FLEX FILMS
“Manufacturing globally to serve you locally”
Technology Overview
Steven Sargeant, Ph.D.General Manager R&D
Jan 2017
CONFIDENTIAL INFORMATION OF UFLEX & FLEX CORPORATION
Vision, Mission & Values
VISION
“Be a leading company and preferred supplier for
providing flexible packaging solutions to customers
across the world maximizing value for all stakeholders”
MISSION
To meet customers’ dynamic packaging needs by
providing innovative, productive, cost-effective, optimized
and eco-friendly packaging solutions, continually adding
value to their business.
About Uflex
Engaged in providing end-to-end flexible packaging solutions to customers viz. packaging design &
color scheme, packaging structure, packaging products (value added anti-counterfeiting solutions to
prevent look alikes from eroding the brand equity of our clients world over)& filling machines;
Most integrated to have presence in all verticals of flexible packaging value chain
Largest flexible packaging company in India and emerging player in the global market
Promoted and founded in 1985 by Mr. Ashok Chaturvedi, a first generation entrepreneur
A great story of entrepreneurship, perseverance, operational excellence, belief and a proven track record of
success
World class manufacturing facilities of packaging films in India, Dubai, Mexico, Egypt, Poland and USA
(Current Capacity– 337,000 TPA) and of packaging products at multiple locations in India (Current
Capacity- 90,000 TPA) accredited by ISO/BRC/HACCP
Focus on innovation, new product development and faster reach to the customers;
Large array of packaging products in terms of size and types of goods they can pack, touching people’s
lives everyday, everywhere.
Strong Global sales and distribution network with customers in about 140 countries
Strategic Business Units
Flex Films Advantages
Manufacturer NAFTA
Region
Sites
Lead-Time Claims
Resolution
Terms Tech
Service
Lead-time
Product
Portfolio
Field Tech
Service
Lead-time
Local
Technical
Staff
FLEX Films 1-USA
1-MEXICO
Typically 7 -14
Days For
Clear
10 Days For
Metalized
30 Day
Target
Typically
Net 30
Typically 1-
2 Days
Broadest platform
of thin films for
packaging,
printing and
converting
markets
World’s largest
film metalizer
Typically 1-2
Days
Yes
Domestic-
NAFTA
DTF
Toray
Mitsubishi
SKC
Polyplex
Typically 4-12
Weeks for
Clear
Metalized 10-
16 Weeks
Variable Typically
Net 30
Long Focused on IT,
electronics and
related
Typically 2-4
weeks
Yes
Offshore-
BRICs
None 8-12 Weeks ? Prepaid ? Thin Films Not Available No
Offshore-Non
BRICs
None 8 Weeks ? Prepaid ? Thin Films Not Available No
Flex is the most committed supplier to the NAFTA region thin film market
Film Grade Chips : Raw Material for manufacturing Polyester Films
Yarn Grade Chips : Raw Material for manufacturing Polyester Yarn
Bottle Grade Chips : Raw Material for production of PET Bottles
Capacity (TPA) : India – 72,000
Properties : Barrier Properties, High Tensile & Dielectric Strength,Thermal & Chemical Stability & Toughness
Application : Food Packaging, Electric Insulation, Graphic Arts andImaging
Capacity (TPA) : India – 54,000; Dubai – 52,000; Mexico- 60,000;Egypt – 30,000; Poland - 30,000 & USA – 30,000 (2,56,000 TPA)Brand : FLEXPET
BOPET Films
Properties : Strong Moisture Barrier, Highly Cost Effective,Functionally Efficient
Application : Food Products Packaging (confectionery, biscuits,bakery, pasta etc.), Cigarette Cartons Wrapping, Bags forReadymade Garments, Adhesive Tapes & Print Lamination
Capacity (TPA) : India – 30,000; Egypt – 35,000 (65,000 TPA)
Brand : FLEXOPP
BOPP Films
Polyester Chips
Packaging Film Business
CPP Films
Properties : Highly Dynamic & Versatile Films with High Gloss,Greater Transparency, Better Heat Sealability, Good TwistingProperty & Better Tear Strength
Application : Retort Packing, Food Wraps, Anti Wraps, Anti Fog,Garments Bag, Deep Freeze Applications etc.
