Reifenhäuser Cast Sheet Coating is set to spotlight its Cast MDO technology at K 2025, presenting a solution that aligns recyclability with production efficiency and added consumer functionality.
As regulatory frameworks like the EU Packaging and Packaging Waste Regulation (PPWR) drive the transition to recyclable mono-material films, Reifenhäuser’s cast film technology demonstrates how producers can achieve these goals without compromising on performance or profitability.
At the K Preview press conference attended by PKN, Marcel Perrevort, CSO of the Reifenhäuser Group, said the company’s early entry into the cast MDO space has allowed it to develop both the hardware and processing know-how to deliver economically viable, high-performance films.
“Our goal is to develop technology for recyclable films that are both functional and economical to produce,” he said. “We will be showcasing the successful results at K 2025.”
Barrier performance with reduced material use
With cast MDO (Machine Direction Orientation), mono-material films made of PP or PE can replicate the stiffness, optical clarity, and barrier properties typically associated with multi-material solutions, enabling the replacement of PET in many applications. This has been particularly effective in applications like all-PE stand-up pouches.
The MDO process stretches the film, reinforcing the barrier properties of EVOH and reducing the amount needed to below five percent of total packaging weight – a threshold critical for recyclability. Reifenhäuser’s cast systems go further with an edge encapsulation process that prevents EVOH from entering the edge trim waste, eliminating the need for an additional extruder and reducing raw material costs. The company estimates producers can save up to €150,000 annually with this solution.
Added functionality with Easy Tear
For end users, the Cast MDO system also delivers functional benefits, notably the ‘Easy Tear’ feature. By controlling the orientation during the stretching process, films can be engineered to tear cleanly in one direction – eliminating the need for laser perforation, which can compromise barrier integrity and shelf life. The feature enhances consumer convenience and packaging reusability, especially in formats like stand-up pouches with resealable closures.
Technology built for today – and tomorrow
Designed for flexibility, the Cast MDO unit is available for integration with all Reifenhäuser cast lines and is compatible with most third-party systems, provided the line width does not exceed 3.6 metres. It can be ordered for new installations or retrofitted in the field.
“At K 2025, we will use product samples to show how Cast MDO films contribute to the circular economy and create tangible value for producers and consumers alike,” said Perrevort.
K 2025, the world's leading trade fair for plastics and rubber, will take place from 8-15 October 2025 in Dusseldorf, Germany.
