Film Quality Control

Polymer Film

QUALITY CONTROL

UFLEX - FILM TYPES

BOPET : Biaxially Oriented Poly Ethylene

Terephthalate BOPP : Biaxially Oriented Poly Propylene CPP : Cast Poly Propylene METALLISED FILMS (BOPET,BOPP,CPP)

FILM FOR THERMAL LAMINATION (BOPP, BOPET)

QUALITY CONTROL

An Image of the company Ensure fitness to use. Controls Customer complaints. Provide product as agreed. Provide data for development.

WHY TESTING REQUIRED

Testing is necessary to ensure:

The product is matching or surpassing the required properties for smooth usage of the product in entire chain from cradle to grave.

TEST STANDARDS

Test standards are followed to maintain uniformity in testing and understanding among different people, group or companies to ensure a similar platform of product performance

Common standards are: ASTM (American) BS (British) IS (Indian) INTERNAL (Uflex)

PROPERTIES REQUIRED

The film properties can be broadly classified as: Dimensional Optical Surfacial Mechanical Thermal Functional Barrier

DIMENSIONAL PROPERTIES

The appropriate dimensions ensures uniformity during process and helps in effective cost calculation of packaging substrate.

Thickness GSM

Yield (α1/GSM) Roll OD Core ID Roll width

DIMENSIONAL PROPERTIESTHICKNESS

Specification : +/- 3% Instrument Used : Millitron Classification

Spot thickness : Highest accuracy By weight method : Average (100 cm2) By average gauge : Avg. of whole width

Profile analysis : By graph

DIMENSIONAL PROPERTIESTHICKNESS

Procedure : Demo

DIMENSIONAL PROPERTIESGSM / YIELD

GSM : The weight in gms of the substrate per unit square meters surface.

Unit : gm/mts2 GSM = Density * Thickness Measurement method : by weighing 100cm2

of sample in gms and multiplying by 100.

Yield : The area of one kg of film Unit : sq.mts./ kg Yield = 1000/GSM

DIMENSIONAL PROPERTIESROLL DIMENTIONS

Machine Direction (MD) Width of roll

Outer diameter (OD)

Inner Diameter (ID)

MD

TD

TD

OPTICAL PROPERTIES

The optical properties makes the printed image realistic when printed from opposite side of viewing surface, properties are:

Haze Transmittance Gloss Colour : L , a, b Clarity (free from scratches, lines ,marks,

patches, impurities at surface etc.)

OPTICAL PROPERTIESHAZE

The percent of transmitted light that is scattered by a specimen responsible for reducing its contrast and producing smoky field.

OPTICAL PROPERTIESHAZE

Film checked : Clear , Matte Specification

Clear Film : 2.0-4.0 % Matte Film: 40 -70 %

Instrument used : Haze guard plus

OPTICAL PROPERTIESTransmittance /Gloss

• Transmittance : The percent of incident light which is transmitted through the specimen.

• Gloss : It is the surface smoothness responsible for reflecting the light without scattering and thus forming shiny appearance.

SURFACIAL PROPERTIES

The surface properties defines the surface characteristics important for runnability, adhesion and surface morphology:

Treatment / Surface wettability Co-efficient of friction ( α1/Slip) Adhesion Surface roughness Gloss (optical also)

SURFACIAL PROPERTIESTREATMENT

Wetting tension is ability of the surface to wet uniformly with a given liquid.

SURFACIAL PROPERTIESTREATMENT

Liquids of different wetting level is made by mixing proper ration of water, cellusolve & formamide.

In general higher the wetting tension higher the adhesion power.

Units : dyne/cm Minimum level for surfacial adhesion

with ink/adhesive : 38 dyne/cm

SURFACIAL PROPERTIESCOF

The resisting force that arises, when a surface of one substance slides over an adjoining surface of itself or another substance.

COF have a major role in determining the slip behavior of the film and is reciprocal in relation.

MECHANICAL PRPERTIES

Mechanical property is identification of strength, flexibility / rigidity of film to understand its behavior on machine and end application:

Tensile Strength Elongation Modulus of Elasticity

MECHANICAL PRPERTIESTENSILE STRENGTH / ELONGATION

Tensile : It indicates the load applied per unit cross sectional area of the specimen at the time of rupture during streching.

MECHANICAL PRPERTIESTENSILE STRENGTH / ELONGATION

Elongation: It indicates the extension visa vis original length in % while stretching at the moment of rupture.

THERMAL PROPERTIES

The properties ensure the uses without distortion and ensure seal integrity test are;

Shrinkage Machine direction (MD) Transverse Direction (TD)

Heat seal Initiation Temperature Seal strength

THERMAL PROPERTIES SHRINKAGE

Shrinkage : It indicate how much film got shrink in both machine and transverse direction from its original dimension when kept in hot air oven.

Test Condition : PET - 150 deg / 30 min BOPP – 120 deg / 5 min

Specification : FOR PET MD <3.0 and TD <1.0 BOPP : MD/TD :: <3.0 / <2.0

FUNCTIONAL PROPERTIES

The properties ensure the product performance in special conditions which are:

Cold Antifog Hot Antifog F-5 Shrinkage at elevated temperature Sealing with PE film

BARRIER PROPERTIES

The food have a higher shelf life when protected against environmental constrains by not allowing them to pass through the package.

Barrier α 1/ Transmission rate Properties are: O2TR (OTR) : Oxygen Transmission Rate

WVTR(MVTR) : Water (Moisture) Vapour Transmission Rate

METALLIZED FILM TESTING

Thin layer of Alumunium of Aprox. 200 Angstrom is deposited on film (BOPET, BOPP,CPP) and following is checked for adhesion and uniformity:

Optical Density Tape test Treatment1,2 Metal Bond

Various defects on Jumbo

Unflush Ripples

Wrinkles

Various defects on slit rolls

Star marks Ripples

Wrinkles

THANKYOU