Development of new BOPP Barrier Films by Coextrusion and Simultaneous

Biaxial Orientation
Brueckner Maschinenbau GmbH, Siegsdorf, Germany,
Dr. M. Wolf, Dr. J. Breil, Dipl.-Ing. R. Lund:

Abstract: Semiindustrial production of transparent, biaxial oriented polypropylene

(BOPP) barrier films with very thin EVOH layers and excellent barrier properties was
successful. Also EVOH based display shrink barrier films as well as opaque, density
reduced barrier films were produced. Comparisons with commercial film types will be
presented, PVDC based barrier films could be replaced.
Metalized UHB BOPP films with improved OTR barrier values of about 0.2 cm³/m² d bar
(0,01 cc/ 100in2 d bar) (23°C (73,4°F)/ 75% r.h.) will be discussed. Aluminium and
metalized BOPET-films could be substituted.
First successful application tests of the new EVOH based packaging barrier films have
been performed in the framework of a funded network project, mainly as snack pack-
ages.
Further cost reductions could be achieved by producing a multifunctional, biaxial
oriented EVOH based barrier film in one step, saving converting steps.
1) Introduction:
Biaxial stretching of thermoplastic polymer films improves mechanical, optical as well as
barrier film properties. This refinement by a biaxial stretching process is applied for many
thermoplastics, the worldwide capacity for biaxially oriented films amounts to about 12.5
Million t/ a in 2008. The biggest share with 65% comes from BOPP, followed by BOPET with
26%.
As in recent years the profit margins for standard biaxial oriented films, e.g. BOPP coex or
BOPP tape decreased mainly due to high resin prices and overcapacity, many BOPP
producers are looking for added-value specialty BOPP films. Additionally, as summarized in
figure 1, current market trends are demanding new packaging solutions. Main general trends
in our opinion are cost reduction and convenience.

Figure 1: General market needs/ trends and derived possible film developments.

1
2) Processes for the production of biaxial oriented films:
There are three different techniques to produce biaxial oriented films: The sequential tenter
frame process, the simultaneous tenter frame orientation as well as the double-bubble
process, which is also a simultaneous stretching method. Thereby for different film types
certain processes have prevailed: For example BOPP and BOPET are mainly produced by
the sequential process, whereas for BOPA all three techniques are used at about the same
shares.

Figure 2: Sequential and simultaneous biaxial stretching techniques for film production.

With the sequential stretching process the first step is a stretching of an extruded cast sheet
in machine direction between roll pairs at very high stretching speeds. As a second step in
transverse direction the film is gripped by a transfixed clip system and via a track rail
stretched over the width. Due to reasons of product quality and processing stability the
stretching ratios in MD as well as in TD, MD resp. TD, can be varied only between rather
narrow limits, typical values for e.g. BOPP are MD=5 and TD=9.
By contrast, with the simultaneous tenter frame process the MD- and TD stretching is done
at moderate stretching speeds (max. 300 %/s ) but at the same time. This is possible due to
a continuous extension of the distances between clips in machine direction during the
simultaneous transverse track rail stretching. Due to a low flexibility in stretching ratios as
well as high mechanical efforts and low line speeds the long well known simultaneous
pantograph- or spindel-systems are seldom used.
These disadvantages were overcome by the simultaneous tenter frame LISIM® technology,
an abbreviation for “Linear Motor Simultaneous Stretching Technology” as shown in figure 3.
With this new technology all clips can be separately driven by linear motors, thus, in
comparison to the sequential process, significantly increasing the utilizable range of MD- as
well as TD-stretching ratios, as shown in figure 4. Even MD stretching ratios up to 10 are
possible, resulting in a significant enhancement of mechanical film properties, e.g. E-
modulus, in machine resp. processing direction as shown in table 1: The higher the MD
stretching ratio the higher the mechanical value.

2
Figure 3: Principle - Linearmotor Simultaneous Stretching Technology

Figure 4: Comparison of simultaneous and sequential stretching process regarding utilizable

range of stretching ratios in MD- and TD direction.

Additional selected advantages of the simultaneous linear motor process are a broad
accessible range of shrinkage film properties, processability of high barrier EVOH grades as
well as contact free stretching of very low SIT materials as shown in figure 31-5).

3
Table 1: Comparison of simultaneous and sequential stretching process regarding
mechanical film properties in MD- and TD direction.

The double-bubble-process results in balanced film properties by simultaneous stretching of

a cooled and reheated bubble. Disadvantageous regarding film product quality and repro-
ducibility is – in contrast to tenter frame processes - the difficult control of temperatures and
other process parameters of this open double-bubble process. Additionally film output is
rather low, typically 300 kg/h.

3) Simultaneous biaxial orientation of different EVOH grades

Among the transparent high barrier films the fastest growing barrier film materials are EVOH
and glass coated film structures as shown in table 26). Despite the efforts to make EVOH
more useful in oriented films to our knowledge only about 5% of the total EVOH film con-
sumption are used in oriented film applications, including also monoaxially oriented films.

Table 2 : Amount of high-barrier materials worldwide.

4
For our experiments we used EVOH grades with varying ethylene contents of the company
Kuraray, the chemical formula is given in figure 5. The ethylene contents have significant
influences on several processing parameters as well as endfilm properties. For example a
higher ethylene content gives better orientability and a better moisture barrier, but on the
other hand results in lower barrier properties. Orientation of EVOH should result in higher
barrier and mechanical properties.
At the starting point of our investigations we found, that the crystallisation of EVOH types
with a certain ethylene content causes a deterioration of the stretchability, resulting in “net
structures” and therefore bad optical film properties, as shown in figure 6 on the left side.
This means, that obviously the crystallisation temperature of a certain EVOH type, especially
with lower ethylene contents, e.g. 24%, overlaps the optimum orientation temperature range
of polypropylene, the base material of our barrier films. Especially the sequential orientation
process of EVOH is difficult due to MD orientation crystallisation and formation of microfibril
structures, which result upon transverse stretching in voids and other optical defects.

Figure 5: Influence of the ethylene content of different EVOH grades on their processability
and film properties

Figure 6: Comparison of optical film properties under polarized light for sequential (left) and
simultaneous (right) tenter film samples.

By using the simultaneous tenter frame stretching technology we found a way to overcome
this problem: A simultaneous orientation at low stretching temperatures and high stretching

5
speeds subdues crystallization and enables the defect free stretching of EVOH coex layers,
resulting in films as shown in figure 6 on the right side.
Starting point of the high barrier evaluations were laboratory scale experiments on a
discontinuous laboratory stretching frame, developing the principles for the production of
optical defect free 7-layer barrier films with thin EVOH layers.
The upscaling experiments on a continuous simultaneous linear motor pilot line could be
performed successfully. It was first time possible to produce biaxially oriented barrier film
rolls with thin EVOH layers (1,3 - 1,8 µm) and total thicknesses between 20 and 30 µm and
EVOH grades containing 24% and 27% of ethylene without optical defects. A typical layer
distribution is shown in figure 7. OTR values of about 1 cm³/m² d bar (23°C (73,4°F)/ 75%
r.h.) could challenge PVDC coated BOPP films as summarized in table 3.

