speciality oriented films - new markets - new applications ... · break-down of raw materials used...

© Brückner

Speciality Plastic Films 2004October 18-19, 2004

Dr. Jürgen BreilBrückner Maschinenbau GmbH

Contents

• Market Overview for Oriented Films• Comparison of Stretching Technologies• Specific Film Types & Developments

- BOPP- BOPET- BOPA- Others

• Conclusion

Speciality Oriented Films - New Markets- New Applications- New Developments

SPF2004

© Brückner

Based on Name Plate Capacity (world) incl. 2004 contracts

Break-Down of Raw Materials used for Oriented Films ( 2004 )

66%

24%

6% 1% 1%2%

897261185120556218159121000 tpa

TotalOthersBOPAOPVC(B)OPSBOPETBOPPFilmtype

Others

BOPA(B)OPS

BOPETBOPP

OPVC

World BO - Market

© Brückner

0

1

2

3

4

5

6Million tpa

1990

1992

1994

1996

1998

2000

2002

2004

Average growth worldwide: 11 % p.a.

BOPP

Based on Name Plate Capacity (world) incl. 2004 contracts

Trend of World Capacity BOPP and BOPET NPC ( Name Plate Capacity )

0

1

2

3

4

5

6Million tpa

1990

1992

1994

1996

1998

2000

2002

2004

BOPET


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0

1

2

3

4

5

6Million tpa

1990

1992

1994

1996

1998

2000

2002

2004

WorldChina


BOPP

0

1

2

3

4

5

6Million tpa

1990

1992

1994

1996

1998

2000

2002

2004

WorldChina

BOPET

Average growth worldwide: 5 % p.a. Based on Name Plate Capacity (world) incl. 2004 contracts

Trend of World Capacity BOPP and BOPET NPC ( Name Plate Capacity )

© Brückner

0

50

100

150

200

250

Thousandtpa

2002

2003

2004

2005

BOPA

WorldChina

0

50

100

150

200

250

Thousandtpa

2002

2003

2004

2005

Shrink Sleeve

Trend of World Capacity BOPA and Sleeve FilmsNPC ( Name Plate Capacity )

© Brückner

EUROPEPP + 135.500 tpaPA + 12.000 tpaOthers + 60.000 tpa

USA & CANADAPP + 20.000 tpaPET + 28.000 tpaPA + 5.000 tpaOthers + 24.000 tpa

LATIN AMERICAPP + 108.500 tpaPET + 18.000 tpa

73,7%

19,4%3,8%3,1%

PP PET PA Others

BO Films – Capacity Increase (01- 04)ASIAPP + 1.472.000 tpaPET + 411.000 tpaPA + 55.000 tpaOthers + 5.000 tpa

Comparison Comparison of of

Stretching TechnologiesStretching Technologies

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Sequential Stretching

Double-BubblePentagraph, Spindle, LISIM®

Simultaneous Stretching

MDO / TDO

Biaxial Orienting Technologies

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28 – 3024 – 2620 - 2414 – 18mProduction room width approx.150150130100mProduction room length approx.

12 – 5012 – 6012 – 6012 – 60µmThickness range> 40,00026,000-38,00015,000-22,0007,000-10,000tpaOutput/year (7500 hours)> 5,3003,500-5,0002,000-3,000900-1,300kg/hOutput/hour

108.26.64.2mWorking width

Sequential BOPP Lines

© Brückner

Typical Specifications • Film Width up to 7 m• Speed up to 450 m/min • Output up to 3500 kg/h• Thickness up to 250 µm ( PET )• Stretching Ratio MD and TD 3 – 10

Simultaneous Stretching LinesLISIM® ( Linear Motor Simultaneous Stretching ) - Technology

AdvantagesContact free StretchingBalanced and Tensilized Process Enhanced Mechanical PropertiesTunable Shrink CharacteristicExcellent Optical PropertiesHigh Flexibility ( Stretching Ratios, - Curves )Experience from 6 years in production scale

