a ronzani sabic presentation multilayer packaging films 25 november linked
TRANSCRIPT
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Exploiting multilayer flexibility for high performance Polyethylene films
Cologne, 25-26 November 2008
Alberto Ronzani, SABIC EUROPE
Scope
Flexible packaging: current macro trends
Multilayer applied to non barrier films: technical and economic benefits
Conclusions
Converters are increasingly under pressure
ENERGY SUPPLIERS
CONVERTER FMCG Brand owners
Consumer Polymerssuppliers
Retailer
Economic of film production
Gross Margin 3,4%
Packaging 1,3%
Resin Price 70%
Overheads 9,4%
Utilities 4,3%
R&D 4,3%
Sales 5,1%
Labor 2,2%
Source: Maack Business Services
Blown film producer capacity 2,5kt/y
Converters are increasingly under pressure
International & NationalRegulation
Packaging taxesC02 reductionRecycling
Media interest in the environment & sustainable development
Corporate Social
Responsibility
Carbon & environmental footprints
Packaging scorecardsPackaging reduction
ENERGY SUPPLIERS
CONVERTER FMCG Brand owners
Consumer Polymerssuppliers
Retailer
Co-extrusion enables :
– New formulations concepts with contrasting film properties
– Down gauging & cost reduction with retained or improved film properties
– Reduced # of production steps per packaging structure
Monolayer, 100% LDPE
Blends of LDPE/LLDPE
Multi-layer of LDPE & LLDPE
1980
2010
Multi-layer including m-LLDPE
Multi-layer with diversity of base materials
monolayer
≥ 5 layers
Film Co-extrusion is nowadays a standard tool
Innovation by resins combination and more layers
Innovation will be realized by solutions based on the right combination of base resins rather than new enhanced resins
LDPE
LDPE
C4-LLDPE
C4-LLDPE
LDPE
m-LLDPE
EVA
EVA
C4-LLDPE
LDPE
m-LLDPE
EVAVLDPE PP
Bi-HDPE
HAO-LLDPE
HDPE
HAO-LLDPE
MDPE
Reclaim
Nu
mb
er of b
uild
ing
blo
cks/com
plexity
Inn
ova
tive
po
wer
/do
wn
gau
gin
g
PA
Converters with co-extrusion capability have a higher flexibility in using a wide raw materials variety
Inter material competition and increased flexibility allow to enhance performance at lower cost
Cost & quality improvement with 5 layers approach
Sabic PE based 5 layers vs. state of the art 3 layersfilms with improved:
1) Cost/quality ratio
– Diapers compression packaging
– Beverage collation shrink
2) Properties & functionalities
– Stand up and retortable pouches
Case 1: Diaper compression packaging
Use
Packaging of diaper ,insulation materials, rockwool, foams, textile articles & waste
Reduce transport and storage costs
Key features
Sealing properties
Puncture and tear propagation resistance
Creep and expansion
Case 1: Diaper compression packaging
•What:Replace 3 layers film by 5 layers structure
•Value proposition:Realize 20% downgauging of market reference film, with cost
competitive solution.
•Performance proposition Match market leader specs of 70μ with new developed 55μ film
•ApplicationDiapers compression film (Jumbo pack 72 diapers 7-18 kg baby)
Case 1: Diaper compression packaging
60% C6LL / 40% LD60% HDPE / 40% C6LL
60% C6LL / 40% LDPE
60% HDPE / 40% C6LL
80% LD / 20% C6 LL
Mat.l Grades used
C6LL Sabic 6118NE (0.918 / 1.0 )
LDPE Sabic 2201TH12 (0.922/ 0.85, Slip/AB)
HDPE Sabic F04660 (0.961/ 0.7 (2.16/190°C))
Ref. film 3 layers:thickness 70μ mLL, EVA based
5 layers alternative:thickness 55μC6 LL, HD, LD based
75% mLL/ 25% LD
70% mLL/30%EVA
75% mLL/ 25% LD 18
34
18
155
155
15
Case 1 Diaper compression packaging: SEAL Strength
Sealing strength on 4 bag plies is most critical property
P&G 50μ P&G 70μ
13 N 15,7 N
P&G 50μ P&G 70μ
28 N 34,8 N
Sabic 55μ
38N
Sabic 55μ
69N
Bags sealed, formed and tested by Lemo GmbH
Patent application filed
2.2
2.1
2.2
2.1
Case 1 Diaper compression packaging: results
Critical specifications for package type fulfilled (P&G Seal strength and mechanical properties)
Cost savings 5 vs. 3 Layers film*:
20 % thickness reduction
~ 60€/t raw material~ 6c€/m2 film saving
~ 1,5 M€/y Raw material per m2 film~ 144k €/y Raw material per KG film
*2008 PE delta prices, 300 working days/y, line 400kg/h
Use
Packaging of 6 bottles water packs,
or beer cans
400 kt/y in Europe, growth 2,5% p.a
Key features
Puncture and tear propagation resistance
Optical properties
Shrink force
Average thickness is around 50-55 μ
3 layers films technology enables ~40 μ
Unfulfilled market request down gauge below 40 μ
Case 2: Beverage collation shrink
Case 2: Beverage collation shrink
•What:Replace 3 layers film by 5 layers structure
•Value proposition:Realize 12 to 20% downgauging of market reference film,
with cost competitive solution.