Figure 7: Structure of a 7-layer transparent BOPP/ EVOH barrier film and key characteristics
Table 3: Comparison between novel biaxial oriented 7-layer barrier films and commercial
products

6
By using suitable polypropylene based copolymers in the thick intermediate layers it was also
possible to produce display shrink barrier films with shrinkage values – depending on applied
temperature – up to 50% in MD- and TD-direction, as shown in figure 8.

Figure 8: Shrinkage data of a 7-layer transparent display BOPP/ EVOH barrier film .
Besides transparent and shrink barrier films also density reduced white opaque films could
be produced successfully. By adding inorganic fillers into the intermediate PP-layer the
formation of vacuoles occurred upon biaxial stretching. The resulting white opaque barrier
films with an total density of 0,78 g/ cm3 (Solid PP: 0.91 g/ cm3  yield increase for 30µm:
16%) display excellent UV protection of the filling goods. OTR- and WVTR-values are only
slightly higher than for transparent barrier films, typical values are OTR=3,5 cm³/m² d bar
(0,23 cc/ 100in2 d bar) (23°C (73,4°F)/ 75% r.h.) and WVTR=1.4 g/ m2 d (0,09 g/ 100in2 d)
(23°C (73,4°F), 85% r.h.).
It is known, that barrier properties of EVOH containing barrier films deteriorate with
increasing humidity7). Figure 9 summarizes for different EVOH types at an EVOH layer
thickness of about 1,5 µm the dependence of the OTR values from the applied relative
humidity.

Figure 9: Influence of relative humidity on OTR values of BOPP based EVOH barrier films at
EVOH thickness of 1,5 µm

7
Figure 9 also clearly shows, that - compared to PVDV coated films and even SiOx coated
BOPP films - the biaxial stretched EVOH barrier films show improved OTR values over a
very broad range of relative humidity, at least up to 85%-90% r.h.. In our opinion even for wet
packaging goods, due to the layer of PP between good and EVOH, relative humidities
between 80 and 85% are realistic conditions and in this range the biaxial oriented barrier
films show only minor barrier deviations.
The EVOH stretching trials can be summarized as follows:
 Sequential stretching is possible for EVOH grades with ethylene content of 44%
and higher, but
 simultaneous stretching by contrast is possible with all available types, even down
to a content of 24% ethylene
 high stretching speeds and/ or low stretching temperatures suppress
crystallization and thus „net structures, enabeling the production of films without
optical defects and good OTR values.
 Due to the choice of base material and machine settings there´s a high flexibility
in end film properties, examples are shrink barrier and density reduced opaque
white films.
 Barrier measurements have shown, that chain orientation effects due to the
biaxial stretching process improve the barrier properties of EVOH by an factor of
about 2.38)

4) Ultra-High Barrier Metalized and SiOx coated BOPP UHB Film

Besides EVOH based, predominantly transparent barrier films also metalized, simultaneously
biaxial oriented „ultra-high-barrier“-films, abbreviated as UHB-films, with exceptional OTR
values have been developed. Also transparent UHB films with SiOx coating could be
produced. Their OTR values of 0.2 cm³/ m² d bar (0,013 cc/ 100in2 d bar (23°C (73,4°F)/ 75%
r.h.) approach those of aluminium foil and are about 250 times lower than that of standard
BOPP metalized films, which are in the range of 40-70 cm³/ m² d bar.
Aluminium foil is essentially impenetrable by moisture and oxygen. However, when packages
made with foil are subjected to the repeated manipulation and handling that are common with
manufacturing, cartoning, shelf stocking and consumer handling in the retail environment,
they can develop pinholes and become permeable10). But an even more important reason to
replace thin aluminium foil with metalized BOPP ultra high barrier films are permanently
increasing aluminium prices and the fact, that thin foils have a thickness of 7 µm, whereas
the aluminium coatings on BOPP films are in a thickness range of 40-60 nm.

Figure 10: Structure of a metalized 5-layer UHB-barrier film and main characteristics

8
Figure 10 summarizes the detailed structure and main characteristics of the UHB-film: A very
thin 0.5-0.8 µm surface layer of a so called “high surface energy polymer“ results in a very
strong bonding of the evaporated aluminium to this film surface, among others due to a very
high surface energy in the range 52-56 dyn. No surface treatment by e.g. corona or flame is
necessary to reach these surface energy values. By using standard optical densities of about
2.3 exceptional OTR values down to 0,15 cm3/ m2 d bar (0,01 cc/ 100in2 d bar) have been
obtained, a typical WVTR value is 0.3 g/ m2 d (0,02 g/ 100in2 d). As the high surface energy
polymer layer can be applied in thicknesses clearly below 1 µm a cost-efficient production is
possible. Alternatively a transparent SiOx coated UHB film with similar barrier values has
been manufactured. At the moment a UHB film with the given polymer layer composition can
be obtained without optical defects only by the simultaneous biaxial tenter frame process.

5) Joint Project along the Added Value Chain: “Thin Films”

In the framework of a funded network project called “Thin Films”8,9,11-13) the above discussed
EVOH based biaxial stretched barrier films as well as the UHB film have been included into
thin packaging film laminates for commercial nut snack filling goods to possibly substitute
current snack packagings.
In the course of this project different packaging film systems have been analyzed along the
entire value-added chain, starting from products of film producer´s like Kopafilm or in this
case Brueckner, followed by metalization and lamination steps, e.g. on Applied Films and
Wipak equipment, up to food packaging trials with Bosch VFFS-machines at food companies
like Kraft and Lorenz. Main packaging goods were nut and chips snacks. The project
partners are summarized in figure 11. The overall project coordination was with the
Fraunhofer IVV (Institute for Process Engineering and Packaging) in Freising, Germany.
Financial fundings were granted by the German BMBF (German Federal Ministry for
Education and Research).