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AdvantagesLower investment costs ( - 25% )Reduced energy consumption ( - 50% on LISIM )Improved features ( higher speed and thickness )Less requirements for customer supplyLower maintenance costsHigh reliability

New Track SystemLinearmotors with integratedCooling

New Drive Systemwith Energy Control

New Generation of LISIM® - LinesImprovements in Comparison with the first Generation

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Lab-Stretching Unit

Production-Line

Pilot-Line

AdvantagesDemonstration of the potentials of theLISIM® - TechnologyBasic R & D for film stretchingDevelopment of new film typesDevelopment of new componentsProduction of Sample Rolls for Pre-Marketing

MethodEvaluation of Process WindowOptimisation of Film PropertiesMeasurement of Stretching ForcesSimulation with FEM-MethodUpscaling to production scale

Upscaling Process

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Specific Filmtypes&

Developments

BOPPBOPETBOPAOthers

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Commodities

Plain Films3 – Layer Heat Sealable Films

Specialities

Labels: wrap-around, self-adhesive, shrinkable, in-mould5 to 7 Layer coextruded filmsFilms with high strength High Barrier filmsShrinkable filmsLow SIT - Films Synthetic PaperLiddings filmsCoated films

BOPP Applications

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Commodities

Value

added

Film Types

Mechanical Properties

Sequential Simultaneous

Shrink Properties

Surface Properties

Barrier Properties

Opportunities for BOPP – Speciality FilmsImprovement of Film Properties

© Brückner

Low SIT film High Seal Integrity Contact freestretching

Requirement forEquipmentAdvantageFilm Type

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

5,5

6

90 95 100 105 110 115 120 125 130 135 140 145Sealing Jaw Temperature [°C]

Seal

Str

engt

h[N

/15m

m]

5-Layer

3-Layer

Copolymer, 0,7µmPP, 2,0 µm

PPTerpolymer, 1,0 µm

Low SIT Copolymer,

0,75 µm

Speciality BOPP Films

© Brückner

0,7 µm Copolymer2 µm PPPP & Additives1 µm Copolymer0,7 µm Low SIT Copolymer

No Unit Average Method1 Thickness - TD µm 25,36 DIN 53370

2 Tensile Strength - MD N/mm² 251 ASTM D 882

- TD N/mm² 168 ASTM D 882

3 Elongation - MD % 60 ASTM D 882

at Break - TD % 93 ASTM D 882

4 Modulus of - MD N/mm² 3091 ASTM D 882

Elasticity - TD N/mm² 2334 ASTM D 882

5 Haze % 1,1 ASTM 1003

6 Gloss - 93 ASTM 2457

7 Coefficient F/F- T/T µs - 0,32 DIN 53375

of Friction F/F- T/T µk - 0,29 DIN 53375

F/F- O/O µs - 0,51 DIN 53375

F/F- O/O µk - 0,34 DIN 53375

Crimp-Seals 85°C N/15mm 0,8 BMS TT 01


Crimp-Seals 95°C N/15mm 2 BMS TT 01

8 Crimp-Seals 100°C N/15mm 3 BMS TT 01

Sealing Strength Crimp-Seals 105°C N/15mm 4,8 BMS TT 01

1,5bar / 0,5sec Crimp-Seals 110°C N/15mm 5,8 BMS TT 01




Crimp-Seals 140°C N/15mm 4 BMS TT 01




9 Sealing Strength Crimp-Seals 105°C N/15mm 3,3 BMS TT 01

2,2bar / 0,2sec Crimp-Seals 110°C N/15mm 4,7 BMS TT 01





10 Thermal 135/5 - MD % 6,6 BMS TT 02

Shrinkage 135/5 - TD % 5,85 BMS TT 02

12 Wetting Tension (Corona) mN/m 39 ASTM 2578

Description

Low SIT Coextrusion Film

© Brückner


Tensilized film Higher PackagingSpeed

High MDstretching ratios

( from 6 to 9 )