•Perfomance propositionMatch 45μ film properties with newly developed of 35μ
•ApplicationCollation shrink for 6 bottles (1,5L) pack
Case 2: Beverage collation shrink
5 layers alternative:thickness 35μLD, HD , C4 LL based
85% C4 LL / 15% LD
50% HDPE / 50% LD
70% LDPE / 30% HDPE
50% HDPE / 50% LD
85% C4 LL / 15% LD
Reference film 3 layers:thickness 45μ mLL, LD based
5
4
17
4
5
Type Grade used
C4LL Sabic 726N (0.926 / 0.7 )
LDPE Sabic 2600TC00 (0.926 / 0.3)
HDPE Sabic F04660 (0.961/ 0.7 (2.16/190°C) )
9
27
985% mLL/ 15% LD
80% LD/20% HD
85% mLL/ 15% LD
Case 2: Beverage collation shrink, results
Cost savings 5 vs. 3 Layers film:23% thickness reduction
~ 120€/t raw material~ 2,5 c€/m2 film
~1,8 M€/y Raw material per m2 film~345 k€/y Raw material per KG film
Reference film specifications matched (Shrink % & force, tensile & optical properties)
First shrink tunnels trials successful
Case 3: Stand up pouches
Use
Food, Petfood, Beverages, retortable
230 kt/y (180 PE, 50 PP) in Europe, 12% yearly growth.
Key features
Balanced mechanicals (High stiffness and good toughness)
Good sealing and hot tack strength
Easy tear characteristics along the perforation
Good organoleptic properties and FDA/ food contact approval
Special requirements:
Sterilisable at 121°C - 30 min
Increased barrier to Water vapour, easy tear
Case 3: Stand up pouches•What:
Develop new multilayer film structure for SUP
•Value proposition:Add extra film functionalities, without lamination step
•Perfomance propositionIncrease barrier to WVTR, easy tear, heat resistance andtransparency
•ApplicationStand up pouch for food packaging, transparent & retortable
Case 3: Stand up pouches better WVTR barrier
Barrier improvement thanks to thin functional HDPE layer
Alternative film:5 layers, 65μ and 70μ:
80% mLL/ 20% LD
60% LD / 20% mLL20% HD
80% mLL/ 20% LD
80% C6 LL / 20% LD
100% HDPE SABIC F04660
80% LD / 20% C6 LL
100% HDPE SABIC F04660
80% C6 LL / 20% LD
Reference film 3 layers, 70μ:
Case 3: HDPE SUP, WVTR and Tear resistance
Full HDPE layers enable increased WVTR and easy tear opening
20 % HD in 5 layers equals WVTR of 70% HD in 3 layer
8,6
4,44,0
2,83,9
8,0
0
1
2
3
4
5
6
7
8
9
reference 2X 5μ HD 2X 7,5μ HD
WV
TR
(g/m
².d
ay)*
0
9
Tear
MD
g/μ
*38°C, 90% R.H.
Case 3: Stand up pouches, retortable
Retorting thanks to functional layers of PP Raco
5 layers film alternative:
80% mLL/ 20% LD
80% LD / 20% mLL
80% mLL/ 20% LD
PP Raco 680K40% C6LL/ 40% mLL/ 20% LD
70% C6 LL / 30% LD
40% C6LL/ 40% mLL/ 20% LD
PP Raco 680K
Reference film 3 layers:
Case 3 Stand up pouches: seal curve after sterilization
0,0
5,0
10,0
15,0
20,0
25,0
30,0
110 120 130 140 150 160 170
Seal bar temperature [°C]
Se
al
forc
e [
N/2
4m
m]
1h at 121°C Reference
Addition of PP Raco enables seal integrity after sterilization
Brüger seal/Zwick tensile test conditionsSeal bar pressure: 0.3 N/mm², Dwell time: 1.0 secSeal bars width/length (mm): 10 , 150Sample width/length (mm): 24, 50Deformation speed: 200mm/min
Case 3: Stand up pouches, conclusions
Properties profile extension main driver to apply 5 layers to SUP film
Additional layers enable lower WVTR (HDPE) and heat sterilization (PP).
PP/PE lamination step can be avoided in some cases
Conclusions
➨A multilayer approach brings clear advantages to film producers also for non barrier films
➨Cost reduction and properties profile extension can be achieved by a more rational and specific raw materials use
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