Figure 11: Joint Project Along the Added Value Chain: “Thin Films”
The target of this project was to demonstrate with selected film systems along the entire
added value chain up to the final application, that a 50% reduction in material is possible
without significant limitations of the technical functionality. Interesting questions among

9
others were the minimum thickness values to obtain the required film properties, e.g.
sufficient dimension stability to prevent damaging of coating layers by elongation of the base
film or sufficient E-modulus to produce packages without wrinkles.
Main motivations for material reductions are of course cost savings, but also the European
packaging law, which makes avoidance and material reduction a priority. The demonstration
of conformity with the European packaging directive is possible according to DIN EN 13 427
ff, reduction of material input at retained functionality is in this norm an explicitly termed
criteria 8,9,10-12).
One reference packaging system we investigated is a three layer packaging for peanut
snacks, meaning it is a triplex compound with two required laminating steps. One of the
layers, the middle one is metalized, either 15µm BOPP or 12 µm BOPET, inner layer is a
50µm PE blown film, outer layer usually is a reverse printed BOPET film. The detailed struc-
ture is given In figure 12 on the left side.
During first trials we successfully reduced the thickness values of single layers and switched
from triplex to duplex laminates, using e.g. 7µm strong BOPET films against 30-40µm strong
BOPE/ PP sealing layers, the latter biaxial oriented to compensate for losses in mechanical
stability.
Additionally for the example of peanut snacks we substituted the commercial film laminate for
a duplex laminate of a transparent EVOH based barrier film and a 30 µm biaxial oriented
sealing layer. For UV protection also the white opaque EVOH based barrier film has been
tested. This approach also resulted in an overall thinner laminate structure as well as
possible cost savings – regarding material and production costs – up to 25%, as illustrated in
figure 12.
In the following selected results from the network project „thin films“ will be presented and
discussed. Figure 13 gives an overview of OTR and WVTR values for commercial and
experimental high barrier laminates. For PET based film systems the thinner 7 µm films show
after metalization and lamination comparable, partly even slightly improved barrier values in
comparison to thicker film systems.
Also the investigated EVOH based barrier film laminates with biaxial oriented sealing film
layer for peanut snack packaging display OTR values of about 0,3 m3/ m2 day bar (0,02cc/
100in2 d bar) and WVTR values below 0.8 g/ m2 d (0,051 g/ 100in2 d), thus challenging
metalized systems BOPETmet/ PE. The same is true for the barrier values of the UHB film
based barrier laminate.

Figure 12: Cost comparison between commercial triplex packagings for peanut snacks
against experimental novel biaxial oriented EVOH based duplex laminates

10
Figure 13: Comparison of OTR and WVTR values for commercial and experimental
packaging film laminates

As summarized in figure 14 for BOPP/ BOPP-systems the thin films are comparable to the
thicker reference films also regarding aroma permeation. The required breakthrough time for
excellent aroma barrier is t  30 days (720 h)11). In the case of BOPET- and EVOH-based
barrier film laminates no breakthrough times could be determined as the measuring values
were clearly below the detection limit.

Figure 14: Aroma breakthrough data for selected packaging barrier film laminates.
Additionally we investigated, how possible elongation processes during the further pro-
cessing chain, e.g. during lamination, influence the barrier values of different film laminates,

11
especially coated ones8,9). The most delicate laminates were those based on very thin
BOPET/ PE films. In contrast for EVOH based systems a slight elongation initially resulted in
a reproducible barrier value improvement.
Assuming that a 2% film elongation has no negative impact on barrier values, figure 15
shows, that the arising forces during the lamination step are clearly smaller than those
necessary for a 2% elongation of the film systems, therefore no deteriorated barrier values
have to be expected.

Figure 15: Overview of forces for a 2% elongation of different film systems in comparison to
arising forces during a lamination step.
Comparable results have been obtained during the packaging process for VFFS packaging
machines at the film form shoulder and at the film propulsion unit, but only when continuous
working VFFS machines are used.
Packaging trials with selected barrier laminates and different snack filling goods with fol-
lowing sensory tests have been successfully performed. For the system biaxial oriented
BOPP EVOH// BOPP7 BOPE a shelf life of 6 month has been granted. Several trials with
“thin films” with 100% tight packages have been performed11).

The findings of the funded network project „thin films“ can be summarized as follows:
 With biaxial orientation the thickness of film laminates based on vacuum coated
film structures can be reduced down to 50% compared to standard film laminates.
 Resulting barrier properties are comparable or even better than for standard film
laminates.
 Barrier properties of thin film laminates are not impaired by following converting
processes, as the resulting elongations are clearly below critical values, when
using an continuous working, vertical packaging machine.
 Intact sealed seams down to
o 27µm for BOPP/ BOPP and
o 37µm for BOPET/ BOPP-PE
 Handling and acceptance by end users has to be evaluated.
For more information please visit www.duenne-folien.de 8,9,11-13)

12
6) Path forward (“Integrated Production Process”) and Conclusion
A next possible future step for further cost reductions could be the total elimination of
lamination steps. Nowadays the production of a barrier film laminate based on vacuum
coating technology (e.g. aluminium, SiOx, AlOx) usually takes four processing steps:
 Extrusion of the carrier film, e.g. BOPP, BOPET, BOPA
 Extrusion of the sealing film, e.g. c-PP, c-PE
 Barrier coating of the carrier film
 Lamination of sealing layer to carrier layer
As the main driving factor in the film supply chain are costs, it would be advantageous not
only to save material by reduced thicknesses, but to produce a barrier film with all required
functionalities, including barrier as well as e.g. sealing properties by a one-step extrusion
process and a following biaxial orientation with the simultaneous tenter frame process. In
terms of an “integrated production process” all necessary functionalities – depending on the
requirements of the packaged good – should be implemented in one processing step.
By developing, testing – also in long-term storage trials with packaged goods - and producing
one-step high barrier films with barrier values challenging laminated structures based on e.g.
PET-Al or PET-SiOx, the replacement of these now existing, clearly more expensive barrier
laminates is our long-term target. Figure 16 proposes cost savings of up to 45% for replacing
a triple laminate BOPET/ BOPETmet/ PE for peanut snack packagings by a biaxially oriented
7-layer EVOH containing one-step BOPP barrier film structure with reduced sealing layer
thickness (estimated costs). The technical feasibility regarding required barrier and sealing
properties has been proven in the funded project “Thin Films”.

Figure 16: Assumed cost savings of about 45% for replacing a triple laminate for peanut
snack packs by a biaxially oriented 7-layer EVOH-containing one-step BOPP
barrier film (estimated costs).

Besides the narrow application range of the funded network project there are much more
applications for the discussed barrier/ high barrier films like lidding films in MAP-, CAP- and
vacuum packages as well as inner bag applications with barrier protection, in the last case
partly substituting paper laminates. A typical film laminate for lidding film applications as
shown in figure 17 consists of a 45 µm blown film sealing layer with barrier function and a
biaxial oriented film for mechanical strength, e.g. a 20 µm BOPP film14).

13
Figure 17: Typical film laminate for barrier lidding film applications.
For inner bag applications also PVDC coated systems are in use as shown in figure 19 on
the left side.
Regarding barrier and mechanical properties these laminated barrier film structures could be
replaced with a 50 µm simultaneous biaxial oriented, frontal printed one-step film, the
mechanical properties in machine and therefore processing direction of the latter due to the
linearmotor stretching process even being higher, compensating for a loss in bending
stiffness. Figures 18 and 19 propose cost savings of up to 40 % resp. 32%.

