Complete Installation of a W&H Varex II Plastic Extrusion Line
Customer
Confidential
Project type
OEM installation
Year
2025
Project scope
$900,000
Project description
As part of a major capacity expansion initiative, a new high-performance blown film extrusion line was installed to increase production capacity and support manufacturing growth. Egzatek was mandated to coordinate and execute all activities required to implement the new production line, from equipment reception through full preparation for commissioning.
The project included installation of a large-scale extrusion line consisting of a multi-level production tower, multiple extruders, cooling systems, film handling equipment, control systems, and winding units. The size of the structure and the complexity of the mechanical, electrical, and pneumatic interfaces required rigorous planning to ensure safe and efficient execution.
Particular attention was given to site preparation, equipment logistics, and coordination between all stakeholders. Egzatek’s teams carried out specialized rigging, precision mechanical assembly, installation of electrical infrastructure and industrial services, as well as alignment verification in accordance with manufacturer requirements.
Drawing on experience gained through dozens of major industrial equipment installations within the flexible packaging industry, Egzatek implemented a structured installation strategy designed to reduce execution risks, optimize the project schedule, and ensure a smooth transition to commissioning and production.
Key work completed
- Detailed project planning and overall stakeholder coordination.
- Equipment reception, unloading, and temporary storage.
- Extrusion tower erection and mechanical structure assembly.
- Heavy rigging and positioning of extruders and auxiliary equipment.
- Precision alignment and anchoring of production equipment.
- Installation of cable trays and industrial utility supports.
- Electrical cable pulling and preparation of control infrastructure.
- Installation of compressed air, process water, and auxiliary utility systems.
- Installation of scrap recovery and pneumatic conveying systems.
- Completion of required mechanical adjustments during assembly.
- Preparation of alignment and compliance reports.
- Support for validation, start-up, and system acceptance activities with W&H technicians.
The operational impact
The addition of this new extrusion line is intended to significantly increase production capacity while providing greater flexibility in the manufacture of technical films for the flexible packaging market. This new infrastructure also supports future operational growth through the integration of modern manufacturing technologies.
The installation is expected to improve process stability, production repeatability, and finished product quality control. The new handling, cooling, and control systems also contribute to optimizing overall line performance.
The implementation of properly designed industrial infrastructure, including electrical, pneumatic, and process services, promotes improved operational reliability while simplifying future maintenance and preventive maintenance activities.
Over the long term, this investment increases plant productivity, reduces the risk of unplanned downtime, and supports growth objectives through a modern, high-performance, and scalable production platform.
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