Choosing a food packaging film today is a complicated process, even for seasoned converting and packaging design professionals. A newcomer to the field or a packaging student, who might be inclined to seek insight from a search engine, would be buried in seconds in a blizzard of global information. The ultimate question is: Why might one film type be a better choice rather than another when considering packaging structures, lamination design and end use?
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PET, BOPP, CPP, MetPET, MetOPP &#; there&#;s an alphabet soup of film choices available. When entering into a dialogue with a customer about choice of film, it&#;s critical to ask specific questions and listen carefully for the functional performance the application requires. Then we can begin to determine whether BOPP, PET, metallized, clear, matte or a combination of films is the right solution.
Aside from the obvious question &#; What is the application? &#; we&#;ll want to explore with the customer FDA compliance, economics and yield requirements, the equipment to be used, targeted line speeds and processing temperatures and conditions. What about the barrier level required? Must it be very good, superior, or somewhere in between? Is moisture barrier of greater concern than oxygen barrier, or are they of equal importance?
We&#;ll also want to define other application processing characteristics, like co-efficient of friction, which can contribute to more efficient processing and packaging manufacturing. Sealability (cold-seal or heat-seal) is also vital. The seal affects manufacturing speeds, shelf life, the appearance of the package, the consumer&#;s ease of use and even how the package travels at different altitudes.
Then there are aesthetic, branding and marketing requirements, which bring haze, clarity, gloss and printability into consideration.
Exploring the similarities and the differences between BOPP and PET, we know that both have been around for decades and have evolved a lot. Today, you can find them at varying levels of technological sophistication.
PET typically offers excellent oxygen barrier and moderate moisture barrier. It&#;s usually stiffer than BOPP and has superior optical qualities. It exhibits good resistance to oil and acidic product contents, whereas BOPP is more likely to absorb and become distorted by those substances. PET is a very stable film, which means it shows less stretching during the printing and laminating processes. It is also known for its excellent thermal stability (the ability to withstand high temperatures during processing) and superior melt temperature that makes it the go-to solution for ovenable food applications, like the need to withstand microwaving or heating in a conventional oven. In terms of mechanical properties, such as modulus and tensile strength, PET typically outperforms BOPP.
Basically, PET is well suited for applications requiring a strong film with high tensile properties, scuff resistance and durability.
By comparison with PET, BOPP film offers an improvement in moisture barrier. Converters and end users often select it for use as a print web, an inside barrier web, or a sealant web in a bag or pouch lamination, or as an HFFS wrapper, for salty snacks, baked items, crackers and cookies. It also takes center stage with its low SIT (seal initiation temperature), superior seal performance and lap seal capability. A low SIT enables increased production throughput.
Cast PP, or CPP, is a very soft, tear- and puncture-resistant film and has high seal-strength and high burst-strength properties. CPP also has good heat resistance so it&#;s a desirable candidate for use in hot-fill or retort applications.
It&#;s important to remember that the packaging films we are discussing are multi-layered and have varying skin and core designs created to achieve specific functionalities. By engineering film skin layers, or &#;dialing in&#; unique functionality for a broad range of end use applications, the barrier, sealability, appearance, feel and printability of most films are customizable.
Transforming PET and BOPP into a metallized structure changes the game even more. Metallization significantly impacts the oxygen and moisture barrier, makes for an opaque barrier to light, offers a high-reflective glossy aesthetic and opens up new packaging application options, like those where foil might be the traditional choice, for example.
If we compare MetPET with MetOPP, we find that MetPET has superior oxygen barrier and good moisture barrier, but the MTVR is still inferior to MetOPP. However, MetPET&#;s bond strength and the general robustness of a lamination are superior to those associated with MetOPP.
MetPET is excellent for replacing foil in a lidding application for dairy foods, like yogurt or ice cream, or for items like applesauce or puddings. In comparison with foil, it offers better economics, improved barrier durability and superior puncture resistance.