Capacity (TPA) : India – 4,000; Egypt – 12,000 (16,000 TPA)
Brand : FLEXCPP
Metallization
Properties : Easy to process because of flexible properties, Getsback to original shape even after folding, Can be used in outer,middle or inner layer because of sealing properties, Easy to slitin narrow widths, High shelf life
Application : Snack food packaging, Biscuits & other Bakeryproducts, Packaging of PET food etc.
Capacity (TPA) : India – 33,600; Dubai – 4,800; Mexico- 15,600;Egypt – 18,000; Poland - 10,800 & USA – 10,800 (93,600 TPA)
Brand : FLEXMET
Packaging Film Business
Overseas Manufacturing Facilities, Capacity &
Commissioning
FME’s state-of-art facility has an installed capacity to produce over 51,600 MT of BOPET film per annum
DUBAI
BOPET Film Line I:
• 6.7 meter wide High Performance BOPET Film line of
22,000 MT p.a. capacity commissioned in Mar 2005
under Phase 1.
• The line produces films for various applications in the
thickness range of 9-50 microns
BOPET Film Line II:
• 8.7 meter wide High Performance BOPET Film line of
30,000 MT p.a. capacity commissioned in Sep 2007
under Phase 2.
• The line produces films for various applications in the
thickness range of 9-50 microns
Metalizer:
• 2.5 meter wide state of art metalizer commissioned
under Phase-1
• Produces over 4,800 MT p.a. of high barrier metallized
films
Contd.
FME’s state-of-art facility has an installed capacity to produce over 60,000 MT of BOPET film p.a.
BOPET Film Line I:
• 8.7 meter wide High Performance BOPET Film line of
30,000 MT p.a. capacity commissioned in April 2009
under Phase 1.
• The line produces films for various applications in the
thickness range of 9-50 microns
MEXICO
BOPET Film Line II:
• 8.7 meter wide High Performance BOPET film line of
30,000 MT p.a. capacity commissioned in July 2011
under Phase 2.
• The line produces films for various applications in the
thickness range of 9-50 microns
Metalizer:
• State-of-art metalizers commissioned under Phase 1/2
• Produces over 15,600 MT p.a. of high barrier metallized
films
• AlOx Production
Contd.
BOPP Film Line & CPP Film Line:
• 8.7 meter wide High Performance BOPP Film line of
35,000 MT p.a. capacity commissioned in
September,2010 under Phase 1.
• 3.7 meter wide High Performance CPP Film line of
12,000 MT p.a. capacity commissioned in July ,2011
EGYPT
Flex P Films state-of-art facility has an installed capacity to produce over 77,000 MT of BOPET/ PP films p.a.
BOPET Film Line:
• 8.7 meter wide High Performance BOPET Film line of
30,000 MT p.a. capacity commissioned in December,
2011 under Phase 2. It is the only Polyester film in
Africa.
• The line produces films for various applications in the
thickness range of 9-50 microns
Metalizer:
• 2.85 meter wide state-of-art metalizers commissioned
• Produces over 18,000 MT p.a. of high barrier metallized
films
AlOx Coating:
• Produces 2,400 MT p.a. of high barrier transparent films
Contd.
BOPET Film Line :
• 8.7 meter wide High Performance BOPET Film line of
30,000 MT p.a. capacity commissioned in July 2012.
• The line produces films for various applications in the
thickness range of 9-50 microns
POLAND
Flex Films Europa’s state-of-art facility has an installed capacity to produce over 30,000 MT of BOPET film p.a.
Metalizer:
• State-of-art metalizer commissioned
• Produces over 10,800 MT p.a. of high barrier metallized
films
Contd.
BOPET Film Line:
• 8.7 meter wide High Performance BOPET Film line of
30,000 MT p.a. capacity commissioned in Jan 2013.
• The line produces films for various applications in the
thickness range of 9-50 microns
• One of the world’s largest film line and bigger than any
other film line presently in the USA
USA-KENTUCKY
Flex Films (USA) state-of-art facility has an installed capacity to produce over 30,000 MT of BOPET film p.a.
