Alpha Marathon's Patented "Layer Sequence Repeater" Production Die

After introducing its patented Nanolayer capable Die Technology at NPE 2012, Alpha Marathon will be showcasing the advancements with this technology over the past three years at Plast 2015 - May 5-9.

A full size 2X die garnered a lot of attention at NPE 2015, showcasing the mature evolution of the innovative 1X die that was first introduced at NPE 2012.

It is available in configurations of up to 20" diameter and from 25 to 200 layers, with an output in excess of 1000 lbs/hour.

With Blow-Up Ratios easily achievable in excess of 5 times, a 2X die is capable of lay-flats over 13 feet.

Alpha’s "Layer Sequence Repeater" 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 5, 7, 9, and 11 layer co-extrusion films – is proof of this.

Alpha Marathon takes this evolution a great step forward with its patented Alpha Layer Sequence Repeater Die Technology.

Our "LSR" Technology is based on an innovative new approach to die design and construction that creates film structures from 25 up to 200 discrete layers – creating never before seen film properties.

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.

Qualitative/Quantitative Phenomena

• Interweaving layers creating a repeating “I” beam structure for maximum strength
• Adjacent ultra-thin layers rapidly quenching resulting in “glass like” clarity, interlayer quenching
• Molecular layer alignment allowing unparalleled extensibility for blow up ratios and orientation capability over 1 ½ times traditional methods
• Interlayer melt stability yielding high melt strengths allowing the creating of films under 2.5 microns in total thickness
• Broadest tolerance of melt rheology in any extrusion technology allowing films to be made from virtually any resin and resin combination

Alpha's Layer Sequence Repeater 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 Layer Sequence Repeater 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