Figure 18: Proposed cost reduction range by one-step 7-layer barrier films for lidding film
applications.

14
Figure 19: Proposed cost reduction range by one-step 7-layer barrier films for inner bag film
applications.
Next steps for us should be sample production for converting and packaging trials as well as
discussions with film converters and end users. Additionally we will try to further optimize the
properties of our films, e.g. sealing properties, hot-tack, shrink, UV protection of transparent
film systems, mechanical properties and test alternative raw materials e. g. UV-Stabilizer,
humidity absorbers or O2-scavengers.
We think that in the future it could be possible in selected cases to substitute PVDV coated
films, shrink barrier films or certain film laminates with our barrier films, additionally we hope,
at least in some cases, also to penetrate into the domain of metalized films!

15
Literature:

[1] J. Breil - Added value speciality films produced with sequential and simultaneous
stretching lines, Speciality Plastic Films 2002, 18th Annual Maack World Congress,
Oct. 29-30, 2002, Swissotel Zürich, Switzerland.

[2] Breil J.: S-BOPP – Film enhancement by LISIM-Technology. SP 1998 Annual world
Congress, Düsseldorf, Oktober 1998.
[3] Breil J., Oedl G., Sieber B.: Synchronous Linear Drives for many Secondaries with
Open Loop, 2nd International Symposium LDIA 1998, Tokyo, Japan, 6th-8th of April,
1998.

[4] Breil J.: LISIM - Linear Motor Simultaneous Stretching Technology, CMM Intern.
Conference, Chicago, USA, 16th April 1997.

[5] M.A. Scarati, Polyolefin films benefit from simultaneous orientation, Modern Plastics
Intern. July 1999, Vol. 29, No. 7, p. 103.
[6] Allied Development Corporation, Lakeville, MN 55044: Brueckner PVDC and EVOH
Market Study”, Oct., 2005.
[7] Gas barrier properties of resins, Technical Bulletin No.110, EVAL Americas,
www.evalca.com.
[8] H.-C. Langowski, C. Schönweitz – Dichtereduzierte Folienmaterialien – Einspar-
potentiale und Verarbeitungseigenschaften, Tagung Verarbeitungsmaschinen und
Verpackungstechnik VVD 2006 am 23.& 24.03.2006, Dresden, Germany.
[9] H.-C. Langowski: Barrier mechanisms of vacuum coated polymers: Where are the
limits for downgauging of substrates and for barrier properties of coated films?
Technical Conference at the International Converting Exhibition ICE 2005, November
22nd, 2005, Munich.
[10] S. Sargeant, K. Chang – Product Protection, Paper, Film & Foil Converter,
March 2007, S.61-65.
[11] Fraunhofer Institute for engineering technology and packaging IVV - Final Report:
Funded Research Project (BMBF): Environmental benefits in production and use of
laminated packaging materials by 50% reduction in material input, March 2003 – May
2006, public version, Freising, 2006.
[12] J. Breil, R. Lund, M. Wolf - Biaxially oriented BOPP barrier films with thin EVOH
layers, European Metallizers Association, Spring Meeting, March 09-10, 2006,
London.
[13] M. Wolf, J. Breil, R. Lund – Neuartige Materialkombinationen in Barrierefolien durch
Coextrusion und simultane biaxiale Orientierung, VDI-Fachtagung Extrusion 2007,
13. & 14.Juni 2007, Neu-Ulm, Germany.
[14] M. Wolf, J. Breil, R. Lund – Neuartige Barrierefolien durch Coextrusion und biaxiale
Orientierung, Innoform Coaching - PE und PP-Folien für flexible Verpackungen
27.+28. November 2007, Germany.

16
 2008 PLACE Conference
September 14-17, 2008
Portsmouth, VA

Development of New BOPP Barrier Films by

Coextrusion and Simultaneous Biaxial Orientation
Dr. M. Wolf, Dr. J. Breil, R. Lund

Presented by:
Dr. Martin Wolf
Brückner Maschinenbau GmbH & Co. KG
Siegsdorf, Germany
Overview

 Introduction
 Processes for Producing Biaxial Oriented Films
● Comparison Sequential and Simultaneous Stretching
● BMS Laboratory Line: High flexibility in Choice of
Base Materials and Machine Settings
 Transparent Barrier Films: Simultaneous Biaxial Orientation of
Different EVOH Grades
● Raw Materials and Processing Issues
● Results and Summary
 Ultra-High-Barrier Metalized Films/ SiOx Coated Films
 Possible Applications: Research Project „Thin Films“, Cost
Comparisons
 Path forward (“Integrated Production Process”) and Conclusion
Introduction: Profile

 Family-owned enterprise

 Headquarters : Siegsdorf

 Headcount: appr. 1,400

 Sales:
● 2007: Euro 388 million

● 2008: Euro 450 million

(Forecast)
Introduction: Why stretching?
Comparison CPP–OPP sequential

Mechanical properties Optical Permeability properties*

(40 µm Thickness)
(25 µm Thickness) properties
(25 µm Thickness)

1,3
90
CPP OPP
CPP OPP

6000
500

500
CPP OPP

70

0,6

3000
250

2000
160

160

900
60
50

400
30

1,5

180
4

MD TD MD TD
[N/mm²] [%] [%] [-] [g/m²d] [cm³/m²dbar]
Tensile Strength Elongation Haze Gloss H2O CO2 O2 N2
at Break
*Source: Nentwig – Kunststofffolien - Hanser Verlag
Introduction: Why stretching?
Comparison CPP–OPP sequential

Mechanical properties Optical Permeability properties*

(40 µm Thickness)
(25 µm Thickness) properties
(25 µm Thickness)

0,08
90
CPP OPP
CPP OPP CPP OPP
500

500

387
70

0,04
250

194

129
160

160

58
60
50

26
30

1,5
4

12
MD TD MD TD
[N/mm²] [%] [%] [-] [g/100in²d] [cc³/100in²dbar]
Tensile Strength Elongation Haze Gloss H2O CO2 O2 N2
at Break
*Source: Nentwig – Kunststofffolien - Hanser Verlag
Introduction: BO Market: Market Analysis

Break-down of raw materials used for oriented films (02/2008)

5% 1% 2% 1%

26%

65%

PP PET PS PVC PA Others

Rawmaterial PP PET PS PVC PA Others Total

1000 tpa 7960 3218 634 140 241 170 12513
* Source: Reference lists of sold equipment (02/2008)
 BOPP Market: Price development (02/2008)