Metalizer:
• State-of-art metalizer commissioned
• Produces over 10,800 MT p.a. of high barrier metallized
films
Film Making Process Front-End
Film Making Process-Backend
Film Making Process-Slitting and
Packaging
Metalizing and METSLIT
PET Film Process
• PET Chip
• Co-Ex Process
• MDO Process
• Inline Coating
• TDO Process
• Metalizing
Film Design Control Points
• Overall population growth continues
• Need for increased barrier products
• Cost effective options allow new forms of flexible packaging
• Convenience and ease of use are critical
• Environmental consciousness expands
• Recyclable options
• Other “Green” Options
• SolventAqueous, UV/EB or Solventless
• Light-weighting options
• Brand awareness creates differentiation
• Clear Barrier-customer can see product
• Printing quality critical
• Digital for short-run customization
• Packaging design for shelf-appeal
• Package security essential
Global Megatrends & Flexible Films
PCR Film
Technology
Flexible Film Surface
Enhancements
Plain FilmPlain Film
Corona Treated
Plain Film
Corona Treated
Acrylic Coated
Plain Film
Corona Treated
Acrylic Coated
Co-ex
Copolyester Coating
1970s 1980s 1990s 2000s
Plain Film Release Coating
Corona Treated Barrier Coating
Acrylic Coated Co-ex Barrier
Co-ex Heat-seal Co-ex Slip
Copolyester Coating Variable Corona
Hybrid Coatings Custom Materials
Super Matte
TODAY
• Twistable Antistatic
• Low Antimony PET film
• Direct Extrusion Coatable
• Special Effect film
• AlOx Coated PET Film
• Universal PET Film
• Easy Stackable Film
• Heat Sealable Film
• Modified Heat Sealable Film
• White Opaque / White Opaque Metalized Film
• Isotropic PET film
• Down Gauged PET film
• Easy Peel
• High Shrink Film
• Matte Film/Super Matte Film
• 9um micron Balloon Film
• UV Block
• Bio Degradable BOPET Film
• PCR based PET films
• Film for digital printing
• Etc.
Available PET Film Offerings
Many available grades expand potential market uses
Flexible Films & Properties
Polymer PET LDPE HDPE PP PS PVC PETG BON
Density 1.35 0.85 0.93 0.90 1.05 1.35 1.28 1.20
Clarity Clear Sl. Haze Sl. Haze Sl. Haze Clear Hazy Clear Clear
Moisture
Barrier
Fair Good Good Excellent Fair Fair Fair Fair
Oxygen Barrier Good Poor Poor Poor Good Poor Good Good
Grease & Oil
Resistance
Excellent Fair Fair Good Fair Good Good Good
Glass
Transition
75C -125C -80C 0C 100C 81C 78C 53C
Stiffness High Low Moderate High Moderate Low High High
Impact Good Excellent Excellent Fair Fair Fair Good Excellent
Heat
Resistance
Excellent Poor Fair Good Fair Fair Good Good
Low
Temperature
Poor Good Excellent Good Poor Poor Fair Fair
Film
Elongation
100-200% 200-400% 200-300% 100% 20-50% 10-200% 100-
300%
100-
200%
Films are chosen for inherent properties and cost
Plastic material with the following attributes
• Very strong (high tensile properties per
thickness)
• Good barrier to water, oxygen, CO2 etc.
• Great thermal resistance
• Clear or hazy depending on formulation
• Easy to print/cut/process
• Highly water and solvent resistant
• Easy to make very thin and very thick
films
Polyethylene Terephthalate
Copolymers to Modify Properties
Diol Diacid Material Use Goal
EG PTA PET Fibers, Films, Bottle Standard
EG iPET ThermoformingLower
Crystallinity
PTA PBT Fiber, FilmLower
Crystallinity
PTA PETG ThermoformingLower
Crystallinity
EG PEN Fiber, FilmHigher
Crystallinity
BOPET Films-Capabilities
Capability Range