MetOPP has excellent moisture barrier, very good oxygen barrier, barrier to light, a highly reflective gloss and better puncture resistance in relation to MetPET and foil, and excellent flex-crack resistance &#;all of which can be achieved at a relatively low cost. It tends to be popular for nutritional bars and higher-end snack food packaging applications.
MetOPP is often designed with a low SIT heat seal layer, allowing it to be used in a two-layer lamination. MetPET doesn&#;t always have this type of heat-seal functionality and is often utilized in a triplex laminate.
There are several trends that are driving changes in packaging today and affecting film selection. Clear product visibility is a key driver of change. The consumer&#;s expectation is that the food they&#;ve purchased is made with fresh ingredients, and visibility offers some assurance. Artisanal products continue to gain favor with the mass market and niche customer, and both groups are driving the trend toward clear packaging. Creating a package that is easily opened and resealable, is also a driver.
Maximizing shelf life continues to be of critical importance with the ongoing expansion of global distribution channels. Barrier to oxygen, moisture, light and contaminants are key performance requirements for optimal product shelf life. Package designs vary from flat bottom bags to standup pouches to pillow packages to rigid containers with high-barrier lidding.
The CPG wants to prevent fats, oils, and vitamins from oxidizing; prevent water absorption that makes food soggy or water depletion that dries out food; and prevent photolytic reactions, which can lead to the deterioration of fats, vitamins, flavors and other ingredients. Look for hermetic sealability to further improve shelf life.
Aesthetics are also driving change. Matte finishes, a soft feel and sophisticated print designs are increasingly popular.
Bio-based polymer technology continues to be a very exciting area. The research and development on bio-based films is very much alive and will continue to expand. Feedstock options are still evolving. In terms of the yield and economics of a bio-based OPP or PET film, it&#;s still higher than with regular film and must come down.
There&#;s no getting around cost as a primary influence in the choice of a film. It&#;s important to think holistically about &#;package economics&#;&#;the total cost to a customer for creating a package lamination structure. In a cradle-to-grave approach, we start with resins and consider the total cost of supply through consumer use and disposal.
There may be higher costs per one pound of packaging film, but by looking for efficiencies or gains during converting, packaging, distribution and point-of-purchase, it&#;s possible to achieve an overall cost-savings.
There are many ways to reduce the total cost, such as examining manufacturing, supply chain and operation efficiencies. One major way to reduce the cost of a packaging structure is by using a thinner gauge film, also known as downgauging.
Having more film footage per roll means that the customer needs fewer rolls, and that in turn means there are fewer roll changes and less waste, fewer pallets used and fewer trucks on the road, so the customer&#;s costs for delivered finished goods are further reduced. You could take that information to the next level and even calculate CO2 reduction.
In general, without performance-value barrier coatings or metallization, BOPP is typically less expensive than PET. Cost is also affected by the quantity purchased, the constant fluctuation of raw material costs and the location of the supply source.
If the converter says his most important goal for the package design is extended shelf life, we know the focus is going to be on protection against moisture, oxygen, outside contaminants and light. So barrier attributes will be a primary consideration to meet that customer&#;s needs.
Toray Plastics (America), Inc.
www.toraytpa.com
Liquids and beverages are notoriously tricky to package. These products require packaging that can be successfully filled, stored, transported, displayed, purchased, used, and disposed of, all while retaining the product&#;s quality.
Liquid items are primarily packaged in bottles, pouches, and containers. These are prepared using paper, glass, plastic resins, or plastic films.
Liquid packaging with films is accompanied by liquid pouches. Plastic films are molded into various shapes for making pouches. The most widely used plastic films for liquid packaging are:
Let&#;s explore some important aspects of liquid pouches.