MD Modulus

0

500

1000

1500

2000

2500

3000

3500

4000

4500

MD TD

Mod

ulus

[ N

/mm

² ]

sequ

entia

l

sequ

entia

l

sim

ulta

neou

s

sim

ulta

neou

s

© Brückner

No Unit Average Method1 Thickness - TD µm 24,79 DIN 53370



3 Elongation at Break - MD % 69 ASTM D 882

- TD % 143 ASTM D 882

4 Modulus of Elasticity - MD N/mm² 3995 ASTM D 882

- TD N/mm² 2737 ASTM D 882

5 Haze % 1,4 ASTM 1003

6 Gloss - 91 ASTM 2457

7 Coefficient F/F- A/B µs - 0,27 DIN 53375

of Friction F/F- A/B µk - 0,26 DIN 53375



8 Sealing Strength Crimp-Seals 120°C N/15mm 2,5 BMS TT 01



120/5 - MD % 4,3 BMS TT 02

9 Thermal 120/5 - TD % 2,9 BMS TT 02

Shrinkage 135/7 - MD % 9.0 BMS TT 02

135/7 - TD % 7.3 BMS TT 02

Description

Properties of 3-Layer S-BOPPStretching Ratio MD 9 x TD 7

© Brückner

Transparent multi-layer

barrier filmEnhancedshelf life

One stepstretching process


PP-HOMO 8,5 µm

EVOH 27 % E.G. 1,3 µmTIE-LAYER 0,4 µm

PP- COPO 0,7µm

PP- COPO 0,7 µm

PP-HOMO 8,5 µmTIE-LAYER 0,4 µm

OTR : 2,08 cm³/m² d bar[ 23°C@75%RH ]

Total 20,5 µm


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Sequential 5x5

Simultaneous 5x5

7-Layer Film with EVOH ( Ethylen-Content 27% )Oriented Films Analysed with Polarized Light

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Shrink overwrap Tight packs withhigh packing speed

Flexibility in MDstretching patterns


Shrink: 16,5 % MDPackaging Speed : 800 p / minShrink by Sealing Jaws only

No Shrink Tunnel RequiredFast Sealing PropertiesInside : Low SIT and High COFExcellent OpticsTight Packaging


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No. Description Unit Method1 Thickness - TD µm DIN 53370

2 Tensile Strength - MD N/mm² ASTM 882

- TD N/mm² ASTM 882

3 Elongation - MD % ASTM 882

at Break - TD % ASTM 882

4 Modulus of - MD N/mm² ASTM 882

Elasticity - TD N/mm² ASTM 882

5 Haze % ASTM 1003

6 Gloss ASTM 2457

F/F- T/T- µs - DIN 53375

7 Coefficient F/F- T/T- µk - DIN ISO 8295

of Friction F/F- T/O- µs - DIN ISO 8295

F/F- T/O- µk - DIN ISO 8295

Inside Outside8 Sealing Strength Crimp-Seals 100°C N/15mm 1,7 BMS TT 01

Crimp-Seals 110°C N/15mm 2,2 1,6 BMS TT 01




10 Thermal 120/5 - MD % BMS TT 02

Shrinkage 120/5 - TD % BMS TT 02

125/5 - MD % BMS TT 02

125/5 - TD % BMS TT 02

130/5 - MD % BMS TT 02

130/5 - TD % BMS TT 02

135/5 - MD % BMS TT 02

135/5 - TD % BMS TT 02

1,5

5,515,03,0

13,5

8,6

Average

10,01,2

0,280,210,340,23

20275

23851,2%

93,0%

18067149

3755

Shrink Tobacco Film

© Brückner

MD shrinkable labels

Cost effectiveLabels forcontoured bottles

MD-post stretchingintegrated process

Requirement forEquipment

Film Type

Cost-effective labelling of contoured bottles

Existing Roll-Fed Labeling Machines can be adapted

An alternative to sleeve technology for contourswith low difference in diameter(30% reduction of cost in relation to sleeves )

Advantage


© Brückner

MD / TD Stretching Curve MD / TD Shrink Properties

-10

0

10

20

30

40

50

70 80 90 100 110 120 130 140

Shrinktemperature [°C]