Film Thickness 6um to 75um
(24Gauge to 300 Gauge)
Length >120,000’
Widths Up to 129”
OD-Max 42”
Core 3”, 6” or 10”
Treatments Plain, Corona, Various coatings
Metalizing OD 0.22 to 3.2
General Purpose Packaging & Printing Films
Grade
Code
Type of Film Typical
Haze
Typical
Thickness
Typical
COF
Dyne Value Typical Applications
F-PAP Plain Film 4.0%-7.0% 7-75um 0.50us
0.54ud
42
52-Corona
Reverse Printing
F-AU Acrylic Coated 4.0%-6.0% 8-50um 0.50us
0.45ud
42 Solvent Printing and Laminations
F-CH Copolyester Coated 4.0%-6.0% 8-50um 0.50us
0.45ud
60 Aqueous Printing and Laminations
F-UPF Polyurethane
Coated
4.0%-6.0% 8-50um 0.50us
0.45ud
48 Retort Laminations and High Bonds
F-AT Modified Acrylic 4.0%-6.0% 8-50um 0.50us
0.45ud
52 Higher dyne value than F-AU
F-DSC 2-Side Coated Film 2.0%-3.5% 12-50um 0.35us
0.30ud
42/42 Double Laminations
F-EXC Direct Extrusion
Coatable
4.0%-6.0% 12um 0.45us
0.40ud
48 Direct Extrusion Coatable High PE Bond
F-ESB Very High Slip <1.5% 12um >1.0us 42/52-coated
side
High COF Outer Webs (Multiwall Bags)
F-ESC Medium Slip <1.5% 12um 0.6us-
0.8us
42 dyne-
coated side
Medium Slip Outer Webs (Multiwall Bags)
F-ALP Low COF 4% 12um 0.27us
0.25ud
38 Low COF Outer Webs
F-PDP Digital Print 4% 12-23um 0.40us
0.38ud
42 HP Indigo Certified
Printing Techniques Need Different Substrates
Ink TypesF-PAP
(Untreated)
F-PAP
(Corona)
F-CHE
(Sulphocop)
F-AUU
(Acrylic)
F-ATU
(Mod
Acrylic)
F-UPF
(Polyurethane)
F-CSP
(Co-ex)F-PDP
F-PGX
(AlOx)
Nitrocellulose P P E E E E E - E
Urethane E E E E E E E - E
Vinyl E E E E E E E - E
Alcohol E E E E E E E - E
Water Based P F E F E P P - P
UV Flexo P P F G G E P - E
EB Cure P P P F P E P - E
Acrylic Shrink
InksP P P P P P P - P
Polyamide
BasedE E E E E E E - E
Polyamide-
Toluene FreeE E E E E E E - E
HP Indigo - - - - - - -RIT
Certified
UV Offset P P P G E p P - P
E=Excellent results G=Good results F=Fair results P=Poor results
Film Surface Printability
Enhancements
• Inline coated PET film
• Enhanced bond strength to metal and many inks,
coatings and adhesives
• Good metal bond-adhesion even after boiling
• Suitable for Retort application up to 130°C
• Excellent adhesion to other substrates
• Smooth surface that enables applicators to avoid ink
defects such as orange peel
• Has good resistance to many solvents, plasticizers and
chemicals
• USFDA & EC Regulation compliance (For indirect food
contact)
Adhesion of Different Inks with F-UPF
INK BASE RESULT
NC PASS
PU PASS
VINYL PASS
ALCOHOL PASS
For UV Inks Needs Primer
Electron Beam Base Ink curing
PASS
F-UPF-Universal coated PET film
BOPET
Hybrid surface coating
PET- usual thickness 12 µ- usually reverse printedAdhesiveMet-PET thickness ≈12 µ. For desirable barrier propertiesAdhesive
LDPE- 20-100 µ- Sealant layer
How is PET Film Used in Flexible Packaging?
Recent Innovations in film
Eco grades• Bio PET
Recently produced in our Mexico facility. This PET film will break down morereadily in typical landfill conditions due to natural biological processes.
• PCR r-PETThis is another range of “Green Films” . This class of film may contain up to
90% post consumer reclaimed. The resin is obtained through a partnership
with container recycling firms under strict FDA guidelines.
• Antimony FreeFilm produced with environmentally safe ingredients, heavy metal free filmwith similar heat resistance as compared to conventional PET film.
