Casting High-Precision Films and Foils:
our technology makes them possible!

Anyone wishing to cast high-quality films and foils with large widths knows that this can only be done on belt casting equipment. For many years now, we have specialized in the construction of this type of plant.

Well-known customers the world over use our casters to make products such as:

     polymethylmethacrylate (PMMA) – e.g. acrylics
     polyimide (PI)
     cellulose acetate / cellulose triacetate (CA, CTA) – TAC

Cast materials are used for the manufacture of products such as:

  • TAC / TFT films for LCD monitors
  • coatings for sunglasses 
  • aircraft accumulators
  • cable insulation 
  • flexible circuit boards 
  • shower cabins

Our casting equipment meets all the requirements to give you market success as a manufacturer of films and foils:

  • Unrivalled precision in production coupled with exceptionally high quality of the finished product
  • Production in large widths gives higher output and reduces cost
  • Optimized energy consumption and environmentally friendly

Over and above this, our casting equipment offers additional advantages that make production significantly simpler and more efficient:

  • High availability of plant and longer belt service life thanks to our bernmatic® belt tensioning and tracking system  
  • Rapid and dirt-free belt changing thanks to our belt changing device

You, too, can benefit from our in-depth expertise and long years of experience in the construction of casting equipment.

Our Services: 

We will accompany your project from the initial idea through to the commissioning of the finished plant. Your requirements and wishes are always the focal point of our planning.

Technical design
Simulation of energy consumption and possible environmental impacts by means of computer simulation
Basic and detail engineering
Complete project management service 
Manufacture
Installation
Commissioning
Staff training

The advantages of our casting systems in detail

  • High quality of execution = high quality of finished product 
    Our drive concept ensures smooth belt running characteristics and freedom from vibration. This reduces visual defects such as ribs in the finished product to a minimum. 

    Uniform distribution of temperature over the entire width and length of the belt makes it possible to produce films of constant thickness. This quality feature ensures that your product can be used in high-tech applications.
  • Energy optimization and higher output
    We analyze the optimal energy balance for your production process using computer-aided simulations and calculation models.

    The result: significantly reduced energy consumption. 

    Heated drums are a key factor in the success of our concept. They enable us to utilize the entire width of the belt, reducing energy consumption compared to finned tube radiators or convection heating systems. 

    The heat obtained from the evaporation process is fed back to the systems. This eliminates the need for the costly equipment previously required to purify large quantities of air, and also reduces environmental impact. 

    Achieving heat transfer by impingement nozzles improves the system’s efficiency and also reduces environmental impact.
  • High availability of production line 
    Our bernmatic® tracking and tensioning system is a standard feature of all our casting systems, ensuring optimal control of belt tracking characteristics.

    Smooth belt running makes it possible to use the entire casting width, extends the service life of the belt, and guarantees optimal energy consumption. Maintenance work is reduced, significantly increasing the availability of the plant. 

    Thanks to smooth running characteristics, it is possible to use a continuous process to make products with tight manufacturing tolerances.

  • Endless steel belts for rapid belt changing and easy maintenance
    The use of an endless steel belt combined with a belt changing device considerably simplifies installation and changing of the belt, greatly reducing the number of staff required for this task. The belt slides into the machine, thus avoiding damage to the casting systems and the belt. The belt changing device also prevents contamination of the plant during belt changing.

    Casting machines with shop laser welded and thereafter completely ground and mirror polished endless steel belts have yet another major advantage: the transverse weld is not visible in the finished product. This translates into a particularly high quality product.

    • Optional extensions

    In order to optimize your production process right down the line, we can also develop the necessary upstream feeder systems and downstream processing components for you too. This also helps us offer optimal energy efficiency. Handling equipment facilitates belt changing and increases the availability of the plant.

    • Product filtering:
      • automatic backflush
      • filtering cartridge filters
    • Product feed equipment: 
      • knife coater 
      • extrusion die 
    • Product drying: 
      • belt machines with drum
      • heating tenter dryers (TDO/MDO) 
      • roller dryers 
    • Product handling and control: 
      • auxiliary winders
      • inspection line with automatic thickness measurement 
      • winders with cutting equipment
    • Air processing: 
      • solvent recovery 
      • air conditioning (heating, filtering)
    • Handling equipment:
      • belt changing device

    More...