2,5
2,25
2
1,75
1,5
€/kg 1,25
1
0,75
0,5
0,25
0

9 86 98 7 98 8 9 89 9 90 9 91 99 2 99 3 99 4 9 9 5 9 96 9 97 9 98 99 9 0 0 0 0 0 1 0 02 0 03 0 04 00 5 0 0 6 0 07 0 08
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2

Resin Film (20micron, Transparent)

High-Barrier-Materials Worldwide (in 1.000 mt/ a)

Material 2000 2004 AGR 2008 AGR

PVDC Film & Coated Film 151 160 1,5% 164 0,6%
Metalized Film 115 152 7,2% 205 7,8%
EVOH Film 26 37 9,2% 55 10,4%
SiOx, AlOx Coated Film 10 16 12,5% 34 20,7%
PVOH 1 1 0,0% 2 10,7%
PAA coated Film <1 1 NA 13 89,9%
Aluminium Foil 436 485 2,7% 535 2,5%

Only ~5.0% of the total EVOH film consumption is oriented films

Source: Allied Development Corporation

Transparent Barrier: Growth Rate by Regions

Region CAGR 2006 - 2011

Western Europe 4,5 %
Eastern Europe 11,5 %
North America 3,3 %
South America 8,6 %
Asia Pacific 6,5 %
Rest of the World 9,7 %
Total 5,2 %

Source: Pira International – Transparent Barrier Films 2006

Transparent Barrier: Growth Rate by Applications

Section CAGR 2006 - 2011

Fresh Meat and Poultry 2,8 %
Processed Meat 4,7 %
Cheese 4,5 %
Fish 3,6 %
Fruits and Vegetables 10,9 %
Baked Products 6,8 %
Convenience Food 4,5 %
Snack Food 8,1 %
Other Foods 13,3 %
Medical 5,6 %
Other non Foods 9,4 %
Total 5,2 %
Source: Pira International – Transparent Barrier Films 2006
Introduction: Market Needs = Our Challenges
Market Needs/ Trends
 Replacement of aluminum foil
 Down gauging
 Reduction of converting steps
 Transparent barrier
 Smaller packages
 Faster packaging
 Robust sealing
 Replacement of PVC sleeves
Our Challenges
 Ultra-high barrier film BOPP met
 Thin films with high mech.
properties
 Multifunctional co-extruded films
 Co-extruded EVOH based barrier
film
 Improved barrier properties
 Low SIT, opt. sealing materials
 High sealing strength BOPP films
 MD shrinkable labels
Introduction: Packaging Requirements for Barrier Films

Packaging Good OTR OTR WVTR WVTR

[cm3/m2dbar] [cc/ 100in²dbar] [g/ m2 d] [g/ 100in² d]

Peanuts, snacks 0,7-10 0,045-0,65 2-8 0,13-0,52

Baby food 0,1-0,8 0,006-0,05 0,7-3 0,045-0,19
Instant coffee 0,2-2 0,013-0,13 0,7-3 0,045-0,19
Vacuum coffee 0,2-3 0,013-0,19 0,8-5 0,052-0,32
Fresh Meat a 4.500-10.000 290-645 10-100 0,65-6,45
Fruits, vegetables, salad 10.000- 645-12903 10-3.000 0,65-194
200.000
Fresh Meat b (Vacuum) 20-40 1,3-2,6 2-4 0,13-0,26
Fresh Meat c (MAP) 1-3 0,065-0,19 2-4 0,13-0,26
Fresh cheese 7-11 0,45-0,71 300-700 19-45
Fresh Bakery Products 30-4.000 1,9-258 600-3.000 39-194
Processes for the production of biaxial oriented films
Sequential Stretching Simultaneous Stretching
MDO - TDO Pentagr., Spindle, Lin.Motor Double-Bubble
LISIM® - Added Value
Linear motor Simultaneous Stretching Technology

 Enhanced mechanical properties

 Customized shrink properties

 Superior barrier properties

 Low SIT sealing properties

 Comparison Sequential / Simultaneous

Sequential Stretching Simultaneous Stretching

TD
10 10
9 9
8 8 MD
7 MD 7
TD
6 6
5 5 Useful area
4 4
3 3
Useful area
2 2
1 1

MDO TDO Linear Motor Simultaneous Stretch. Technology

Comparison of Mechanical Film Properties:
Sequential / Simultaneous

Sequential Linear Motor Simultaneous

Stretching ratio
5x9 8x8 10 x 5
(MD x TD)

Tensile- MD 140 258 310

strength
[N/mm²] TD 290 252 208

MD 200 78 52
Elongation at
break [%]
TD 55 82 110

MD 2000 3060 4070

E-modulus
[N/mm²]
TD 3500 3130 2685
Technology Centre since 1998

Labstretcher Pilot Line

Film Laboratory Life Time Tests

Pilot line

Polymers

Stretching Modes
Upscaling Process
Lab-Stretching Unit
Method
 Evaluation of Process Window
 Optimization of Film Properties
 Measurement of Stretching
Forces
 Simulation with FEM-Method
 Upscaling to Production Scale
Pilot Line Production Line
Advantages
 Demonstration of the Simultaneous
Linear Motor - Technology Potential
 Basic R & D for Film Stretching
 Development of New Film Types
 Development of New Components
 Production of Sample Rolls for Pre-
Marketing
Simultaneous Biaxial Orientation of Different
EVOH grades

Fundamental Issues:
 Crystallization behavior of EVOH
 Property overlap
● Crystallization temperature overlaps the optimum orientation temperature
range of other polymers
 Sequential orientation
● Sequential orientation of EVOH
● is difficult due to the orientation crystallization and formation of micro fibril
structure
 Simultaneous orientation
● Simultaneous orientation at low
stretching temperatures and/ or
high stretching speeds subdues
crystallization

Source:
7-Layer Film with EVOH ( Ethylen-Content 27% )
Comparison Simultaneous/Sequential

sequential 5x5 simultaneous 5x5

A: Skin 1 µm
B: PP Blend 8 µm
C: Tie Layer 0,5 µm
D: Barrier Layer 1,5 µm
E: Tie Layer 0,5 µm
F: PP Blend 8 µm
G: Skin 1µm
20 µm
7-Layer Barrier Film
Influence of EVOH ethylene-content on OTR-Values

4,5

4
OTR 23°C (73,4°F)@75%RH

3,5
[cm³x20µm/m²xdxbar]

Stretching Ratio MDXTD=7x7

Stretching Temperature=160°C
3 Stretching Speed= 400%/s

2,5

1,5

0,5

0
20 25 30 35 40 45 50
Ethylene content [%]
Sequ.