• PCR based film options available
• 30-90% PCR content
• Exploring higher content
• Coated grades
• High COF Grades
• Custom or exclusive product options
“Green Film Options”-Using PCR
Grade Name PCR Content Purpose Thickness Non-PCR
Offset
F-ESR 30% High COF
outer web
12um F-ESB
F-CHR 50% Print Web 12um F-CHE
F-CHR 50% Bag
Strength
23um F-CHE
C-CHR/M 50% Barrier
Web
12um F-CHE/M
F-SLC 90% Liner 23um, 36um F-SLC
Traditional Film
Oil Feed Monomer/Polymer Film
Process/Collect
Oil Feed Monomer/Polymer Bottles
RepelletizeFilm
PCR Film
BioPET
• New additive chemistry allow BOPET film to degrade through natural process• More cost effective than PLA films• Converts like standard PET film
Material BioPET Oxo Degradable PLA
Breakdown
Process
Biodegradation Fragmentation Industrial
Composting
Landfill
Biodegradable
Yes No Slow
Heat Stability High Moderate Moderate
Moisture
Resistance
High High Moderate
Recyclable Yes No Yes
Remnants Soil and Gases Plastic particle Soil and Gases
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Label and Tape Grade Films
Grade Type of Film Thickness Haze Shrinkage COF Pretreatments Typical Applications
F-SLR* Silicone
Release Liner
12um-
50um
3.0% 3.0%MD
1.0%TD
0.22us
0.19ud
Silicone
Release
· Release liners for PSA
emulsions
F-MAT Matte Film 12um-
50um
45%-
80%
<3.0%MD
<1.0%TD
0.50us
0.45ud
Corona
Optional
· Durable label stock
· Tape base
F-XLR Very Clear
Film
12um-
36um
1.1% <3.0%MD
<1.0%TD
0.50us
0.45ud
Acrylic Coating · Over lamination film
· Durable label stock
F-CLR Clear Film 12um-
50um
1.5% <3.0%MD
<1.0%TD
0.35us
0.30ud
Corona
Treatment
Acrylic Coating
· PSA labels
· Decorative laminations
F-DSC Two Side
Coated
12um-
50um
2.0%-
3.5%
<3.0%MD
<1.0%%TD
0.35us
0.30ud
Acrylic Coating · Label stock
· Tape base
F-ELE Electrical
Grade Film
12um-
50um
4.5% <3.0%MD
<1.0%TD
0.50us
0.45ud
Corona
Optional
· Tape base
F-SLC Film for
Silicone
Coating
19um-
50um
6.0% 3.0%MD
0%TD
0.35us
0.30ud
Corona
Optional
· Base film for off-line silicone
coating
F-EMB Embossable
Film
13um 3.0% <3.0%MD
<1.0%TD
0.70us
0.50ud
Embossable
Surface
· Base film for holographic
embossing
· Film for brushed applications
Specialized PET Films
Grade Type Applications Site Manufactured
F-IST Isotropic Film for lidding etc.MEX, USA, DUBAI, INDIA,
POLAND
F-XLR Very low haze film USA, DUBAI
F-MAT Matte surface finished film MEX, DUBAI
F-CLR/M Ultra glossy metalized USA
F-PAB Thin gauge high barrier films USA
F-TSTEasy twisting film to replace
cellophaneMEX, DUBAI, INDIA
F-WAPWhite film for lidding and
packagingMEX, DUBAI, INDIA
F-PDPDigitally printed labels and
packagingINDIA
F-PCR PCR Based Film USA
Optical Grade Comparisons
Grade 12um F-MAT 12um F-MSH 23um F-MAT 23um F-MSH
Haze (%) 40 70 45 85
Gloss (45) ~45 28 ~40 25
Tensile
Strength at
Break (MD)
24.2 KPSI 21.4 KPSI 22.7 KPSI 19.9 KPSI
Tensile
Strength at
Break (TD)
28.5 KPSI 27.0 KPSI 28.5 KPSI 27.0 KPSI
Grade 12um F-PAP 12um F-XLR 12um F-CLR 12um F-ESB
Haze (%) 3.5% 1.2% 1.6% 0.5%
A/A COF ~0.33uS ~0.50uS ~0.35uS >0.8uS
A/B COF ~0.33uS ~0.50uS ~0.35uS ~0.45uS
Ma
tte
Film
sC
lea
r F
ilms
Metalized Packaging & Printing Films
Opaque(shiny) Metalized Film
Vacuum metalized PET films are
an effective replacement to
aluminum foils
Continuous development of
improvement to adhesion and
barrier extends the fitness for use
applications
Bag in box
Medical products
Extended shelf-life
applications
Decorative or high-gloss
applications
Thickness (um) 6 7 8 9 10 11 12
Al Foil Yield 43,556 37,333 32,667 29,037 26,133 23,758 21,778
Al Foil$/MSI
$1.75/# 0.040 0.047 0.054 0.060 0.067 0.074 0.080
$/MSI $2.00/# 0.046 0.054 0.061 0.069 0.077 0.084 0.092
$/MSI $2.25/# 0.052 0.060 0.069 0.077 0.086 0.095 0.103
$/MSI $2.50/# 0.057 0.067 0.077 0.086 0.096 0.105 0.115
PET Film Yield 84,000 72,000 63,000 56,000 50,400 45,818 42,000
PET Film$/MSI
$1.30/# -- -- -- -- 0.026 0.028 0.031
$/MSI $1.40/# -- -- 0.022 0.025 0.028 0.031 0.033
$/MSI $1.50/# -- -- 0.024 0.027 0.030 0.033 0.036
$/MSI $1.60/# -- -- 0.025 0.029 0.032 0.035 0.038
$/MSI $1.75/# -- -- 0.028 0.031 0.035 0.038 0.042
METPET films are cost effective replacements to Al foil
Special Effect Films-Extending
Applications
Decorative embossing requires• Thermoplastic film with “soft” surface for
texturizing
• Diffraction shim
• Metalization to enhance contrast
Applications
• Lamination with different substrates
• Lamination with polyester to make pouches or boxes to
eliminate piracy or counterfeiting.