Liquid Packaging Solutions
Liquid pouches offer a lower cost than traditional rigid plastic liquid containers and are friendly to the environment. Many types of liquid pouches are used for securing liquid goods. The essential types of liquid pouches are as follow:
Stand-up pouches are a popular method for holding liquid contents due to their flexibility, ease of use, and ability to keep substances fresh. These pouches can accommodate products such as soups, juices, and laundry detergent.
One of the conveniences of stand-up pouches is the ability to place the label on the front or back of the pouch. Resealable labels can also be applied to stand-up pouches to preserve the good&#;s freshness by resealing the pouch after it has been opened.
Stand-up liquid pouches are made from plastic films such as BOPP, Nylon, Aluminium, and BOPET. BOPET film is mainly employed for making stand-up liquid pouches.
Stand-up Liquid Pouches
This pouch is the latest innovation in the continuing evolution and development of stand-up pouches and packaging technology with the integration of closures into the flexible package.
It features a reclosable spout that is hermetically sealed to the packaging material. This spout protects the product through its lifecycle and can be used for both liquids and powders. These flexible pouches safely contain liquid products and stand up easily on store shelves for a more effective display.
Best of all, when done correctly, spouted stand-up pouches are one of the lowest-cost options for liquid and beverage packaging. Compare spouted bags (made with BOPET film) to glass and rigid plastic &#; when it comes to quality and price, there&#;s no contest. It is mainly used for:
BOPET Stand-up Pouch with Spout
The Burst Pouch is a flexible pouch with a layer of poly-film sealed inside to create chambers. The consumer can cut the bottom of the pouch, place it into the desired container, and squeeze it, forcing the liquid to &#;burst&#; through the poly membrane and into the desired container. These pouches are usually one hundred percent clear.
The burst pouch, also known as burst bag, is the most advanced technology available for adhesive packaging solutions for two or three-component premeasured liquid systems. They are used mainly for non-edible packaging liq uids, powders, and industrial products.
Burst Liquid Pouch
The Center Seal Pouch, also known as Pillow Pouch, T-Seal, or Back Pouch, is a standard packaging method used in several industries due to its low cost, flexibility, light-weighted, customizable, and attractive packaging.
The Center Seal Pouch is made of PET/Al/Poly or PET/Poly materials, where it is then formed in the shape of a pillow with a center seat at the back that extends to the end of the product, where it meets the top and bottom seal. The pouch is usually delivered to customers with an opening to allow the filling of their desired contents.
Center Seal Liquid Pouch
Dual pouches contain more than one connected pouch separated with a seal. They package multiple industrial powders and liquids needed for specific applications.
Dual Components Liquid Pouch
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These liquid pouches are manufactured of one side of metal foil and the other clear plastic or two metal foil pieces. They are mostly used for packaging household products like spices, pet food, and other edible and non-edible products.
Three-Sided Seal Pouches
Some most common materials that are used to make liquid pouches include:
A BOPET film is most widely used in liquid packaging for making liquid pouches. It is highly recommended for packaging liquid due to following reasons:
BOPET Liquid Pouches
Liquid pouches are used for the following applications:
Liquid pouches made with BOPET film are used in the automotive sector to package cleansers, polishes, solvents, grease, and oils.
They are used in the health and beauty sector for packaging hair care products, lotions, cosmetics, and many more.
These pouches are used in packaging a wide range of nutritional products such as liquid vitamins and many supplements.
Liquid pouches provide packaging solutions for many industrial applications like cleansers and lubricants.
Liquid pouches are used for packaging a wide range of household solutions, such as cleaning products, laundry solutions, and pet care items.
Other household products packaged by liquid pouches include sauces, syrup, energy drinks, nut butter, honey liquid packaging, and lawn and garden liquid packaging.