Shrin

kage

[%]

MD

TD

Film Sample: 50µm MD-Shrink-LabelfilmShrinkage Curve

© Brückner

Film Test Results:

A: 2µm PE/ Slip + Antiblock MB

Applications:Reel-fed Labels for Bottles and Boxes

Film Requirements:High MD-ShrinkExcellent Gloss and transparencyCustomised shrink forceGood slip properties Good antistatic properties

B: 46µm PP Blend

A: 2µm PE/ Slip + Antiblock MB

No Unit Average Method1 -TD µm 50 DIN 53370

-MD N/mm² 178 DIN 53455-TD N/mm² 164 DIN 53455 -MD % 118 DIN 53455-TD % 144 DIN 53455-MD N/mm² 1990 DIN 53457-TD N/mm² 1503 DIN 53457

Coefficient of — 0,3 DIN 53375Friction — 0,28 DIN 53375

6 % 2,96 ASTM 1003

7 — 90 ASTM 2457

-MD % 31 BMS TT 02-TD % 1 BMS TT 02

DescriptionThickness

2 Tensile Strength

3 Elongation at Break

4 Modulus ofElasticity

8 Thermal Shrinkage

5 F/F- T/O - µsF/F- T/O - µk

Haze

Gloss

Film Sample: 50µm MD-Shrinkfilm

© Brückner

50µm MD-Shrink LabelfilmLabeling on Rollfed Labeling Machine with UV-Curing

© Brückner

MD shrinkable bundle film

Downgaged BundleShrink Film

MD-post stretchingintegrated process

Requirement forEquipmentAdvantagesFilm Type

Downgaging ( 60 µm 30 µm )

Superior Optics

Superior Shrinkforce

High MD, Low TD Shrink Values

Excellent reproducibility and thickness tolerances


© Brückner

Film Test Results:

A: 2µm PP-Copo/ Slip + Antiblock MB

Applications:Shrink Films for Beveragesand other CollectivePackaging

Film Requirements:High MD-ShrinkforceExcellent Gloss & transparency High MD-ShrinkReasonable slip properties Reasonable antistatic properties

B: 26µm PP Copo

A: 2µm PP-Copo/ Slip + Antiblock MB

No Unit Average Method1 -TD µm 30 DIN 53370



6 % 1,7 ASTM 1003

7 — 91 ASTM 2457

-MD % 41 BMS TT 02-TD % 9 BMS TT 028 Thermal Shrinkage


Haze

Gloss




2 Tensile Strength

30µm Bundle-Shrink Film

© Brückner

020406080

100120140160180200220240

MD-Tensile Strength[N/mm²]

Gloss [-] Haze [%]

Blown Film

Brückner Film

Downgaging from 60 µm to 30 µm

Film Properties of Bundle Shrink FilmBlown Film / Brückner Film

© Brückner

High surface tension film

Better adhesion for● printing● lamination● metallisation

1-Step Stretching with low strain rates

MD and TD

Requirement forEquipmentAdvantagesFilm Type

High Surface Tension MaterialsHigh Surface Tension Materialsfor Vacuum Coating, Printing, Laminationfor Vacuum Coating, Printing, Lamination

High Treatment Level for ink adhesion High Treatment Level for ink adhesion 50 50 dyndyn without treatmentwithout treatment58 58 dyndyn with treatmentwith treatment

Ultra High Barrier of Ultra High Barrier of metallizedmetallized film film OTR, WVTROTR, WVTR


© Brückner

BOPPBOPETBOPAOthers

Specific Filmtypes&

Developments

© Brückner

Commodities

Plain film for packaging applicationsLamination film

Specialities

Ultrathin FilmsThick films for optical applicationsTensilized filmCoextruded filmsWhite films for graphic applicationsSynthetic PaperLiddings films

Photographic9%

Packaging36%

Reprographics7%

Other Industrial27%

Hot Stamping Foils4%

Electrical/Electronic

8%

Magnetic Tapes10%

BOPET Applications

© Brückner

24 – 26221820mProduction room width approx.13010290110mProduction room length approx.

