Raw Materials & Compounding
In order to be able to offer films with constant quality and at the highest level, we process only high-quality raw materials. In addition, we produce unique raw material composites by means of compounding. During the compounding process, different raw materials, which also differ in their consistency, are mixed into a resin that is processible for extruders.

These compounds cannot be obtained on the market, we manufacture them on the basis of our technical expertise and know-how. This forms the backbone for premium end products that fulfill your individual requirements in the best possible way.

Extrusion Plastic films are made in the extrusion process. Plastic pellets are crushed and melted continuously under the application of heat. The liquid hotmelt is extruded from a nozzle. In the blown film process, a ring die forms the extruded hotmelt into a sleeve. Blowing air inside expands the sleeve. The plastic is cooled down slowly by the air that flows past the sleeve and solidifies it into a film sleeve. Blown film extrusion is one of Billion Flex’s core competences. A variety of machine configurations based on the latest technology and the high performance of the facilities enable the production of a particularly wide range of blown films.

Flexographic Printing A versatile printing technology, flexography offers a unique blend of high quality graphics on a wide variety of substances (film, shrink sleeves) and supports flexible production requirements. Flexography (Flexo) printing uses a raised-image printing plate. Photopolymer plates are used to transfer the line art images onto film. The plates are mounted on to the plate cylinders. As the plate cylinder rotates, it comes in contact with an anilox, or ink roller, which inks the raised portion of the printing plate. The anilox roll is laser-engraved with thousands of recessed cells that fill up with ink. The doctor blade controls the ink transfer to the plate. The doctor blade wipes off all ink except what is in the cells of the anilox roll. The Impression Cylinder applies pressure to the Plate Cylinder, the plate then transfers the ink to the film.

Optimized for cost, with straightforward plate making process, lower make-ready costs, and easier design changes, Flexo printing is well suited for printing shorter runs (smaller quantities) of packaging products which may need to be redesigned based on current marketing schemes.

Rotogravure Printing The gravure printing process enables particularly brilliant print qualities. With the help of top-notch rotogravure presses, and thanks to close cooperation with the preliminary suppliers (reproduction and cylinder producers), Billion Flex can flawlessly print extravagant half-tone design motifs with up to ten colors during gravure printing.

Rotogravure technology utilizes engraved metal printing cylinders for printing. The image from the finalized artwork is electronically engraved into a copper cylinder, and then the cylinder is chromed. The gravure cylinder has a long service life and will yield a very large number of impressions without degradation of image quality. The cylinder rotates in a bath of ink. As the cylinder rotates the excess ink is wiped off the cylinder by a flexible steel doctor blade. The ink remains in the recessed cells (engraved area) and then directly transfers to the substrate (LLDP/LLDPE, HM, PET, PVC, OPP) as it passes between the cylinder and the impression roller.

Optimized for high volumes, and renowned for its superior quality graphics, consistency over long runs and excellent color capacity, rotogravure printing is the technology of choice for half-tone/photography and high volume package printing.

This printing technology is ideal for printing carry bags with half-tone photography design, full body shrink sleeves, shrink building wraps for multi-packs using brilliant metallics inks.