• Balloons
• Security Holograms to avoid duplicity
• Labels
• Holograms ( 2D/3D, Available in sheets ) Used for
Brand protection/ document protection/ and aesthetic look.
• General patterns increases the aesthetic value of product
helps in increasing the market value of a brand on shelf.
Film for Lidding Application F-IST
• Especially designed for the Isotropic
properties by working together with the
customer & project team
• Critical properties of Isotropic ratio is
achieved for a wide roll width
Shrinkage, tensile and
elongation taken every 1M & at
4 orientations
Haze, thickness etc taken L/C/R
and at 2 orientations (MD/TD)
Mill Roll Width
Developmental Areas
• Heat-sealable Films• PET films with properties like Nylon
• F-ETF; Easier to tear PET film• F-TFP; Thermoforming and puncture• F-ISB: CFF formable
• Barrier Films
• Clear
• AlOx coated + inline topcoat
• Opaque
• F-LBP/M for Bag-in box
• Super High Barrier Metalized (SHB)
• Shrink films
• Customer specific developments
Heat-sealable PET Films-
Expanding Market Areas
0
5000
10000
15000
20000
25000
2000 2005 2010 2015
NAFTA Market For Heat-seal PET Films
MT
Ye
ar
Year
Large Growth-Why?
• Convenience applications are
growing dramatically
• Safety utility of Heat-seal PET
film growing for tray use
• Overall material costs reduced
• Suitable for mono-web film use
due to OK O2TR
• Dual-ovenable use
• Stand-up pouch use growth is
accelerating
• The functional side Sealable with APET, CPET and other
polar materials to give lock seal over a wide range of sealing
temperature.
• Opposite Side UT/CT or coated
• Development options exist
Heat Sealable Films
0
200
400
600
800
1000
1200
80 100 120 140 160 180 200
F-HSP Typical Seal Curves 30um
23um
12um
Sealant
Corona, Plain or Coating
Core Layers
Product Structures
gf/
inch
Temp (C)
Heat Sealable Films
Grade Code Type of
Film
Type of
Seal
Substrates to Seal With Typical Seal
Strengths
Thickness
Offered
Typical End-uses Can be Back-
side Treated?
F-HSP Co-extruded
PET
WELD -Self Sealing
-Sealable to CPET, PVC,
Glass
450gram/force 12-30um -Laminations
-Dust Covers
-Cap/Liners
-Microwave structures
Yes
F-CSP Co-extruded
PET
WELD -Self Sealing
-Sealable to CPET, PVC,
APET
250-
300gram/force
10-15um -Laminations
-Tack seal for gussets
-Microwave structures
Yes
F-HLS Co-extruded
PET
WELD -Self Sealing
-Sealable to CPET, PVC,
Glass
550gram/force 12um -Laminations
-High seal structures
-Microwave structures
Yes
F-HSP_U1 Co-extruded
PET
Backside
primed
WELD -Self Sealing
-Sealable to CPET, PVC,
Glass
450gram/force 12-30um -Laminations requiring
higher ink or adhesive
bond
-Monoweb structures
No
*F-HSP_U1/M Metalized
Heat Seal
Film
Weld -Self Sealing
-Sealable to CPET, PVC,
Glass
450gram/force 12-30um -Metalized film for
complex structures
-thicker films for
monoweb use
No
*F-HSP/AlOx AlOx & Heat-
seal
WELD -Self seals
-Clear barrier webs
-Unique structures possible
450gram/force 12um -Clear heat-seal barrier
use
NO
*=Developmental item not commercially available yet
Transparent High Barrier Vacuum Coated PET
Transparent PET barrier webs allow
the consumer to see the product. This
increases brand awareness and shelf
appeal. Dry foods, retort, even liquids
are being packaged.