Simultaneous
7-Layer Barrier Film
Influence of EVOH ethylene-content on OTR-Values

0,3
OTR 23°C (73,4°F)@75%RH

0,25
[ccx20µm/ 100in²xdxbar]

Stretching Ratio MDXTD=7x7

Stretching Temperature=160°C
0,2 Stretching Speed= 400%/s

0,15

0,1

0,05

0
20 25 30 35 40 45 50
Ethylene content [%]
Sequ.
Simultaneous
Influence of relative humidity on OTR values of BOPP
based barrier films, EVOH-thickness 1,5 µm

30
EVOH 27% ethylene cont., 1,5µm
25 SiOx, ~50 nm
OTR [cm³/m²xdxbar]

PVDC, ~ 2µm
20

15

10

0
50 55 60 65 70 75 80 85 90 95 100
Relative Humidity [%]
Influence of relative humidity on OTR values of BOPP
based barrier films, EVOH-thickness 1,5 µm

1,8 EVOH 27% ethylene cont., 1,5µm

1,6 SiOx, ~50 nm
OTR [cc/100in²xdxbar]

1,4 PVDC, ~ 2µm

1,2
1
0,8
0,6
0,4
0,2
0
50 55 60 65 70 75 80 85 90 95 100
Relative Humidity [%]
s-BOPP 7-Layer 20 µm Transparent Barrier Film

Structure Application
A: Skin
B: PP Blend
C: Tie Layer
D: Barrier Layer
E: Tie Layer
F: PP Blend
G: Skin

Advantages OTR Transparent

cm³ new development
 7-layer structure m²bar
commercial films
3-layer coex
1000
 Superior oxygen barrier
0,5 (24% Eth.) – 1,2 (27% Eth.) cm3/ m2dbar
100 7-layer with PA Simult.
(0,032 - 0,077 cc/ 100in²dbar) PVDC coated 7-layer EVOH Sequent.
(23°C (73,4°F)/ 50% r.h.) 10 SiOx coated

 Excellent optics PVOH coated

7-layer EVOH Simult.
 Low temperature sealing 1

properties
Comparison with Customary Barrier Films

Commercial 1 Commercial 2 7-Layer BOPP

PVDC coated PVOH coated (EVOH 27 % Eth.)
Thickness [µm] 26 25 29
Gloss [] 98 90 91
Haze [%] 1,6 1,1 1,6
Shrink MD (120 °C, 5 min) [%] 3 3 4
Shrink TD (120 °C, 5 min) [%] 2,5 2,5 2
Young‘s Modulus MD [N/mm²] 2200 2200 2526
Young‘s Modulus TD [N/mm²] 3500 3500 1807
Tensile Strength MD [N/mm²] 135 135 211
Tensile Strength TD [N/mm²] 275 275 160
Coefficient of Friction [µs] 0,25 0,25 0,15
OTR [cm³/m²dbar] 20 3 1,4
(23°C (73,4°F) / 75% RH) (1,3cc/ 100in²dbar) (0,2cc/ 100in²dbar) (0,1cc/ 100in²dbar)
WVTR [g/m²d] 4,2 5 4,5
(38°C (100,4°F) / 90% RH) (0,27 g/ 100in²d) (0,32 g/ 100in²d) (0,29 g/ 100in²d)
 s-BOPP 7-Layer 20µm Barrier Shrink Film

Structure Application
A: Skin
B: PP Blend
C: Tie Layer
D: Barrier Layer
E: Tie Layer
F: PP Blend
G: Skin

Advantages
60
 Good Mechanical Properties BMS-Barriershrink MD
 High Flexibility of Raw Materials for 50 BMS-Barriershrink TD

Layer B/F 40

Shrink [%]
 High Shrinkage 30

 Barrier properties: 20

● (before shrinkage) OTR: 3.5 cm³/m² d bar 10

(23°C (73,4°F)/ 75% r.h.) (0,23 cc/100 in² d bar)
0
● (before shrinkage) WVTR: 11 g/m²d 80 90 100 110 120 130 140
Shrink temperature [°C]
(38°C (100,4°F)/ 90% r.h.) (0,71 g/100 in² d)
Comparison with Customary Barrier Shrink Films

Commercial Shrink Film 7-Layer

(PVDC ) (EVOH 27 % Eth.)
Thickness [µm] 25 19
Density [ g/cm³] 0,945 0,915
Haze [%] 7,0 1,6
Shrink MD (110 °C, 5 min) [%] 40 28
Shrink TD (110 °C, 5 min) [%] 40 28
Young‘s Modulus MD [N/mm²] 450 1471
Young‘s Modulus TD [N/mm²] 400 1426
Tensile Strength MD [N/mm²] 75 166
Tensile Strength TD [N/mm²] 65 136
Coefficient of Friction [µs] 0,2 0,15
OTR [cm³/ m²dbar] 15 3,5
(23°C(73,4°F)/ 75% r.h.) (0,97 cc/ 100in²dbar) (0,23 cc/ 100in²dbar)

WVTR [g/ m²d] 12 11

(38°C(100,4°F)/ 90% r.h.)
(0,77 g/ 100in²d) (0,71 g/ 100in²d)
 s-BOPP 7-Layer 29µm Opaque Density Reduced Barrier Film

Structure
A: PE or Terpolymer
Application
B: PP-Blend
C: Tie-Layer
D: Barrier Layer
E: Tie-Layer
F: PP-Blend
G: Terpolymer
(Corona)

Advantages Transparent
OTR
cm³
 Low Oxygen Transmission m²dbar
commercial films
3-layer coex
new development

● ~ 3,5 cm3/ m2 d bar

1000

(0,23 cc/100in2/dbar) (23°C(73,4°F),50% r.h.)

100
 Low Water Vapor Transmission 7-layer with PA Simult.

● ~ 1,4 g/ m2 d PVDC coated

SiOx coated
7-layer EVOH Sequent.
10
(0,09 g/ 100in2d) (23°C(73,4°F), 85% r. h.)
PVOH coated
 UV Protection 7-layer EVOH Simult.
1
 Decreased Density: 0,78 g/ cm3
 High MD Strength
Summary of the EVOH biaxial orienting tests:

 Sequential stretching is possible at ethylene contents of 44% and

higher
 Simultaneous stretching possible with all types, even with only 24%
ethylene content
 High stretching speeds and/ or low stretching temperatures suppress
crystallization and thus „net structure“, good optics
 Low OTR values
 High flexibility due to choice of base material and machine
adjustments:
● Shrink barrier films

● Density reduced films

Ultra-High-Barrier Metalized Films/ SiOx Coated Films
20µm High Surface Tension ( HST ) 5-Layer s-BOPP
Structure Application

A: High Surf.
Energy Polymer
B: Adhesive Layer
C: PP Core Layer
D: PP
E: Co-Polymer

Advantages
 High Surface Tension

Treatment level (dyn)

● 50 dyn without treatment 58 dyn with treatment
● 58 dyn with treatment
 Good Printability 50 dyn without treatment

