraflex again from German based engineering company Windmöller & Hölscher. "This investment is another significant step towards maximizing quality and productivity," explains Michael Fischer, Regional Manager of Windmöller & Hölscher based in Bangkok Thailand. "The Astraflex is the fastest running flexographic printing machine currently operating in the ASEAN region, with output speeds of up to 465 m/min, depending on job specification."

Equipped with 8 color decks configured for a maximum printing width of 1570 mm. It is combines with the robotic makeready system Portalift for automatic change-over of plate cylinders and anilox rollers.

A Softal corona discharge treater serves for refreshing the treatment level. Skip treatment is possible both in the machine and transverse direction and may be desirable, for instance, in order to ensure good heat-sealing properties of the film in the area of the side gussets.

The unwind and rewind units are both in shaftless design and feature an automatic reel loading/unloading table. Flying splice reel changes are, therefore, accomplished at full production speed.

A feature of important in achieving superior print quality with the Astraflex is the double-walled temperature controlled central impression cylinder. "The C.I. cylinder has a special surface finish," comments Michael Fischer, "which counteracts the risk of corrosion as a result of the prevailing high air humidity in Malaysia. Run-out tolerances are minimized to 5 microns and maintained even at speeds of 465 m/min. To achieve such outstanding precision, obviously, takes the ultimate in engineering quality, and this is what the name Windmöller & Hölscher stands for world-wide."

The new investments are impressive evidence of Great Wall's ongoing commitment to high-quality flexible packaging and of its relentless endeavors to satisfy its customers' needs and wishes. "We see ourselves as the market leader in Malaysia with a monthly PE throughput of roughly 3000 metric tons." David Lim points out "With new products such as, stretch hoods for industrial packaging applications, one of our most recent developments, we are accommodating the current market trend in South East Asia, especially in Singapore and Thailand," adds General Manager Marketing Mr. C.K. Ng. "We are determined to further expand our export business which accounts already now for 40 % of overall sales. To do so, we need new products."