High Barrier Transparent PET Films
• Alternative to PVDC Coated films
• Sterilizable and retortable (121C/30 minutes)
• Microwaveable
• High Barrier PET film through transparent AlOx Coating
• Products Available
AlOx Protect™ F-PLO
AlOx Protect™ F-PLX
AlOx Protect™ F-PGX
• AlOx available only on PET Film and not on BOPP/CPP.
F-PLO F-PLX F-PGX
O2TR
CC/M^2/Day
8.0 2.0 0.5-1.0
MVTR
Gram/M^2/Day
8.0 2.0 0.5
Retortable (No) (No) Yes
Topcoated No Yes Yes
Date :- 12-03-2014
S.NO.Trial
StagesProperties Unit Method F-PLX (R-105)
1 Micron Standard 12.5
coated side 48
Plain side 46
NC Pass
PU Pass
Vinyl Pass
Alcohol Pass
1.54
1.71
Super combi-2000Mitsui retort Adhesive (polyurathane
based)-Takelac-pp-6260 (8 kg)
Hardner-I-3000 (1kg)
Pet film(12mic)/adhesive/BON
(15mic)/ADHESIVE/70 mic CPP(Retort)
70 mtr/min
IST
Pass gm/15mm 280-300 (Tear)
IIND
Pass gm/15mm 800 (Tear)
200 x 150 mm
VINEGAR + SALAD OIL + TOMATO
KETCHUP
1+1+1
150 gm
Pet film(12mic)/adhesive/BON
(15mic)/ADHESIVE/70 mic CPP(Retort)
PASS
IST
Pass gm/15mm 250
IIND
Pass gm/15mm 750 (Tear)
1.53
1.89
7
4
RESULT
LAMINATE SAMPLES HAVE TAKEN OUT FROM HOT ROOM AFTER 15 DAY CURING
LAMINATE STRUCTURE
POUCH SIZE
INGREDIENT FILL IN POUCH
TOTAL QUANTITY FILL IN POUCH
PET/BON/CPP
Machine
(Autoclave/121°C/30min)
Lamination
Run
O.T.R at 230C 0% R.H (cc/m2/day)
Barrier
Results
(After
Retort)
Thermal
Shock Test
Ref: Retort lamination trial on Aloxpet F-PLX..
Barrier
Results
W.V.T.R at 380C & 90% R.H (gm/m
2/day)
O.T.R at 230C 0% R.H (cc/m2/day)
3Ink Adhesion
(coated side ) Use all FCL Inks
2
5
ASTM-D-2578
Thickness (By wt)
Treatment
Laminate Structure
Dyne/cm
M/C speed
Adhesive Type
Q.A Deptt.
LAMINATION PROCESS DETAILS
PET/BON/CPP
INGREDIENT MIXING
W.V.T.R at 380C & 90% R.H
(gm/m2/day)
Laminate bond strength (Before
Retort)6
Laminate bond strength (After
Retort)8
9
0123456789
10 O2TR (CC M^2/Day)
MVTR (G M^2/Day)
AlOx Film Properties
F-PGX Barrier
Stability
Opaque Metalized PET Films-
Extended Applications
Sample Reference Laminate Structure Test
Result(2)
UFLEX
(Developmental
sample F-UPF-M)
PET/Ink/Adh/MPE
T-Coated/Adh/PE
OK
UFLEX F-CHE-M PET/Ink/Adh/MPE
T-Coated/Adh/PE
Delaminate
Temp=74C, Time=4 hrs
Material Metal
Adhesion(1)
Metal
Durability
Comment Recommended for
Bag in Box?
