a ronzani sabic presentation multilayer packaging films 25 november linked
TRANSCRIPT
![Page 1: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/1.jpg)
v
Exploiting multilayer flexibility for high performance Polyethylene films
Cologne, 25-26 November 2008
Alberto Ronzani, SABIC EUROPE
![Page 2: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/2.jpg)
Scope
Flexible packaging: current macro trends
Multilayer applied to non barrier films: technical and economic benefits
Conclusions
![Page 3: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/3.jpg)
Converters are increasingly under pressure
ENERGY SUPPLIERS
CONVERTER FMCG Brand owners
Consumer Polymerssuppliers
Retailer
![Page 4: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/4.jpg)
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
![Page 5: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/5.jpg)
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
![Page 6: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/6.jpg)
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
![Page 7: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/7.jpg)
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
![Page 8: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/8.jpg)
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
![Page 9: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/9.jpg)
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
![Page 10: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/10.jpg)
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)
![Page 11: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/11.jpg)
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
![Page 12: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/12.jpg)
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
![Page 13: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/13.jpg)
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
![Page 14: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/14.jpg)
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
![Page 15: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/15.jpg)
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
![Page 16: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/16.jpg)
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
![Page 17: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/17.jpg)
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
![Page 18: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/18.jpg)
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
![Page 19: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/19.jpg)
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
![Page 20: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/20.jpg)
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:
![Page 21: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/21.jpg)
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.
![Page 22: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/22.jpg)
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:
![Page 23: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/23.jpg)
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
![Page 24: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/24.jpg)
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
![Page 25: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/25.jpg)
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
![Page 26: A Ronzani Sabic Presentation Multilayer Packaging Films 25 November Linked](https://reader035.vdocuments.mx/reader035/viewer/2022081417/55547801b4c90548358b4752/html5/thumbnails/26.jpg)
26
Visit us at our conference table top