 Excellent Optics 42 dyn with treatment – degrading over

 High MD Strength time
 Excellent Metal Adhesion
 High Barrier after Metallization or
SiOx Coating
Time
 Ultra-High Barrier Metalized s-BOPP UHB Film

Structure Application
Metalized Surface

A: High Surf.
Energy Polymer
B: Adhesive Layer
C: PP Core Layer
D: PP
E: Co-Polymer

Metalized
Advantages OTR
cm³ commercial films new development
m²dbar
 Exceptional Gas and Aroma Barrier 1000
● OTR: 0,2 cm3/ m2 d bar (23°C(73,4°F)/ 75%r.h.)
0,013 cc/ 100 in²dbar 100 standard metalized
● WVTR: 0,3 g/ m2 d (38°C(100,4°F)/ 90%r.h.)
high barrier met.
0,02 g/ 100 in²d 10 SiOx coated film
 High MD-strength, low MD-elongation
 Excellent metal adhesion without surface 1
treatment, up to 4.5 N/ 15 mm
 Very thin layer A, typical value: 0,6µm 0,1
ultra high barrier met. 5-layer UHB met.
20µm Ceramic Coated 5-Layer s-BOPP (UHB transparent)

Structure Application
Ceramic Coated Surface

A: High Surf.
Energy Polymer
B: Adhesive Layer
C: PP Core Layer
D: PP
E: Co-Polymer

Advantages OTR
cm³
Metalized or Coated
commercial films new development
 High Surface Tension m²dbar
1000
 Very Low Oxygen Transmission
 Low Water Vapor Transmission standard metalized
100
 Good Crack Resistance
 Excellent Optics / Transparency high barrier met.
10 SiOx Coated Film
 High MD Strength
 Low MD Elongation
1
 Excellent Coating Adhesion
UHB Film met. 5-layer SiOx Coated
0,1
Transparent High Barrier Film HST SiOx- Coated

Unit Value Condition Method

Thickness TD µm 19,6 ASTM D 882

Tensile Strength MD N/mm2 267 ASTM D 882

TD N/mm2 203 ASTM D 882

Elongation at Break MD % 74 ASTM D 882

TD % 134 ASTM D 882

Modulus of Elasticity MD N/mm2 3475 ASTM D 882

TD N/mm2 2485 ASTM D 882

Haze % 1 ASTM 1003

Gloss 45° - 95 ASTM 2457

Thermal Shrinkage MD % 3,2 120 °C/5min BMS TT 02

TD % 1,8 120 °C/5min BMS TT 02

Sealing Strength crimp seal N/15mm 2,5 120 °C/1,5bar/0,5sec. BMS TT 01

Min. Sealing Temperature °C 110 BMS TT 03

Oxygen Transmission cm3/(m2dbar) 0,2 23 °C (73,4°F)/ 75% r.H. ASTM 3985

cc/(100in2dbar) 0,01 23 °C (73,4°F/ 75% r.H. ASTM 3985

Water Vapor Transmission g/(m2d) 0,3 38 °C (100,4°F)/ 90% r.H. ASTM E 96

g/(100in2d) 0,02 38 °C (100,4°F)/ 90% r.H. ASTM E 96

Possible Applications:
Joint Project Along the Added Value Chain: “Thin Films”

Target: Demonstrate with selected film systems along entire added value chain,
that a 50% reduction in material is possible without significant limitations of the
technical functionality

Project coordination

Database Simulation

Film- Metalization Lamination Packaging End user

Production SiOx Print Packaging
Simultaneous, Adhesive properties
sequential e.g. haptics
Selected Applications: Peanuts

Today

BOPET 12µm
Reversed Print

Lamination
BOPET 12µm, metal. (BOPP
15µm, metal.)

Lamination

PE-LD 50µm
Comparison of film properties for peanut snacks:

Unit Actual Actual Future

Standard Standard Potential
(12µm BOPET (15µm BOPP (7µm BOPET
met.) met.) met./ BOPE)

Thickness [m] 79 82 51
Tensile strength MD [ N/ mm2 ] 82 63 114
TD [ N/ mm2 ] 83 90 82

E-Modulus MD [ N/ mm2 ] 1763 1327 2198

TD [ N/ mm2 ] 1819 1857 1470
Elongation at break MD [%] 126 119 54
TD [%] 108 44 128
Bending Stiffness MD [N/ m] - 12,52 4,20
TD [N/ m] - 18,99 3,64
Example for substituted film laminates, cost comparison:
Possible application: Peanuts
BOPET,12µm,
Reversed Print Transparent
barrier, 27% E
Lamination
Lamination
BOPET, 12µm, metal.
Lamination Thin sealing
film, 30 µm
PE-LD, 50µm

Actual Standard Future Potentials

Material BOPET 12µm //BOPETmet 7-Layer BOPP EVOH 20µm //
12µm // PE-LD 50µm BOPP/ BOPE 30µm
Process Sequential Linear Motor Simultaneous
Gauge 76 µm 51 µm
Remark  Triplex Compound  Duplex Compound
 2 Lamination steps (0,065 €/m2 )  1 Lamination Steps (0,045 €/m2 )
Packaging costs  ~198 €/ 1000 m2  ~147 €/ 1000 m2

Estimated Packaging cost reduction of ~ 20-25 % possible !

Barrier values after metalizing/ laminating steps

BOPET (7µm)
BOPET (12µm)

BOPETmet/LDPE (12/75µm)
Reference
BOPETmet (12µm)

BOPETmet /PEPP (7/30µm)

BOPETmet (7µm)
„Thin films“

UHB: BOPP15H-AI-PEPP30

BOEVOHPP20-PEPP30 H2O in g/(m2 d)

O2 in cm3(STP)/(m2 d bar)
BOEVOHPP30-PEPP30

0,0001 0,001 0,01 0,1 1 10 100 1000

Source:
Barrier values after metalizing/ laminating steps

BOPET (7µm)
BOPET (12µm)

BOPETmet/LDPE (12/75µm)
Reference
BOPETmet (12µm)

BOPETmet /PEPP (7/30µm)

„Thin films“
BOPETmet (7µm)

UHB: BOPP15H-AI-PEPP30

BOEVOHPP20-PEPP30 H2O in g/(100in2 d)

O2 in cc/(100in2 d bar)
BOEVOHPP30-PEPP30

0,00 0,00 0,01 0,10 1,00 10,00 100,00

Source:
Aroma Barrier of selected film laminates
Required breakthrough time for excellent aroma barrier: t  30 days (720 h)

All
target
values
reached
 met. BOPP-film 28 µm: comparable to 45-µm standard film
 met. BOPET-film and BOPP-laminate with EVOH barrier: Values  detection
limit (0,3-0,5 µg)

Source:
Lamination: Influence elongation on barrier?

