Alpha Marathon's Patented "2X" Nano-Layer Production Die

After introducing its patented Nano-Layer Die Technology at NPE 2012, Alpha Marathon will be displaying a production ready “2X” Nano-Layer Die at NPE 2105 March 23rd - 27th. The 2X die is a larger scale production version of the innovative 1X die that garnered a lot of attention at NPE 2012. It is available in configurations of up to 18” diameter and from 29 to 200 layers, with an output in excess of 1000 lbs/hour. With Blow Up Ratios as high as 5x achievable, a 2X die is capable of lay-flats of up to 12 feet.

Alpha’s Nano-Layer Die Technology represents the next great leap forward in annular extrusion die technology for end-users and packaging producers seeking innovative new solutions to create higher performing and lower cost films and packaging. It builds on the now well understood and proven principle that increasing the layer structure of plastic films creates great opportunities for improving their mechanical and barrier properties while also reducing input resin and other production costs. The evolution from mono-layer to 3-layer co-extrusion films – and then on to five, seven, nine, and eleven layer co-extrusion films – is proof of this.

Alpha Marathon takes this evolution a great step forward with its patented Alpha Nano-Layer Die Technology. Our Nano-Layer Die Technology is based on an innovative new approach to die design and construction that creates film structures from 23 up to 200 discrete layers – creating never before seen film properties.

nanolayer die

The secret is the ability to create and inter-weave layers that are less than a micron thick. These "Nano-Layers" have unique physical and mechanical characteristics that allow them to combine with other resins in new and important ways. Alpha's Nano-Layer Die Technology creates films that exceed the performance envelopes of current multi-layer films, including:

  • Improved mechanical strength properties: increased puncture, resistance and dart drop values
  • Smoother, stronger film surfaces enhancing printing and sealing properties
  • Improved optical qualities for clear packaging
  • Creation of higher performing barrier films within a single co-extrusion
  • Achievement of properties currently only possible thru post-lamination processes within a single co-extrusion process


Alpha Nano-Layer also creates great opportunities to down-gauge current film applications to significantly reduce cost without sacrificing performance. When combined with Alpha's GlacierTM Water Quench technology, substantial production cost reductions can be generated, including:

  • 20-30% gauge reduction with no loss of mechanical properties
  • 5-10% reduction in input resin blend cost/kg
  • 15-25% through-put increase on a linear feet or square meter basis
  • Production cost reductions thru integration of current post-lamination processes into the co-extrusion process

Prime applications for Alpha's Nano-Layer and Glacier technologies include:

  • Food Packaging: all forms of barrier and non-barrier applications; FFS (form/fill/seal); thermoforming (eg. Clam-shell trays)
  • Medical: IV bags and other sterile pouches
  • Industrial: Heavy Duty Shipping Sacks (HDSS); shrink bundling/hoods; vapour barrier sheeting; protective sheet
  • Technology: battery and capacitor insulator films

Alpha Marathon recently shipped its first Alpha Nano-Layer Die destined for the Asian market. The "Nano-Layer 1X" die was purchased by a large petro-chemical producer and was recently the subject of extensive pre-delivery customer testing at Alpha’s Nano-Layer Technology facility where it exceeded all customer expectations. The initial configuration of the die will produce a 29 layer structure composed of 5 resins.

Alpha's nanolayer technology structure

Nano-Layer Structure

If you’re going to be at NPE 2015 and interested to learn how Alpha Marathon Nano-Layer Die Technology can improve your products and cost structure, please come visit us at Booth S21197. If you can’t make it to NPE this year, for more information on how Nano-layer can benefit your business, please contact us at This email address is being protected from spambots. You need JavaScript enabled to view it..

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