FLEXIBLES: FILMDEVELOPMENTS
consistency through the printing process, giving better registration and press speed. Finally, the filmis suitable for
reverse printing. Therefore it can replace BOPP or even PET laminates. Also, it can be laminated to blown PE, giving a 100 per cent recyclable laminate.
TYPICAL APPLICATIONS OF BOPE 25-40 micron gauges of BOPE can be used to replace what would be the current job of 40-80 micron PE. The material, with its attendant costs and waste saving, laminates to all other films to facilitate VFFS and HFFS structures such as bags and pouches. Its unique tear structure even allows re-sealable packs to be created. Frozen foods, chilled foods, meat, fish, dry goods, pouches, liquids are all suitable for packaging in BOPE using the appropriate structure. The applications are as extensive as current PE films and more. The cost savings, weight, waste savings, along with the attendant environmental advantages make this new film one of the most exciting developments for some years in this sector. After its success in the Chinese market it is being introduced in Europe. There are also some other
developments which are enabling film suppliers to assist retailers in meeting their Courtauld commitment.
transported, energy required for manufacture plus reduced carbon emissions with all the attendant environmental benefits this implies. Second of all, despite the
reduction in thickness, higher impact and puncture resistance is improved, particularly in freezer applications. Thismakes the filmideal for frozen foods where packaging products with sharp corners is often a problem. Thirdly, the filmoffers high hot
tack plus a stronger seal, which enables VFFS applications, even for heavy products such as potatoes. Also, packing lines can generally be run at faster speeds which improves productivity. A fourth benefit is BOPE’s
extra flatness, as it allowsmore
IMPROVED POLYPROPYLENE FILMS In the last ten years, new OPP production lines have been installed in virtually every developed country in the world. The more modern the line, the more consistent the quality of the film, and, as a consequence, the more opportunities arise to fully exploit extra rigidity and clarity of the film. Food companies constantly try
to reduce their costs by driving down the price of the film. Too often they ignore technological improvements with the potential to change their existing films, or indeed use the ones they have more effectively. Usually this is due to “production pressures” but in reality this is often due to inertia and a lack of willingness to change, thus they continue to use the same films Ad Nauseam. Modern OPP films have higher tensile strength, better puncture
PackagingGazette.co.uk | Packaging Gazette | 21
resistance, and better optics. Therefore in many applications simply reducing the thickness of the film by 5-10 microns can save 20-25 per cent of the cost whilst doing exactly the same job. There is a recent example of a large, well-known bakery, who had refused to countenance change for many years as they were simply too busy - when reluctantly economic pressure finally forced the issue they called in the packaging technologists. The result was a consolidation in the number of pack sizes used from eleven to seven and the film was down gauged. The resultant saving will be 22 tonnes less film purchased per year, therefore 22 tonne of potential ‘waste’ saved. After all the years of delay the project only took four weeks from inception to completion. No adverse comments have come
extrusions are a totally under- exploited resource when considering new pack formats. Co-extrusions up to nine layers which incorporate high barrier materials such as EVOH or Surlyn allow reductions in thickness and make ideal laminate or board replacement.
THE FUTURE In 2010-11 our people visited five major exhibitions world- wide and identified over 30 new films, all of which offered additional benefits for food packaging. These involved better barrier for food protection and extended shelf life, better puncture resistance, better running speeds for packaging machinery, and better gloss for aesthetics. Improving film technology is
an underutilised resource as food manufacturers find change
“Food companies constantly try to reduce their costs by driving down the price of the film. Too often they ignore technological improvementswith the potential to change their existing films”
from the customers and the cost savings are excellent. Modern film technology
should be exploited not ignored. But regrettably, there are so few packaging specialists around that really understand flexibles so companies use the same films year after year almost by default. Similar change exercises have
taken place, replacing carton boxes and developing a flexible pack whilst multiple co-
difficult, whilst retailers often seek reductions in price but in many cases do not support changes in pack design. The new materials are available to reduce waste film and thickness as is the knowhow. What is often missing is the will to change. The Courtauld Commitment is
pushing everyone along the right path but sometimes the going can be tough.
Barry says that FMCGmanufacturers need to concentratemore on improving their filmtechnology rather than driving down costs
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