THIN-WALL PACKAGING | MATERIALS
Product protection: thin-wall packaging
Recent advances in thin-wall packaging include new thermoformable PLA film and biax film, the use of microcellular foam structures and other ways to boost sustainability
The trend towards reducing the amount of plastics in packaging has accelerated the need for thin-wall containers – with producers looking to slim down wall thickness as much as they can. At K2022, Kuhne Anlagenbau showed a
large-scale line for biaxially oriented thermoform- ing films using its Triple Bubble technology. With a thickness of 80 to 120 microns, the films
are only about half the thickness of conventional cast films used in food packaging, says Kuhne. The maximum achievable thermoforming ratio is 1:10. This means a reduction in material consumption – and in greenhouse gas emissions by around 50%. Thanks to optimised cooling rates, the lines can achieve throughputs of up to 2,000 kg/h or annual outputs over 15,000 tonnes – so can surpass the productivity and profitability of cast film lines. Typical applications of these multilayer films include vacuum packaging for transporting and stor- ing large pieces of ham, meat or cheese. Generally based on PA, EVOH and PE, these films combine
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high transparency with good thermoforming characteristics and elevated puncture resistance. Triple Bubble lines currently enable production
of films with up to 17 layers at widths of up to 3,000mm double flat (6,000mm film width). Thermoforming formulations contain well below 10% PA and EVOH and permit a large reduction in thickness. Monomaterial solutions are also possi- ble. A high level of molecular orientation improves the films’ mechanical and barrier properties. “Working with us gives customers more than just delivery and installation of the Triple Bubble line,” said Jürgen Schiffmann, CEO of Kuhne. “Our service also includes application-specific film formulation and tuning of process parameters.”
Vacuum skins Harpak-Ulma has developed a thermoforming solution for packaging fresh foods. Its TFS 216 is designed to produce vacuum skin packs on a flat cardboard base. It uses cardboard
November 2022 | FILM & SHEET EXTRUSION 21
Main image: Promix has used chemical foaming to cut material use in PET trays by 20%
IMAGE: PROMIX
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