Bag-in-box packaging is a modern and highly efficient technology for aseptic filling, transportation, and storage of a wide range of liquid and paste-like food and non-food products. They offer the following benefits:
Bag-in-Box Liquid Packaging
Bag-in-Box is mainly used for packaging of following products:
If you are in the packaging industry, you may already be familiar with Customized BOPP Film. BOPP stands for Biaxially Oriented Polypropylene, which is a type of plastic film that is widely used for packaging products. BOPP film is known for its durability, clarity, and ability to be printed on, making it an ideal choice for a range of applications. However, did you know that you can also customize BOPP film to meet your specific needs?
Customized BOPP film allows you to create packaging that is tailored to your product and brand. You can choose from a range of options, including film thickness, color, print design, and special features such as matte or gloss finishes. This means that you can create unique packaging that stands out on the shelf and helps to build brand recognition.
Customized BOPP film can also offer additional benefits such as improved product protection, tamper-evident seals, and increased shelf life. By working with a manufacturer to create customized BOPP film, you can ensure that your packaging meets your exact specifications and provides the best possible protection for your product.
Biaxially Oriented Polypropylene (BOPP) film is a type of plastic film that is widely used in the packaging industry. BOPP film is known for its high tensile strength, durability, and clarity. It is also resistant to moisture, chemicals, and punctures, making it an ideal choice for packaging applications.
Customized BOPP film is a type of BOPP film that is designed to meet specific requirements of the customer. Customized BOPP film can be tailored to meet the needs of different industries, such as food, pharmaceuticals, and cosmetics.
Customized BOPP film can be produced in different thicknesses, ranging from 12 to 70 microns. The thickness of the film depends on the specific requirements of the customer. Thicker films are more durable and can withstand more wear and tear, while thinner films are more flexible and lightweight.
Customized BOPP film can also be produced in different colors and finishes. The film can be printed with custom designs, logos, and product information. It can also be laminated with other materials to enhance its properties, such as heat resistance, moisture resistance, and UV protection.
Overall, customized BOPP film is a versatile and cost-effective solution for packaging applications. It can be tailored to meet the specific needs of different industries and products, while providing high-quality protection and presentation.
When it comes to customized BOPP film, the manufacturing process involves several steps that ensure the final product meets the specific requirements of the customer. Below are the key stages in the manufacturing process of customized BOPP film.
The first step in the manufacturing process is raw material selection. The polypropylene resin (PP) is selected based on the specific characteristics required for the final product. The resin is melted into a liquid form at high temperatures and then used for the subsequent film production.
The second step is extrusion. The melted polypropylene resin is extruded through a flat die to form a continuous sheet of film. The thickness of the film is controlled by the gap between the die and the chill roll. The chill roll cools the film to ensure it solidifies and maintains its shape.
The third step is orientation. The film is stretched in both the machine and transverse directions to improve its mechanical and optical properties. The stretching process is known as biaxial orientation. This process aligns the molecules in the film, making it stronger and more transparent.
The final step is coating and laminating. The film can be coated with a variety of materials to improve its performance in different applications. For example, the film can be coated with a heat-sealable material to improve its sealability. The film can also be laminated with other films or materials to improve its barrier properties.
Overall, the manufacturing process of customized BOPP film involves several key steps that ensure the final product meets the specific requirements of the customer. By selecting the right raw materials, extruding the film, orienting the film, and coating and laminating the film, manufacturers can produce BOPP film that is strong, transparent, and performs well in a variety of applications.
To make your BOPP film stand out, customization is key. Here are some techniques to consider:
Printing is a popular customization technique for BOPP films. It offers the ability to add branding, logos, and other designs to the film. One of the most common printing techniques is flexography, which uses a flexible plate to transfer ink onto the film. Other printing techniques include gravure and digital printing. When choosing a printing technique, consider factors such as the complexity of the design, the quantity of film needed, and the desired quality of the final product.
Sizing is another customization technique for BOPP films. It involves adjusting the dimensions of the film to meet specific requirements. This can include changing the width, length, or shape of the film. Sizing is commonly used in the food packaging industry to create bags and pouches of various sizes. It can also be used to create custom labels for products.
