PowerCast XL

World debut: processing high-performance stretch film with 30 % PCR resin from Braskem

SML’s PowerCast XL is a unique 4.5 wide stretch film line with a net output capacity of up to 3.400 kg/h. At SML’s booth at K2022, the line processed a new type of PCR resin developed together with Braskem into premium stretch film. A technical highlight of the PowerCast XL is its patented triple turret winder: the first in the market for manufacturing 2” stretch film hand rolls on a 4.5 m wide line.


“SML PowerCast XL stands for high volume and superior stretch film quality. It can be fitted with a 7 to 67 layer feedblock, and it comes with the biggest chill roll of 1,600 mm in the field. Nevertheless, it requires only 240 m² floor space”, says Thomas Rauscher, Product Manager at SML.


Excellence in process technology 
The PowerCast XL was able to process 30 % post-consumer-recycling material that came from mechanical recycling. For the manufacturing of high-performance stretch film with PCR, SML joined forces with the Brazilian petrochemical company Braskem. Together, they presented on K 2022 a commonly developed solution that combines SML’s technology in film processing and Braskem post-consumer recycled resin. The newly developed Wenew DL085C resin is a 100 % PCR resin and allows the production of completely transparent stretch film with excellent mechanical properties on SML stretch film lines. These films are highly resilient and withstand strong mechanical loads, i.e. in the area of transport safety or for automatic applications in the beverage industry.


EU recycling targets for 2025 anticipated 
SML Product Manager Thomas Rauscher about the joint development works with Braskem: “At first it seemed nigh on impossible to find a sustainable and economical solution, especially when it comes to downgauged products. Finally, after two years of very close collaboration, development work and countless trials together with Braskem, we are now in a position to offer the market a solution to the PCR demand in stretch film production which is certain to delight end users. And a satisfying answer on both the raw material side as well as the manufacturing side,” Thomas Rauscher comments.


Currently, there are intense discussions in EU-institutions to introduce a mandatory 25-%-share of post-consumer recycled materials in packaging products form plastics by 2025. With their joint development activities, Braskem and SML are providing their customers with a workable and solution three years in advance.


"The stretch film developed together with SML shows how far Braskem has already increased PCR quality and what is already feasible today. Combining Wenew product with Braskem's portfolio, we can achieve a film with extremely high-quality and thus helping to open completely new perspectives for the use of recycled materials in a wide range of applications," says Carlos André Silva, Subject Matter Expert at Braskem.


Increasing product diversity with “three-turrets-in-one-frame” concept 
The PowerCast XL was in operation at K 2022 with SML’s newly patented turret winder W4000-4S-3T. Its “three-turrets-in-one-frame” concept supports significantly higher production speeds for maximum output quantities – especially at the lighter 2” rolls. “The possibility to manufacture also 2” rolls on that 4.5 m wide increases the product diversity and productivity of our PowerCast stretch film line significantly,” says SML Product Manager Thomas Rauscher. Until now, it was only possible to run 2” hand rolls on lines up to 3 m width, thus the new development boosts the output of hand rolls by about 50 %. As before, 3” hand rolls, machine rolls and jumbo rolls an also be manufactured, with ease, with this new solution.


Technical features of PowerCast XL + W4000-4S3T:

  • Output up to 3,400 kg/h net
  • Compact design – 240 m² floor space
  • Ø 1,600 mm chill roll – the biggest in this sector
  • 7 or 67 layers
  • Ready to manufacture PIR and PCR
  • Maximum flexibility: 2” hand rolls 3” hand rolls, machine rolls and jumbo rolls
  • ThinCore technology
  • Coreless technology
  • Modified Edges


Redlham, 04.10.2022


Convince yourself of our joint performance at the K 2022 and watch the video: