a ronzani sabic presentation multilayer packaging films 25 november linked

Download A Ronzani Sabic Presentation Multilayer Packaging Films  25 November Linked

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  • 1.Exploiting multilayer flexibility for high performance Polyethylene films Cologne, 25-26 November 2008 Alberto Ronzani,SABIC EUROPE

2. Scope

  • Flexible packaging: current macro trends
  • Multilayer applied to non barrier films: technical and economic benefits
  • Conclusions

3. Converters are increasingly under pressure ENERGYSUPPLIERS CONVERTER FMCGBrand ownersConsumer Polymers suppliers Retailer 4. Economic of film production Source: Maack Business Services Blown film producer capacity 2,5kt/y 5. Converters are increasingly under pressure Media interest in the environment&sustainable development ENERGYSUPPLIERS International& National Regulation Packaging taxes C02 reduction Recycling CorporateSocialResponsibility Carbon &environmentalfootprints Packaging scorecards Packaging reduction CONVERTER FMCGBrand ownersConsumer Polymers suppliers Retailer 6.

  • 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

Film Co-extrusion is nowadays a standard tool Monolayer, 100% LDPE Blends of LDPE/LLDPE Multi-layer of LDPE & LLDPE 1980 2010 Multi-layer including m-LLDPE Multi-layer with diversity of basematerials monolayer 5 layers 7. Innovation by resins combination and more layers Innovation will be realized by solutions basedon the right combination of base resinsrather thannew enhanced resins

  • 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

LDPE LDPE C4-LLDPE C4-LLDPE LDPE m-LLDPE EVA EVA C4-LLDPE LDPE m-LLDPE EVA VLDPE PP Bi-HDPE HAO-LLDPE HDPE HAO-LLDPE MDPE Reclaim Number of building blocks/complexity Innovative power/downgauging PA 8. Cost & quality improvement with 5 layers approach

  • Sabic PE based 5 layers vs. state of the art 3 layers
  • films with improved:
  • Cost/quality ratio
    • Diapers compression packaging
    • Beverage collation shrink
  • Properties & functionalities
    • Stand up and retortable pouches

9. 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

10. 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 of70 with new developed55film
  • Application
  • Diapers compression film (Jumbo pack 72 diapers 7-18 kg baby)

11. Case 1: Diaper compression packaging 60% C6LL / 40% LD 60% HDPE/ 40% C6LL 60% C6LL / 40% LDPE 60% HDPE/ 40% C6LL 80% LD / 20% C6 LL Ref. film 3 layers: thickness70 mLL, EVA based 5 layers alternative: thickness55 C6 LL, HD, LD based Sabic F04660 (0.961/ 0.7(2.16/190 C ) ) HDPE Sabic 2201TH12 (0.922/ 0.85, Slip/AB)LDPE Sabic 6118NE (0.918 / 1.0 ) C6LL Grades used Mat.l 75% mLL/ 25% LD 70% mLL/30%EVA 75% mLL/ 25% LD 12. Case 1Diaper compression packaging:SEAL Strength

  • Sealing strength on 4 bag plies is most critical property

Sabic 55 38N Sabic 55 69N Patent application filed P&G 50P&G 70 13 N15,7 N P&G 50P&G 70 28 N34,8 N Bags sealed, formed and tested by Lemo GmbH 2.2 2.1 2.2 2.1 13. Case 1Diaper compression packaging:results

  • Critical specifications for package type fulfilled (P&G Seal strength and mechanical properties)

Cost savings 5 vs. 3 Layersfilm*: 20 % thickness reduction ~60/t raw material ~6c/m 2film saving ~1,5 M/yRaw material per m2 film ~144k /yRaw material per KG film *2008 PE delta prices, 300 working days/y, line 400kg/h 14.

  • 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 around50-55
  • 3 layers films technology enables~ 40
  • Unfulfilled market request down gauge below 40

Case 2: Beverage collation shrink 15. 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 proposition
  • Match45 filmpropertieswith newly developed of35
  • Application
  • Collation shrink for 6 bottles (1,5L) pack

16. Case 2: Beverage collation shrink 5 layers alternative: thickness35 LD, HD , C4 LL based 85% C4 LL / 15% LD50% HDPE/ 50% LD 70% LDPE / 30% HDPE 50% HDPE/ 50% LD 85% C4 LL / 15% LD Reference film 3 layers: thickness45mLL, LD based Sabic F04660 (0.961/ 0.7(2.16/190 C)) HDPE Sabic 2600TC00 (0.926 / 0.3)LDPE Sabic 726N (0.926 / 0.7 ) C4LL Grade used Type 85% mLL/ 15% LD 80% LD/20% HD 85% mLL/ 15% LD 17. Case 2:Beverage collation shrink,results Cost savings 5 vs. 3 Layersfilm: 23% thickness reduction ~120/t raw material ~2,5 c/m 2film ~ 1,8 M/yRaw material per m 2film ~ 345 k /yRaw material per KG film

  • Reference film specifications matched (Shrink %
  • & force, tensile & optical properties)
  • First shrink tunnels trials successful

18. 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 121C - 30 min
  • Increased barrier to Water vapour, easy tear

19. Case 3: Stand up pouches

  • What:
  • Develop new multilayer film structure for SUP
  • Value proposition:
  • Add extra film functionalities, without lamination step
  • Perfomance proposition
  • Increase barrier toWVTR ,easy tear, heat resistanceand
  • transparency
  • Application
  • Stand up pouch for food packaging, transparent & retortable

20. Case 3:Stand up pouchesbetter WVTR barrier Barrier improvement thanks to thin functional HDPE layer Alternative film: 5 layers, 65 and 70 : 80% C6 LL / 20% LD 100% HDPE SABIC F04660 80% LD / 20% C6 LL 100% HDPESABIC F04660 80% C6 LL / 20% LD Reference film 3 layers, 70 : WVTR barrier Easy Tear 80% mLL/ 20% LD 60% LD / 20% mLL 20% HD 80% mLL/ 20% LD 21. Case 3:HDPE SUP , WVTRandTear resistance Full HDPE layers enable increased WVTR and easy tear opening 20 % HD in 5 layers equals WVTR of 70% HD in 3 layer*38 C, 90% R.H. 22. Case 3:Stand up pouches,retortable Retorting thanks to functional layers of PP Raco 5 layers film alternative: PP Raco 680K 40% C6LL/ 40% mLL/ 20% LD 70% C6 LL / 30% LD 40% C6LL/ 40% mLL/ 20% LD PP Raco 680K Reference film 3 layers: Heat resistance Transparency 80% mLL/ 20% LD 80% LD / 20% mLL 80% mLL/ 20% LD 23. Case 3 Stand up pouches :seal curve after sterilization Addition of PP Raco enables seal integrity after sterilization Brger seal/Zwick tensile test conditions Seal barpressure: 0.3 N/mm, Dwell time: 1.0 sec Seal bars width/length (mm): 10 , 150 Sample width/length (mm): 24, 50 Deformation speed: 200mm/min 24. 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

25. 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

26. Visit us at our conference table top

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