MULTILAYER PACKAGING FILMS 2007

27-29 March 2007, Cologne, Germany.

Future of

in

Flexible Packaging

Presentation by :

PIYUSH GUPTA, ASST. VICE PRESIDENT

FLEX INDUSTRIES LTD.

METALLIZED FILM

A plastic film that has been coated on one/both sides with a very thin layer of metal incorporating the benefits of both metal and plastic films, offering consumers much more versatility in application.

VACCUM METALLIZATION
Vacuum metallizing involves evaporating a metal, such as aluminum, silver or any other metal in a vacuum chamber, so the metal vapor condenses on the film.

METALLIZED FILMS BUT WHY ?

To form a Barrier for protection against Light, Water, Moisture, Gases etc.

METALLIZED FILMS BUT WHY ?

Its high gloss coupled with the outer Eye-catching packaging enhances the shelf appeal and life of the end product.

METALLIZED FILMS BUT WHY ?

Metallized films provide excellent machinability during Micro Slitting resulting in HIGHER PRODUCTIVITY.

HISTORY OF METALLIZERS

First Metallizer of 650 mm width was put up in Italy in 1959. There are over 1100 metallizers installed worldwide today. An addition of 300-350 units is expected in the next 5 years.

HISTORY OF BARRIER FILMS

High Barrier Packaging had its beginning in Foil Substrates way back in 50s when certain companies started to extrude PE and then laminate to foils.

HISTORY OF BARRIER FILMS

It was the customers demand initially which brought barrier films to the forefront in the packaging market.

MAIN DRIVING FORCES

Getting foods to the consumers in the freshest possible state

MAIN DRIVING FORCES

With Flexible Packaging replacing metal cans, glass or rigid structures, the requirement of barrier materials and coex structures was generated. Low cost of production

HISTORY OF BARRIER FILMS

In the early 90s, primarily 4 basic coating barrier materials were there NYLON PVDC EVOH and Metallized films.

The more flavourful, higher quality foods, generated the demand for more sophisticated packaging solutions

HISTORY OF BARRIER FILMS

Meat packaging was one of the areas where early action in this field took place.

HISTORY OF BARRIER FILMS

Once this technology was developed, other segments like snacks, cheese and confectionery items started being packaged in laminate structures using barrier films.

TODAY.

Polyester and PP are most commonly used for the base substrate in high barrier packaging films.

TODAY.

These are being used to build multilayer structures, depending on the end application.

TODAY ALUMINIUM FOIL IS LAMINATED WITH POLYESTER AND PP FILMS

IN ORDER TO PROVIDE REQUISITE BARRIER

TODAY.

The art is in balancing the overall ratio of cost to performance

AL FOIL
VIS A VIS

METALLIZED FILMS

NOW, AL. FOIL IS BEING REPLACED BY HIGH BARRIER METALLIZED FILMS IN A BIG WAY DUE TO VARIOUS REASONS

AL FOIL

VIS A VIS

METALLIZED FILMS

ALUMINIUM FOIL
DIFFICULT TO PROCESS BECAUSE OF RIGID AND BREAKABLE PROPERTIES DEAD FOLD PROPERTIES CAN ONLY BE USED IN MIDDLE LAYER OR SURFACE PRINTING DIFFICULT TO SLIT IN NARROW WIDTHS

METALLIZED FILM
EASY TO PROCESS BECAUSE OF FLEXIBLE PROPERTIES. GETS BACK TO ORIGINAL SHAPE EVEN AFTER FOLDING CAN BE USED IN OUTER, MIDDLE OR INNER LAYER BECAUSE OF SEALING PROPERTIES EASY TO SLIT IN NARROW WIDTHS

AL FOIL

VIS A VIS

METALLIZED FILMS

COMPARISON OF BARRIER PROPERTIES

PROPERTY

AL FOIL

NORMAL METALLIZED FILM (OD 2.2)

PLASMA
METALLIZED

PLASMA
METALLIZED

FILM (OD 2.2)

FILM (OD 2.7)

OTR cc/sq mday WVTR Gm/sq m-day

<1.0

0.7-0.8

0.4-0.5

<1.0

0.7-0.8

0.4-0.5

AL FOIL

VIS A VIS

METALLIZED FILMS

AL FOIL Available only in MATT FINISH Usage results in Pin-hole defects

METALLIZED FILM Can be available in both MATT and MIRROR FINISH No such problem

AL FOIL

VIS A VIS

METALLIZED FILMS

AL FOIL Very good barrier properties but available in fixed Optical density Low shelf life

METALLIZED FILM Comparable barrier with choice of Optical density available

High shelf life

AL FOIL

VIS A VIS

METALLIZED FILMS

AL FOIL Easy to tear High cost Limited choice of thickness range available (9, 12 mic) Fixed density (2.7)

METALLIZED FILM Difficult to tear Low cost High choice of thickness range available (9-50 mic) Density range between 0.9-1.4 available

PLASMA METALLIZED FILMS a step further

The process of Plasma metallization involves: An inline web treatment prior to metallizing to promote surface cleanliness and chemical modification, encouraging metal adhesion and improvements in barrier functionality.

