Post on 30-Jul-2018
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PE film solutions for modern packaging
Merete SkarApplication Product Developer
Business Unit Film & Fibre
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Market Dynamics
Needs Solutions
Faster Resin processability Film performance: Sealing, stiffness Machine developments
Cheaper Thinner films with better performance New packaging solution Material replacement
Nicer Print quality and optical performance Laminated structures
Environment Material reduction per unit packed Energy consumption per unit packed
Safer Reduced migration and taste/odour Limit package breakage
Technology
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The involved technologies
• Catalysts
• Reactor configuration
• Comonomer
• Additives
PolymerisationGPR
Loop
Slurry
Solution
Autoclave
Butene
Hexene
Vinyl Acetate
Acrylates
LPPE ZN Cat
LPPE SSC
HPPE
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The involved technologies
• Die design
• Co-extrusion
• Thickness control
• Tension control
• Surface treating
• Post orientation
Processing
• Material combinations:
• LDPE
• LLDPE/mLLDPE
• Borstar LLDPE
• HDPE
• PP
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The involved technologies
Converting
• Printing
• Lamination
• Bag making
• VFFS
• HFFS
• Wrapping
• Sealing
• Vacuum- formers
• Palletisers
• Shrink tunnels
Packaging
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FB2230 FB4230 FB4250T FB2310 FB4370 FB1350
MFR2 [g/10 min] 0.2 0.4 0.4 0.2 0.4 -
MFR21 [g/10 min] 22 40 40 20 40 15
Density [kg/m³] 923 923 925 931 937 935
Vicat softening point 104°C 104°C 102°C 108°C 110°C 109°C
DSC melting point 124°C 124°C 124°C 127°C 128°C 128°C
Borstar enhanced LLDPE products
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New Borstar Products
• FB4250T => Transparency as low MFR LDPE => Easy processing and excellent draw down => Applications: monofilms, carrier bags, pouches
• FB4370 => Increased stiffness with good toughness => Easy processing and reduced melt pressure => Applications: coex films, FFS packaging, lamination
• FB1350 => Medium density with semi high Mw => Applications
1) Geomembranes 2) MDPE for high neck extrusion and also blends and coex
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mLLDPE (“Single site LLDPE”) Properties in film applications: typical features
+ High strength
+ High clarity
+ Good organoleptics
+ Low heat seal temperature
– Low output and high process pressures
mLLDPE gives better adhesion to PP than Z-N LLDPE
+ High dart drop
+ Low haze
+ Low extractables
+ Low uniform melt temperature
– High viscosity
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• FM5220 (1.3 / 922)
• FM5270 (1.3 / 927)
• FM5340 (1.3 / 934)
• FM5226 (1.3 / 922), Slip+AB
• FM5276 (1.3 / 927), Slip+AB
Borecene mLLDPE film products
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BoreceneTM mLLDPE and Borstar® LLDPE in coextruded structuresAn excellent combination for flexible packaging!
• High clarity and gloss
• Extrusion of mLLDPE rich films with excellent bubble stability!
• Excellent sealing & high strength
BoreceneTM mLLDPE-rich layer (incl. LDPE)A
Borstar® LLDPE as preferred core layer materialB
BoreceneTM mLLDPE-rich layer (incl. LDPE)A
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Although all Borecene coex. films exhibit excellent properties …
• … Fine-tuning can be achieved by selection of main core layer material
• Main component core layer:
Borstar LLDPE (FB2230)
Unimodal HDPE VL5580
PP: BorclearTM
RB707CF
Dart-drop
Tear resistance
StiffnessHeat resistance
Optical properties
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FB4370
Tailoring the balance of properties impact strength vs. stiffness for 40µm monofilm
Tensile Modulus [MPa]
Dar
t dro
p [g
/50]
C4-LLD
C8-LLD
FB2230 FB2310
150 MPa
100 g
500 g
450 MPa
FB4230
| | | | | | |
LDPE
FM5220
FM5270FM5340
C6LLDPE
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Key properties @ customer How to enhance them?