1,40

1,20
Force for 2 % Elongation
F/N/mm

1,00 measured web tension

0,80

0,60

0,40

0,20

0,00
PET, BOPP, BOPP, Compound: Compound:
7 µm 12 µm 15 µm PET, 7 µm // BOPP 12 µm //
sealing films BOPP 15 µm

Source:
Summary „Thin Films“ (1)

 With biaxial orientation the thickness of film laminates based

on vacuum coated film structures can be reduced down to 50%
compared to standard film laminates.

 Resulting barrier properties are comparable or even better than

for standard film laminates.

 Barrier properties of thin film laminates are not impaired by

following converting processes, as the resulting elongations
are clearly below critical values, when using an continuous
working, vertical packaging machine.

Source:
Summary „Thin Films“ (2)

 Intact sealed seams down to

● 27µm for BOPP/ BOPP and
● 37µm for BOPET/ BOPP-PE
 Handling and acceptance by end users
has to be evaluated.

www.duenne-folien.de
Path forward: Barrier values for different film systems
WVTR [g/ m2 d] (25°C (77°F)/ 100% r.h.)

PLA

THB

UHB PET
met. metalized PP-O
metalized

Steel
Aluminium
Glass

OTR [cm3/ m2 d bar] (25°C (77°F)/50%r.h.)

Source: Alcan/ BMS

Comparison of different BOPP barrier film systems

Metalized AlOx SiOx EVOH transp. EVOH opaque PVDC

OTR + + + ++ ++ +
WVTR ++ + ++ o o o
Aroma ++ + ++ ++ + ++
UV- ++ - 0 - + 0
Protection
VIS Light ++ - - - + -
Protection
Colour + + ++ +
Index
Flex-Crack -- -- - + + +
Retortability -- ++ ++ - - +
Additional cost reduction possibilities:
„Integrated production process“:

BOPET,12µm,
Reversed Print
Film without
Lamination Lamination
BOPET, 12µm, metal.
Lamination
PE-LD, 50µm

Actual Standard Future Potentials

Material BOPET 12µm //BOPETmet 7-Layer BOPP-EVOH 20 µm /
12µm // PE-LD 50µm BOPE-LLD 30µm
Process Sequential Linear Motor Simultaneous
Gauge 76 µm 50 µm
Remark  Triplex Compound  1 Step Process
 2 Laminating Steps (0,065€/m2 )
Packaging costs  ~198 €/ 1000 m2  ~100 €/ 1000 m2

Estimated Packaging cost reduction of ~ 44-48 % possible !

7-Layer Blown Film PE/HV/PA/EVOH/PA/HV/PP-Copo

PE Blend 13 µm
Adhesive Layer 2 µm
PA Layer 2 µm
EVOH Layer 2 µm
PA Layer 2 µm
Adhesive Layer 2 µm
Copolymer 22 µm
Gauge: 45 µm
BOPP Reverse Print // PE/HV/PA/EVOH/PA/HV/PP-Copo
(Application: MAP-, CAP-, vacuum lidding films)

BOPP Reversed printed 20 µm

Lamination 1 µm
PE Blend 13 µm
Adhesive Layer 2 µm
PA Layer 2 µm
EVOH Layer 2 µm
PA Layer 2 µm
Adhesive Layer 2 µm
Copolymer 22 µm
Gauge: 66 µm

 BOPP reversed printed

 Duplex Compound
 OTR: ~2 cm3/ m2 d bar (0,13 cc/100 in² d bar) (23°C (73,4°F)/ 0% r.h.)
 WVTR: ~1.2 g/ m2 d (0,08 g/100 in² d) (23°C (73,4°F)/ 85% r.h.)
BOPP-PVDC // BOPP
(Application: Flow pack, bags)

PP – PVDC 20 µm
Lamination 1 µm
PP 21 µm

Gauge: 42 µm

 BOPP coated with PVDC

 Reversed printed
 Duplex Compound
 OTR: ~25 cm3/ m2 d bar (1,61 cc/100 in² d bar) (23°C (73,4°F)/ 0% r.h.)
 WVTR: ~1.2 g/ m2 d (0,08 g/100 in² d) (23°C (73,4°F)/ 85% r.h.)
7 Layer – 1 Step Process BOPP/ BOEVOH/ BOPE

Terpolymer 1,5 µm
Homopolymer 10,5 µm
Adhesive Layer 0,5 µm
EVOH 1,5 µm
Adhesive Layer 0,5 µm
Homopolymer 10,5 µm
PE/ PP-Copo 25 µm
Gauge: 50 µm
 BOPP front side printed
 One Step Process
 Yield = 0,046 kg/m2
 OTR*: ~1 cm3/ m2 d bar (~0,065 cc/ 100in² d bar) 23°C (73,4°F)/ 50% r.h
 WVTR*: ~1 g/ m2 d (~0,065 g/ 100in² d) 23°C (73,4°F)/ 85% r.h.

*Results for a laminated BOPP/ BOEVOH// BOPE-structure: LP0932

Additional cost reduction possibilities:
„Integrated production process“:

Actual Standard Future Potentials

Material BOPP 20µm // 7-Layer BOPP/BOEVOH/BOPE
PE/Ad/PA/EVOH/PA/Ad/PP
Process Sequential / Blownfilm Linear Motor Simultaneous
Dicke 66 µm 50 µm
Remark  Duplex Compound  1 Step Process
 1 Laminating Steps (0,045€/m2 )
Packaging costs  ~167 €/ 1000 m2  ~101 €/ 1000 m2

Estimated Packaging cost reduction of ~ 38 - 42 % possible !

Additional cost reduction possibilities:
„Integrated production process“:

Actual Standard Future Potentials

Material BOPP/PVDC // BOPP 7-Layer 20 µm / PE-LLD 30µm
Process Sequential Linear Motor Simultaneous
Gauge 42 µm 50 µm
Remark  Duplex Compound  1 Step Process
 1 Laminating Steps (0,045€/m2 )
Packaging costs  147 €/ 1000 m2  ~101 €/ 1000 m2

Estimated Packaging cost reduction of ~ 30 - 35 % possible !

Path Forward and Conclusion

 Sample production for converting and packaging trials, also

long-term storage trials, discussions with film converters and
end users
 Optimization of properties, e.g. sealing and hot tack properties,
shrink & mechanical properties and tests of further raw materials
e. g. UV-Stabilizer,O2-scavengers, humidity absorbers
 Replacement of aluminium
 Replacement of PVOH and/or PVDC coated films
 Replacement of film laminates (PA/ PE, PET/ PE)
 Penetration in the domain of metalized films (better flex crack
resistance, less leakage, opaque films)
 Thank You
PRESENTED BY
Dr. Martin Wolf
Brückner Maschinenbau GmbH & Co. KG
Siegsdorf, Germany

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