8 – 756 – 1256 – 12525 – 200µmThickness range24,70017,6009,75024,000TpaOutput/year (7500 hours)3,3002,3501,3003,200kg/hOutput/hour

8,2Regular Film

6,7Regular Film

4,6 Regular Film

5,8 Thick Film

mWorking width

Sequential BOPET Lines

© Brückner

40-60 µm sealable PE7 or 9 µm alufoil

PET film 12 µm

Adhesive

Reverse printing

Typical laminate for packaging with standard PET-film

Structure● Triplex-Laminate, i.e. for coffee, tea, peanuts, cosmetics

Coffee● PET12-alufoil- PE60

Coffee bag● OPP30-reverse print-PET12met- PE60

Peanuts● PET12-alufoil- PE60

Cosmetics sachets● PET12-alufoil- PE40

© Brückner

Transparent topcoat

PrintingWhite pre printing (optional)

PrimerSealing lacquer for PS and PP

White polyester film

Substitution of alufoilYoghurt, margarineFast foods (soups, pastas)Drinks (mineral water, fruits)High puncture resistanceUse of metal detectors possibleLid does not tear like the alufoil lid

Polyester film for youghurt lidding

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Special films with CoextrusionCost reduction by using only pigments in the skin layersfor standard films, matt films, hot stamp films, …Better optical properties (high transparent/ low haze films)by the use a low amount of masterbatch (only skin layers pigmented)One side smooth surface (for metallization or ceramic coating)Multi layer configuration for improved barrier propertiesHot sealing films e.g. separation of pigmentation and sealing material possibleMulti layer structure to improve further processing of the filme.g. PE – Lamination

Special Film by Inline CoatingImproved adhesion of metal during metallizationImproved adhesion of ink during printingImproved adhesion for subsequent polyolefin laminationImproved release properties of the filmImproved barrier properties for gases and moisturee.g. as substitution of aluminum layer plastic film (microwave capability, …)

Trends for sequential oriented BOPET Films

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Ultra-thin Films for CapacitorsThickness down to 0,5 µm High StiffnessGood Runnability

Tensilized Films for technical applicationsThickness Range 4 – 12 µmUltra High ModulusGood Runnability

Thick Films for optical applicationsThickness up to 250 µmExcellent optical propertiesVery low shrinkage valuesIsotropic mechanical propertiesLow Bowing

Trends for simultaneous oriented BOPET Films

© Brückner

No. Description Unit Average Method

1 Thickness - TD µm 120 DIN 53370



3 F-5 Value - MD N/mm² 104 ASTM D 882


4 Elongation - MD % 183 ASTM D 882

at Break - TD % 179 ASTM D 882

5 Modulus of - MD N/mm² 4070 ASTM D 882

Elasticity - TD N/mm² 4242 ASTM D 882

6 Coefficient F/F- µs - 0,32 DIN 53375

7 of Friction F/F- µk - 0,28 DIN 53375

8 Haze % 2,8 ASTM 1003

9 Gloss 45° - 128 ASTM 2457

10 Thermal 150°C/30min - MD % 0,3 BMS TT 11

Shrinkage 150°C/30min - TD % 0,4 BMS TT 11

S-BOPET Thick Film

© Brückner

Biaxial Oriented Polyamide FilmPackaging Applications

Frozen foods, cooked foods

Pickled vegetables

Retorted Food Pouches

Medical products, medicine and machine parts etc. packaging

Aquatic products, distilled goods packaging

© Brückner

BOPA Sequential Line

2018mProduction room width approx.10297mProduction room length approx.