Processability
Optics
Sealing Toughness
Stiffness
Borstar
Borstar
Borstar
Borecene
Borecene
Borecene
LDPE
LDPE
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Example : Shrink films• Tubular and flat
printed and non- printed
• Hoods and collation
• Transport protection or point of sale
Key advantages with Borstar
• Low hot shrink force
• No hole burning
• High cold shrink force
• Collation and holding forces
• Strength / toughness
• Less puncture with sharp edges
• Stiffness
• Film handling and printing
• Matt surface
• Easy to open and install
Borstar Mono Solutions
• Borstar FB2310/FB4370 in blends with LDPE
• FB4250T with high BUR
Borealis Coex Solutions
• 3 Layer ABA films
• A layer = Borecene + LDPE
• B layer = Borstar + LDPE
• High gloss film with good mechanical and shrink properties
APPLICATIONS
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Packaging technology + PE innovation EBA - Stretch hood film solutions
• Film elasticity !• Tear resistance !• Puncture resistance !• Good optical properties !• Bundling/holding force !
• Solutions• Co-extruded films• EBA copolymers• Borecene / Borstar
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Processing + PE Product innovation MDO Films
Nip rolls
Collapsing frame
Inflated film
bubble
DieExtruder MDO unit Winder
Heating
Annealing
V1 Stretching (V2>V1)
V2
Draw ratio = V2/V1
Granules
Cooling
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High Impact Strength and Stiffness
• Dynatest (DIN 53373)• Energy at break
=> Increase 3-4 times
• E-Modulus (ISO 527)
=> Increase 3 times => Balanced in MD/TD
0
10
20
30
40
50
60
Blown MDO
Ener
gy a
t Bre
ak [J
/mm
]
0
100
200
300
400
500
600
700
800
900
Blow n MDO
Tens
ile M
odul
us [M
Pa]
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Better – Higher – New standards !
• Tensile strength
• Stiffness
• Toughness
• Optical properties
• Co-extruded formulations
• Package performance• Less material consumption • Creep resistance• Packaging line speed• Less package breakages• Less product waste• Product display• Attractiveness• Easy tailoring of properties
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Properties of 80µm Shipping Sack
Meets all specified requirements!
Property 150µm Spec 80µm OPE
Film thickness 100 % 80 µm
2-Sigma < 5 % 3,1 % Stiffness TD > 350 MPa 520 MPa Film Impact > 550 g/50% 590 g/50%
Fold Impact > 450 g/50% 500 Static COF > 0,50 0,51 MD Tear > 7 N 7,8 N
Sealing Range > 10 °C 20 °C Creep 23°C < 10 % 5,0 % Creep 70°C < 15 % 4,2 %
Film Thickness
2-Sigma(<8%)
Stiffness (>250MPa)
Film Impact(>550g)
Delta Impact(<20%)
Fold Impact(>450g)
MD Tear(>10N)
Sealing range(>10°C)
Creep70(<15%)
Outside Friction (>0,45<0,65)
Creep23(<10%)
Film Thickness
2-Sigma(<8%)
Stiffness (>250MPa)
Film Impact(>550g)
Delta Impact(<20%)
Fold Impact(>450g)
MD Tear(>10N)
Sealing range(>10°C)
Creep70(<15%)
Outside Friction (>0,45<0,65)
Creep23(<10%)
Specification
80µm MDO Borstar
Specification
80µm MDO Borstar
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New MDO Application Opportunities
Shipping sacks
Candy Wraps
Compression Packaging
Magazine Wraps
Labels
Stand Up Pouches
Courier/security envelopes
Lamination films
Breathable films
…. And more
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Technology innovations and solutions A key technology driver for success
Unimodal Bimodal BorDry XFL0503
AC, Tub Himod EBA Stretch Hood
Standard Enhanced Differentiated
Borstar
BorPlus
Specialities
HDPE
LDPE
LLDPE
mLLDPE
High Clear XF0601
Borecene
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Thank you for your attention