PLASMA METALLIZED FILMS

Surface of the web is prepared in-line with the Aluminium coating process. The plasma is formed when a gas, or combination of gases are injected into an isolated treatment zone and ionized under vacuum conditions.

PLASMA METALLIZED FILMS

Plasma interacts with the surface of the web in a variety of ways. In addition to removing moisture and other contaminants, it also acts to increase the number of nucleation sites through the introduction of polar groups, resulting in a coating with homogenous surface morphology and less defects.

ADVANTAGES OF PLASMA METALLIZATION

Better Metal Adhesion An increase in the surface energy of the substrate as a result of plasma treatment leads to better bonding of Aluminium to the substrate. The bond strength is increased by 40%.

ADVANTAGES OF PLASMA METALLIZATION

Web Cleaning : The plasma cleaning process removes organic contaminants, dust particles, moisture etc. from the film substrates.

ADVANTAGES OF PLASMA METALLIZATION

Better barrier properties: Barrier properties of the film are enhanced substantially because of improved metal adhesion and web cleaning which leads to removal of unmetallized spots. OTR and WVTR are reduced by almost 30%.

METALLIZED FILMS

A WIN WIN SITUATION

.AND A GREAT FUTURE

METALLIZED FILMS

MAKING HEADWAY IN WORLDWIDE FLEXIBLE PACKAGING MARKET ESTIMATED TO BE US$ 60 BILLION Source : FPA

GLOBAL METALLIZED FILM MARKETS

Metallized Film production worldwide : 450,000 tons/year About 84% of metallized films are being used in FLEXIBLE PACKAGING.

TODAY

GH BARRIER PACKAGING FILMS ARE BEING UTILIZED FOR

MILK POWDER / HEALTH DRINKS PACKAGING

A GOOD EXAMPLE OF AL. FOIL BEING REPLACED BY METALLIZED FILMS

TEA / COFFEE PACKAGING

METALLIZED FILM BEING EXTENSIVELY USED FOR:

JUICE PACKAGING

Rigid containers and Pet bottles being fast eplaced by flexible packaging.

Aluminium foil in flexible aminate being replaced by Metallized films.

SNACK FOODS PACKAGING

tallized films finding their way into snack food packaging oviding increased shelf life.

e to this, snack food industry is growing rapidly because e package can now reach far off places without losing the

LOW FAT SNACK FOODS

With the new health concious generation being on the rise, this is a new market segment that can look forward to a boom in the usage of metallized films.

LOW FAT SNACK FOODS

As the amount of fat in food is reduced, the flavour retention capabilities go down, hence better barrier properties are required to maintain the aroma and shelf life of the product.

ACKAGING OF BISCUITS AND OTHER BAKERY PRODUCTS

Metallized films are being added onto the biscuit and other bakery item packaging laminate to provide a better shelf life to retain the freshness for a longer period.

PACKAGING OF PET FOOD

With more and more varieties of pet food being launched in the market, this is another area which can look forward to a high demand of metallized/high barrier films.

PACKAGING OF LIQUOR BOTTLES

CARTONS BEING REPLACED BY FLEXIBLE LAMINATED PACKAGING WITH METALLIZED FILMS FOR :

BETTER AESTHETICS

SECURITY

BRAND PROMOTION

SHAMPOO PORTION PACKAGING

METALLIZED FILMS BEING USED BY MAJOR MANUFACTURERS LIKE P&G IN SMALL SACHETS.

REASON: MOISTURE LOSS IS REDUCED. THE PRODUCT

TATOOS AND OTHER PROMOTIONAL MATERIAL

METALLIZED FILMS ARE BEING USED IN TATOOS, DECORATIVE STICKERS, GIFT WRAPS AND OTHER PROMOTIONAL MATERIAL FOR:

AESTHETICS

BRAND PROMOTION

CONCLUSION

Success in business usually comes from finding ways to overcome barriers. But, in flexible packaging business, success is all about barriers, and in some cases, the higher the barrier, the better.

Metallized films are going to stay and will find increased usage in Flexible Packaging.

THANK YOU.
Presentation by : Presentation by :

PRADEEP TYLE

- Sr. President - Sr. President