Thickness control is a crucial aspect of BOPP film customization. It involves adjusting the thickness of the film to meet specific requirements. This can include creating thinner or thicker films depending on the intended use. Thinner films are often used in applications where flexibility is important, such as in packaging for food products. Thicker films are commonly used in applications where durability is important, such as in packaging for industrial products.
By using these customization techniques, you can create BOPP films that meet your specific needs and stand out in the market.
Biaxially Oriented Polypropylene (BOPP) film is a versatile material that can be customized to meet the specific needs of different industries. Customized BOPP film can be used for packaging, labeling, and industrial applications.
Customized BOPP film is widely used in the packaging industry due to its high strength and durability. It can be used for packaging a wide range of products, including food, beverages, and consumer goods. Customized BOPP film can be designed with specific thickness, clarity, and barrier properties to ensure the product stays fresh and protected during transportation and storage.
Customized BOPP film can be used as a labeling material for a wide range of products, including bottles, cans, and boxes. It can be printed with high-quality graphics and text to create eye-catching labels that enhance the brand&#;s image and attract customers. Customized BOPP film labels are resistant to water, oil, and chemicals, making them ideal for products that require durable and long-lasting labels.
Customized BOPP film can also be used in various industrial applications, including insulation, capacitor films, and adhesive tapes. It can be customized to meet specific requirements, such as high tensile strength, low elongation, and excellent electrical properties. Customized BOPP film can also be used as a base material for laminates, coatings, and adhesives, providing additional functionality and performance.
In summary, customized BOPP film is a versatile material that can be customized to meet the specific needs of different industries. It can be used for packaging, labeling, and industrial applications, providing excellent performance and functionality.
Customized BOPP films are becoming increasingly popular due to their versatility and cost-effectiveness. As a result, the market for customized BOPP films is expected to grow significantly in the coming years.
One of the major trends in the BOPP film industry is the increasing demand for eco-friendly packaging options. Consumers are becoming more environmentally conscious and are demanding sustainable packaging solutions. Customized BOPP films are a great option for companies looking to meet this demand as they can be made from biodegradable materials.
Another trend in the BOPP film market is the increasing demand for UV light barrier films. These films are used to protect products from the harmful effects of UV light, which can cause discoloration and degradation. Customized BOPP films can be designed to provide the necessary level of UV protection for a wide range of products, including food, pharmaceuticals, and cosmetics.
In addition, the demand for transparent packaging is also driving the growth of the BOPP film market. Customized BOPP films offer transparency in product packaging, allowing customers to inspect the goods quickly. This is particularly important in the food industry, where customers want to see the quality of the product they are purchasing.
Overall, the market for customized BOPP films is expected to continue to grow as companies look for cost-effective and sustainable packaging solutions. With the ability to customize films to meet specific needs, BOPP films are becoming an increasingly popular choice for companies looking to differentiate their products in a crowded market.
When it comes to packaging materials, environmental sustainability is a growing concern. BOPP film, like many other types of plastic packaging, has a significant environmental impact. However, there are steps you can take to reduce this impact.
One way to reduce the environmental impact of BOPP film is to recycle it. BOPP film bales, which primarily consist of used and discarded BOPP film, can be collected and repurposed. This reduces the amount of waste that ends up in landfills and helps to conserve natural resources.
Another way to reduce the environmental impact of BOPP film is to choose a customized film that is designed with sustainability in mind. There are many options available, including films that are made from recycled materials, films that are biodegradable, and films that are designed to be reused.
When choosing a customized BOPP film, it is important to consider not only the environmental impact of the film itself, but also the impact of the production process. Look for films that are produced using sustainable practices and that are manufactured in facilities that prioritize energy efficiency and waste reduction.
By choosing a customized BOPP film that is designed with sustainability in mind, you can reduce the environmental impact of your packaging materials while still ensuring that your products are protected and presented in the best possible way.
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