Film Quality Control
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Transcript of Film Quality Control
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Polymer Film
QUALITY CONTROL
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UFLEX - FILM TYPES
BOPET : Biaxially Oriented Poly Ethylene
Terephthalate BOPP : Biaxially Oriented Poly Propylene CPP : Cast Poly Propylene METALLISED FILMS (BOPET,BOPP,CPP)
FILM FOR THERMAL LAMINATION (BOPP, BOPET)
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QUALITY CONTROL
An Image of the company Ensure fitness to use. Controls Customer complaints. Provide product as agreed. Provide data for development.
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WHY TESTING REQUIRED
Testing is necessary to ensure:
The product is matching or surpassing the required properties for smooth usage of the product in entire chain from cradle to grave.
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TEST STANDARDS
Test standards are followed to maintain uniformity in testing and understanding among different people, group or companies to ensure a similar platform of product performance
Common standards are: ASTM (American) BS (British) IS (Indian) INTERNAL (Uflex)
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PROPERTIES REQUIRED
The film properties can be broadly classified as: Dimensional Optical Surfacial Mechanical Thermal Functional Barrier
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DIMENSIONAL PROPERTIES
The appropriate dimensions ensures uniformity during process and helps in effective cost calculation of packaging substrate.
Thickness GSM
Yield (α1/GSM) Roll OD Core ID Roll width
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DIMENSIONAL PROPERTIESTHICKNESS
Specification : +/- 3% Instrument Used : Millitron Classification
Spot thickness : Highest accuracy By weight method : Average (100 cm2) By average gauge : Avg. of whole width
Profile analysis : By graph
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DIMENSIONAL PROPERTIESTHICKNESS
Procedure : Demo
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DIMENSIONAL PROPERTIESGSM / YIELD
GSM : The weight in gms of the substrate per unit square meters surface.
Unit : gm/mts2 GSM = Density * Thickness Measurement method : by weighing 100cm2
of sample in gms and multiplying by 100.
Yield : The area of one kg of film Unit : sq.mts./ kg Yield = 1000/GSM
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DIMENSIONAL PROPERTIESROLL DIMENTIONS
Machine Direction (MD) Width of roll
Outer diameter (OD)
Inner Diameter (ID)
MD
TD
TD
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OPTICAL PROPERTIES
The optical properties makes the printed image realistic when printed from opposite side of viewing surface, properties are:
Haze Transmittance Gloss Colour : L , a, b Clarity (free from scratches, lines ,marks,
patches, impurities at surface etc.)
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OPTICAL PROPERTIESHAZE
The percent of transmitted light that is scattered by a specimen responsible for reducing its contrast and producing smoky field.
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OPTICAL PROPERTIESHAZE
Film checked : Clear , Matte Specification
Clear Film : 2.0-4.0 % Matte Film: 40 -70 %
Instrument used : Haze guard plus
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OPTICAL PROPERTIESTransmittance /Gloss
• Transmittance : The percent of incident light which is transmitted through the specimen.
• Gloss : It is the surface smoothness responsible for reflecting the light without scattering and thus forming shiny appearance.
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SURFACIAL PROPERTIES
The surface properties defines the surface characteristics important for runnability, adhesion and surface morphology:
Treatment / Surface wettability Co-efficient of friction ( α1/Slip) Adhesion Surface roughness Gloss (optical also)
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SURFACIAL PROPERTIESTREATMENT
Wetting tension is ability of the surface to wet uniformly with a given liquid.
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SURFACIAL PROPERTIESTREATMENT
Liquids of different wetting level is made by mixing proper ration of water, cellusolve & formamide.
In general higher the wetting tension higher the adhesion power.
Units : dyne/cm Minimum level for surfacial adhesion
with ink/adhesive : 38 dyne/cm
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SURFACIAL PROPERTIESCOF
The resisting force that arises, when a surface of one substance slides over an adjoining surface of itself or another substance.
COF have a major role in determining the slip behavior of the film and is reciprocal in relation.
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MECHANICAL PRPERTIES
Mechanical property is identification of strength, flexibility / rigidity of film to understand its behavior on machine and end application:
Tensile Strength Elongation Modulus of Elasticity
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MECHANICAL PRPERTIESTENSILE STRENGTH / ELONGATION
Tensile : It indicates the load applied per unit cross sectional area of the specimen at the time of rupture during streching.
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MECHANICAL PRPERTIESTENSILE STRENGTH / ELONGATION
Elongation: It indicates the extension visa vis original length in % while stretching at the moment of rupture.
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THERMAL PROPERTIES
The properties ensure the uses without distortion and ensure seal integrity test are;
Shrinkage Machine direction (MD) Transverse Direction (TD)
Heat seal Initiation Temperature Seal strength
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THERMAL PROPERTIES SHRINKAGE
Shrinkage : It indicate how much film got shrink in both machine and transverse direction from its original dimension when kept in hot air oven.
Test Condition : PET - 150 deg / 30 min BOPP – 120 deg / 5 min
Specification : FOR PET MD <3.0 and TD <1.0 BOPP : MD/TD :: <3.0 / <2.0
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FUNCTIONAL PROPERTIES
The properties ensure the product performance in special conditions which are:
Cold Antifog Hot Antifog F-5 Shrinkage at elevated temperature Sealing with PE film
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BARRIER PROPERTIES
The food have a higher shelf life when protected against environmental constrains by not allowing them to pass through the package.
Barrier α 1/ Transmission rate Properties are: O2TR (OTR) : Oxygen Transmission Rate
WVTR(MVTR) : Water (Moisture) Vapour Transmission Rate
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METALLIZED FILM TESTING
Thin layer of Alumunium of Aprox. 200 Angstrom is deposited on film (BOPET, BOPP,CPP) and following is checked for adhesion and uniformity:
Optical Density Tape test Treatment1,2 Metal Bond
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Various defects on Jumbo
Unflush Ripples
Wrinkles
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Various defects on slit rolls
Star marks Ripples
Wrinkles
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THANKYOU