F-LBP/M >600g/inch Excellent Highest
Adhesion
Yes-Aseptic
Applications
Yes-Dry Foods
Yes-Bulk Liquids
F-UPF/M >600g/inch Excellent-
Good
Excellent Wet
Bond
Yes-Dry Foods
Yes-Bulk Liquids
F-MTG_PZ >300g/inch Good Snack Food
Grade Film
No
[1] Measured by AIMCAL method[2] Internal test method
New Coated/Metalized
grades are suitable for;
(1) Hot-Fill
(2) Bag in box
(3) High adhesion and
robust packaging
BOPET
Hybrid surface
coating Al Metal
Super High Barrier Opaque
Seed-coat
Al metal
Topcoat
PET film
Seed-coat
Al metal
PET film
Goals•<0.25 CC Day O2TR•<0.25g Day MVTR•Significantly improved robustness•Ability to supply monoweb materials•Proprietary Technology
Trial MVTR O2TR Abrasion Note
Control 1.2 1.4 Poor
Trail #1 0.08 0.15 Excellent
Trial #2 0.19 0.32 Good Became F-
EBP
Trial #3 0.05 0.06 Excellent On hold
Data is Meter^2/Day
New Opaque Barrier Grade F-EBP
New barrier technology; relies on several
technology stacking concepts
• Base Film design
• Metalizing material and alloy
• Metalizing process control
Potential for Foil Replacement
Structure O2TR
M^2/Day
Target
O2TR M^2/Day
Measured
Lowest
Value
Note
Incumbent <0.2CC ~0.18CC N/A 4-Ply Foil
F-EBP <0.3CC 0.16CC 0.09CC Flat sheet data
F-EBP/Laminate <0.3CC 0.19CC 0.13CC 3-Ply laminate
Real-world Data
0
0.2
0.4
0.6
0.8
1
1.2
-5 0 5 10 15 20 25 30
O2TRdataasafunctionofsmoothness
O2
TRC
C/M
^2/D
ay
MetalizedFilmSurfaceSmoothness(Sra nm)
F-MTG
F-EBP
FlexData
TypicalHigh
BarrierMPET
F-EBPCustomerData
• New process for making biax PET to give nylon like character for;
• Improved puncture & impact
• Improved formability
• Asymmetrical tear properties
• Maintains similar converting properties to PET
• Cost effective to BON
• Patent Pending “Metaphasic PET” Process Technology
“Nylon Like” PET Films F-TFP, F-ETF & F-ISB
Grade Name Purpose Thickness Where
Produced
Drug Master File
F-ETF Create structures with unique tear 12um
19um
KY No
F-TFP Forming web and generic Nylon
replacement
12um
19um
23um
KY
India
Dubai
Egypt
No
F-ISB Cold forming web 23um
36um
India Yes
When compared to Nylon;
F-TFP Test Results
Test Type Material Puncture Dart ImpactBiaxially Oriented
Nylon Film
23um Biaxially Oriented
Nylon Film
9.14 N/mm 710 gf/cm^2
New F-TFP* 23um Metaphasic Biaxially
Oriented PET Film
9.38 N/mm 700 gf/cm^2
Standard PET
Film
23um Biaxially Oriented
PET Film
8.23 N/MM 609 gf/cm^2
*Similar puncture and impact resistance.
When compared to PETG;
Test Type Material Total Film
Elongation
Cavity Well
Volume
FormationPETG Amorphous Copolyester Film 240% >180CC
New F-TFP* 23um Metaphasic Biaxially
Oriented PET Film
260% >170CC
Standard PET
Film
23um Biaxially Oriented PET
Film
115% Film Got Broken In
Test
*Similar elongation and formed volume.
Date :- 20-02-2015
S. No. Unit MethodF-TFP-12 (KY
sample)
F-TFP-19 (KY
sample)
F-TFP-23 (Egypt
sample)
MD 2015-2125 1902-1933 1900-2000
TD 2947-3019 2575-2910 2611-2761
MD 204-214 231-233 232-237
TD 115-124 101-119 120-138
MD 7.2 6.9 5.0
TD 3.0 2.8 1.7
% ASTM-D-1204
Tensile strength Kg/cm² ASTM-D-882
Elongation % ASTM-D-882
UFLEX LIMITED
A-1 SECTOR -60, NOIDA
FILM DIVISION QA
3
Properties
Ref:- F-TFP BOPET film sample test report.
1
2
Shrinkage
(At 150˚c 30 Minutes).
Cold
Fo
rmin
g F
-IS
B
Te
ar
Pro
pert
ies F
-ET
F
Hig
h E
longa
tion
F-T
FP
TEST DATA
• Tear initiation reduces as a function of PET film thickness• These data are un-notched tear (ASTM D1004)
• Examples of customer specific developments
• Low COF film for denesting in stand-up pouch
• High gloss metalized films for decorative laminations
• Cold Forming film for medical packaging
• F-ETF
• Unique shrink/haze combinations
• Triplex laminatable film for bag in box use
• Etc
• >50% of R&D resource globally dedicated to custom
development
Customer Specific Developments
Thank You!