Modular Upgrades & Performance Services: Brückner Servtec Unveils Cutting-Edge Innovations at K 2025

At K 2025 in Düsseldorf, Brückner Servtec showcases a powerful portfolio of modular upgrades and new performance services designed to future-proof BO film stretching lines. From advanced inline coating and BOPE conversions to data-driven support tools and digital training with a virtual line twin, the company delivers smart solutions for increased efficiency, sustainability, and production output.

Modular upgrades for line transformation and production increase

Targeted retrofit solutions for tomorrow’s state-of-the-art BO film stretching lines:

• Inline coating upgrade (ILC): With layer thicknesses in the nanometer range, new formulas improve printability and take the barrier properties of BOPP films to a new level. In recent years, Brückner Maschinenbau and Servtec have sold more than 25 ILC systems that support the production of recyclable mono-material packaging – as required by EU Regulation 2025/40 on packaging and packaging waste (PPWR).
• BOPE upgrade: The enhanced concept supplements existing BOPP lines with the option of producing LLD-PE and HD-PE – an important element for mono-material solutions for simplified recycling. It is an integral part of the portfolio and enables nearly 100% PE output compared to the original production, for example by means of targeted extruder modifications.
• Productivity upgrade: An efficient solution to increase the line output – using mechanical, electrical, or software-based measures, depending on requirements. Here is one example: Optimization of the highly complex TDO (transversal direction orienter) chain system component, for instance by replacing FOK 4.4.6 with FOK 8.8. In combination with double nips in the MDO (machine direction orienter) stretching frame, additional TDO frequency converters, or updating the IMC software, production speed can be increased by up to 20%.

New performance services 

Fast on-site support for film manufacturers thanks to new service products.

• Line inspection (1 day): Analysis of the line processes to reveal hidden efficiency potential – including immediately implementable optimization measures such as process parameter adjustments
• KPI check (3 days): Industry comparison based on real operating data to assess key performance indicators (energy consumption, maintenance quality, productivity) and derived conversion and service suggestions
• Performance boost (5 days): Profound process optimization with a focus on increased production output, improved energy efficiency, and knowledge transfer. In addition: targeted approaches to quality improvements and the development of future-oriented film types. In comparable applications, the line yield was increased by up to 40%. 

Brückner ONE: the next step in digital services

The current generation of Brückner ONE provides advancements for increased efficiency, safety, and flexibility in digital line operation.

• Condition monitoring 2.0: Shorter reporting intervals, in-depth analyses, and specific recommendations for action allow for an even more targeted condition monitoring of key line components (main extruder gearbox, TDO chain, parts of the extraction system) as well as early planning of maintenance measures. Further line components will be integrated successively.
• Support: For the first time converted to web technology and decoupled from the line network, it combines a ticket system with remote support and a communication solution. A central overview of all lines and flexible access independent of locations and devices increase the user friendliness and deepen the internal know-how.
• Cybersecurity service: The level of security is strengthened further and expanded in accordance with legal requirements. Continuous monitoring detects dynamic security gaps and digital cyber threats at an early stage, allowing for specific response measures to be initiated by the customer to secure their production environment.

Brückner Academy: state-of-the-art training with a digital line twin

Sustainable training courses for improved operating skills.

• Central platform for all existing and new programs
• Expanded portfolio: operator training (essential & advanced), electrical/mechanical maintenance (essential & advanced), and customized training
• Training on the digital line twin: simulations of line operation, optimization, and realistic emergency & malfunction scenarios; without affecting the ongoing film production
• Flexible implementation by experts: hands-on at the customer’s site, in Brückner training centers worldwide, or in Siegsdorf

Future. Made by Brückner Group

As part of a world-leading group of companies, Brückner Servtec builds on a strong foundation of shared expertise and innovation. United by a common vision, the Brückner Group aims to shape global markets and the future of plastic and material processing with sustainable solutions – flexible, fast and customer-focused. To make this shared purpose tangible, the Group and its business units will be represented together at a joint stand for the first time. This presence offers customers and stakeholders the opportunity to experience the combined strength of leading global companies in the fields of plastics and alternatives, packaging and technical applications, machinery and production plants, as well as holistic solution providing.

Each business unit contributes cutting-edge technologies for future-oriented markets that embody the Brückner Group’s collective commitment to sustainability, digitalization, and technological leadership. From more efficient production technologies and smart automation to new packaging approaches and digital interfaces – these developments reflect the shared drive to lead with purpose.

Together, they stand for collaboration, excellence, and a bold vision: shaping the industry of today and tomorrow.