8 – 308 – 30µmThickness range6,9005,250tpaOutput/year (7500 hours)920700kg/hOutput/hour

5.04.2mWorking width

© Brückner

High MD-stretching ratioLow bowingLow shrinkageHigh strengthExcellent barrier properties ( PA / EVOH - Type )

Opportunities for simultaneous oriented BOPA Films

© Brückner

Improved MD Stretching Ratio

MD Stretching Ratio 3,0MD Relax 0%

TD Stretching Ratio 3,15TD Relax 5%

MD Stretching Ratio 3,5 - MD Relax 5%

TD Stretching Ratio 3.0 - TD Relax 5%

Advantages:• Higher Production Speed• Higher MD-Modulus• Low Bowing• Low Shrinkage

State of the ArtMechanical Simultaneous LISIM®

© Brückner

Measures:Optimized MD – Stretching ProfileAntibowing – ZoneMD- and TD - Relaxation

Result:Bowing 0,2 %

BOPA Film produced with LISIM®-TechnologyLow Bowing Sample

© Brückner

Balanced Low Bowing Low Shrinkage Film

Film Requirements:• Good Printability• Consistent Properties• Very Low Shrinkage

Applications:

• Food Packaging

• Stand-Up Pouches

No Unit Average Method

1 -TD µm 15,5 DIN 53370 -MD N/mm² 207 DIN 53455-TD N/mm² 240 DIN 53455 -MD % 126 DIN 53455-TD % 86 DIN 53455-MD N/mm² 3587 DIN 53457-TD N/mm² 3417 DIN 53457


6 % 7,4 ASTM 1003

7 — 85 ASTM 2457

-MD % 0,08 BMS TT 02-TD % 0,14 BMS TT 02

8 Thermal Shrinkage

5F/F- T/O - µsF/F- T/O - µk

Haze

Gloss


4Modulus ofElasticity

Description

Thickness

2 Tensile Strength

© Brückner

Barrier Film with EVOH

No Unit Average Method1 -TD µm 15,8 DIN 53370



6 % 0,97 ASTM 1003

7 — 111 ASTM 2457

8 % DIN 53146-MD % 1 BMS TT 02-TD % 2,8 BMS TT 02

10 Oxygen Transmission ( 50% / RH ) cm3/m2/d 0,4 ASTM D 3985

11 Water Vapour Transmission g/m2/d 11,2 ASTM F-1249

Gloss

Opacity

9 Thermal Shrinkage


Haze




2 Tensile Strength

A: PA 6 4,1 µm

Film Requirements:• High Barrier Properties

(Oxygen)

Applications:

• Food Packaging

• High Barrier Packaging

A: PA 6 4,1 µmB: EVOH 7,6 µm

© Brückner

0

10

20

30

40

50

60

70

80

50 55 60 65 70 75 80 85 90 95

Temperatutre (°C)

100

Shr

inka

ge (%

)

OPVCOPS

OPP

OPET

Temperature [°C]

Typical TD Shrink Curves of Sleeve Films

© Brückner

Characteristics OPVCOutput up to 2.700 kg/hThickness range 25 - 100 µm• Good shrink values• Low shrink initial temperatur

Characteristics OPET-GOutput up to 1.000 kg/hThickness range 25 - 100 µm• Environmentally friendly• High shrink value

© Brückner

Characteristics BOPSOutput up to 2.700 kg/hThickness range 100 - 800 µm• Food approval• Good thermoforming abilityCharacteristics MOPSOutput up to 1.000 kg/hThickness range 25 - 100 µm• High shrink value• Good separation to PET

Characteristics MOPET-GOutput up to 1.000 kg/hThickness range 25 - 100 µm• Shrink labels• Sleeves

© Brückner

Film

prod

uctio

n

Vacu

umDep

osit

Coatin

g

Conve

rting

Pack

agin

g

End-

User

Ecol

ogica

lAsp

ects

BrücknerKopafilm

Applied FilmsKopafilm

IVV

WipackHenkel

IVV

BahlsenKraft

Bosch

BahlsenKraft

BoschIVV

MetallisisationSiOx, AlOx

LaminationPrinting

TU DresdenIVV

Data Base Simulation

HFFSVFFS

PackagingProperties

SimultaneousSequential

EcologicBalance

Packaging with minimum amount of raw materialPartner Companies in a Funded Research Project

speciality oriented films - new markets - new applications ... · break-down of raw materials used...

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