Huhtamaki (Elif) boosts film quality with Nordson BKG continuous melt filtration

Nordson Corporation, through its Polymer Processing Systems (PPS) division, has announced that Huhtamaki’s Elif division, a global leader in sustainable flexible packaging solutions, has successfully implemented Nordson’s BKG® continuous melt filtration technology to improve blown-film production performance while increasing the use of recycled materials. As part of its sustainability strategy, Elif set out to increase recycled content in its polypropylene (PP) and polyethylene (PE) blown-film applications.

However, the variability typically associated with recycled feedstock created significant processing challenges on its extrusion line operating at 350 kg/h. The company experienced frequent production interruptions, elevated waste levels, and visible film defects due to inconsistent melt filtration. To address these challenges, Elif partnered with Nordson Polymer Processing Systems to evaluate a continuous melt filtration solution designed for demanding blown-film applications.

Addressing downtime and product quality challenges
Elif faced significant operational challenges as its existing discontinuous filtration system struggled to cope with the fluctuations in melt purity typically associated with recycled materials. The limitations of the system resulted in frequent production interruptions caused by filtration-related downtime, adversely affecting overall manufacturing efficiency. At the same time, higher gel content in the processed material led to product quality issues, making it difficult to consistently meet customer specifications.

The filtration constraints also reduced operational flexibility, limiting Elif's ability to process recycled feedstocks of varying quality. As a result, the company experienced higher material waste, lower productivity, and reduced commercial output, while the recurring inefficiencies hindered its efforts to achieve its sustainability objectives by maximizing the use of recycled materials in production.

Nordson BKG® continuous melt filtration solution
To address its filtration challenges, Elif partnered with Nordson to conduct on-line testing using the BKG® HiCon™ K-SWE-HD/RS continuous melt filter. Installed downstream of a 90 mm extruder and operating at inlet pressures of up to 550 bar, the system provides filtration fineness of between 125 and 150 microns. Unlike conventional discontinuous filtration systems, the BKG® HiCon™ technology delivers true continuous filtration, eliminating production interruptions while maintaining stable melt pressure and temperature for consistent blown-film quality.

The system is specifically designed to process recycled materials with varying contamination levels, helping improve operational flexibility and reduce material waste. Its advanced backflush technology enables continuous, automated screen cleaning without halting production, ensuring stable processing even during periods of high contamination. The result is enhanced line efficiency, improved product quality, and proven reliability in demanding blown-film applications, making it well suited for manufacturers seeking to increase recycled content without compromising productivity.

Measurable performance gains
Following a short trial period, Elif reported immediate and measurable improvements in production performance, prompting the company to purchase and fully implement the Nordson BKG® HiCon™ continuous melt filtration system across its operations. The new system successfully eliminated unplanned downtime associated with melt filtration, enabling uninterrupted production while significantly improving overall process efficiency and increasing the output of sellable products.

The implementation also delivered substantial quality and sustainability benefits. Material waste was reduced, film quality improved markedly with minimal gel formation, and the fully automated, hands-free operation enhanced operator safety by minimizing manual intervention. In addition, the system provided greater processing flexibility, allowing Elif to efficiently handle a broader range of recycled materials while maintaining consistent product quality and operational reliability.

“The introduction of the fully automated self-cleaning filter greatly improved our operator safety. With the BKG® HiCon™ K-SWE-HD/RS, we were able to replace manual filter changes on a running machine—which previously posed high safety risks—with an automated, waste-free process requiring no operator intervention,” said Karim Saber, Global Senior Manager Extrusion & Recycling Operations.

Supporting sustainability and profitability
By stabilizing extrusion conditions and eliminating filtration-related interruptions, Elif has strengthened both its sustainability performance and operational profitability. The ability to reliably process higher levels of recycled content without compromising quality supports the company’s broader environmental goals.

“This project clearly shows the value of continuous melt filtration when processing recycled materials. By combining automation, process stability, and robust filtration performance, we help customers like Elif achieve their sustainability goals while improving safety, efficiency, and profitability,” said Frank Thomas, Manager Sales, Nordson BKG®.

A proven partnership
Elif's successful implementation of Nordson's advanced melt filtration technology highlights the company's commitment to delivering innovative polymer processing solutions that help manufacturers address evolving market demands and increasingly stringent environmental requirements. By enhancing production efficiency, improving product quality, and enabling greater use of recycled materials, the solution supports customers in their transition toward more sustainable manufacturing practices.

Leveraging its advanced melt filtration technologies and extensive process expertise, Nordson Polymer Processing Systems continues to assist manufacturers worldwide in optimizing production performance while reducing material waste and operating costs. The company's solutions enable processors to achieve greater operational efficiency, maintain consistent product quality, and advance their economic as well as environmental sustainability goals.

Nordson ventures
Nordson Polymer Processing Systems provides customers with engineered components to melt, homogenize, filter, meter, and give shape to plastic and fluid coating materials. Nordson Corp. leverages the collective plastics industry experience from a series of strategic acquisitions to offer a uniquely broad portfolio of industry-leading technologies. Nordson delivers a full range of precision melt stream products — from filtration systems, pumps, and valves to extrusion dies and pelletizing systems — to meet the constantly evolving needs of the polymer industry. Nordson provides customers with local technical sales, service, and remanufacturing capabilities through its sales organizations and regional manufacturing operations.

Nordson Corporation is an innovative precision technology company that leverages a scalable growth framework to deliver top-tier growth with leading margins and returns. The Company’s direct sales model and applications expertise serves global customers through a wide variety of critical applications. Its diverse end market exposure includes consumer non-durable, medical, electronics and industrial end markets. Founded in 1954 and headquartered in Westlake, Ohio, the Company has operations and support offices in over thirty-five countries.


DILIP KUMAR JHA
Editor
dilip.jha@polymerupdate.com