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PE film solutions for modern packaging

Merete SkarApplication Product Developer

Business Unit Film & Fibre

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Market Dynamics

Needs Solutions

Faster Resin processability Film performance: Sealing, stiffness Machine developments

Cheaper Thinner films with better performance New packaging solution Material replacement

Nicer Print quality and optical performance Laminated structures

Environment Material reduction per unit packed Energy consumption per unit packed

Safer Reduced migration and taste/odour Limit package breakage

Technology

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Reference

The involved technologies

• Catalysts

• Reactor configuration

• Comonomer

• Additives

PolymerisationGPR

Loop

Slurry

Solution

Autoclave

Butene

Hexene

Vinyl Acetate

Acrylates

LPPE ZN Cat

LPPE SSC

HPPE

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The involved technologies

• Die design

• Co-extrusion

• Thickness control

• Tension control

• Surface treating

• Post orientation

Processing

• Material combinations:

• LDPE

• LLDPE/mLLDPE

• Borstar LLDPE

• HDPE

• PP

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The involved technologies

Converting

• Printing

• Lamination

• Bag making

• VFFS

• HFFS

• Wrapping

• Sealing

• Vacuum- formers

• Palletisers

• Shrink tunnels

Packaging

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Reference

FB2230 FB4230 FB4250T FB2310 FB4370 FB1350

MFR2 [g/10 min] 0.2 0.4 0.4 0.2 0.4 -

MFR21 [g/10 min] 22 40 40 20 40 15

Density [kg/m³] 923 923 925 931 937 935

Vicat softening point 104°C 104°C 102°C 108°C 110°C 109°C

DSC melting point 124°C 124°C 124°C 127°C 128°C 128°C

Borstar enhanced LLDPE products

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New Borstar Products

• FB4250T => Transparency as low MFR LDPE => Easy processing and excellent draw down => Applications: monofilms, carrier bags, pouches

• FB4370 => Increased stiffness with good toughness => Easy processing and reduced melt pressure => Applications: coex films, FFS packaging, lamination

• FB1350 => Medium density with semi high Mw => Applications

1) Geomembranes 2) MDPE for high neck extrusion and also blends and coex

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mLLDPE (“Single site LLDPE”) Properties in film applications: typical features

+ High strength

+ High clarity

+ Good organoleptics

+ Low heat seal temperature

– Low output and high process pressures

mLLDPE gives better adhesion to PP than Z-N LLDPE

+ High dart drop

+ Low haze

+ Low extractables

+ Low uniform melt temperature

– High viscosity

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• FM5220 (1.3 / 922)

• FM5270 (1.3 / 927)

• FM5340 (1.3 / 934)

• FM5226 (1.3 / 922), Slip+AB

• FM5276 (1.3 / 927), Slip+AB

Borecene mLLDPE film products

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BoreceneTM mLLDPE and Borstar® LLDPE in coextruded structuresAn excellent combination for flexible packaging!

• High clarity and gloss

• Extrusion of mLLDPE rich films with excellent bubble stability!

• Excellent sealing & high strength

BoreceneTM mLLDPE-rich layer (incl. LDPE)A

Borstar® LLDPE as preferred core layer materialB

BoreceneTM mLLDPE-rich layer (incl. LDPE)A

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Although all Borecene coex. films exhibit excellent properties …

• … Fine-tuning can be achieved by selection of main core layer material

• Main component core layer:

Borstar LLDPE (FB2230)

Unimodal HDPE VL5580

PP: BorclearTM

RB707CF

Dart-drop

Tear resistance

StiffnessHeat resistance

Optical properties

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Reference

FB4370

Tailoring the balance of properties impact strength vs. stiffness for 40µm monofilm

Tensile Modulus [MPa]

Dar

t dro

p [g

/50]

C4-LLD

C8-LLD

FB2230 FB2310

150 MPa

100 g

500 g

450 MPa

FB4230

| | | | | | |

LDPE

FM5220

FM5270FM5340

C6LLDPE

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Key properties @ customer How to enhance them?

Processability

Optics

Sealing Toughness

Stiffness

Borstar

Borstar

Borstar

Borecene

Borecene

Borecene

LDPE

LDPE

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Example : Shrink films• Tubular and flat

printed and non- printed

• Hoods and collation

• Transport protection or point of sale

Key advantages with Borstar

• Low hot shrink force

• No hole burning

• High cold shrink force

• Collation and holding forces

• Strength / toughness

• Less puncture with sharp edges

• Stiffness

• Film handling and printing

• Matt surface

• Easy to open and install

Borstar Mono Solutions

• Borstar FB2310/FB4370 in blends with LDPE

• FB4250T with high BUR

Borealis Coex Solutions

• 3 Layer ABA films

• A layer = Borecene + LDPE

• B layer = Borstar + LDPE

• High gloss film with good mechanical and shrink properties

APPLICATIONS

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Packaging technology + PE innovation EBA - Stretch hood film solutions

• Film elasticity !• Tear resistance !• Puncture resistance !• Good optical properties !• Bundling/holding force !

• Solutions• Co-extruded films• EBA copolymers• Borecene / Borstar

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Processing + PE Product innovation MDO Films

Nip rolls

Collapsing frame

Inflated film

bubble

DieExtruder MDO unit Winder

Heating

Annealing

V1 Stretching (V2>V1)

V2

Draw ratio = V2/V1

Granules

Cooling

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High Impact Strength and Stiffness

• Dynatest (DIN 53373)• Energy at break

=> Increase 3-4 times

• E-Modulus (ISO 527)

=> Increase 3 times => Balanced in MD/TD

0

10

20

30

40

50

60

Blown MDO

Ener

gy a

t Bre

ak [J

/mm

]

0

100

200

300

400

500

600

700

800

900

Blow n MDO

Tens

ile M

odul

us [M

Pa]

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Better – Higher – New standards !

• Tensile strength

• Stiffness

• Toughness

• Optical properties

• Co-extruded formulations

• Package performance• Less material consumption • Creep resistance• Packaging line speed• Less package breakages• Less product waste• Product display• Attractiveness• Easy tailoring of properties

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Properties of 80µm Shipping Sack

Meets all specified requirements!

Property 150µm Spec 80µm OPE

Film thickness 100 % 80 µm

2-Sigma < 5 % 3,1 % Stiffness TD > 350 MPa 520 MPa Film Impact > 550 g/50% 590 g/50%

Fold Impact > 450 g/50% 500 Static COF > 0,50 0,51 MD Tear > 7 N 7,8 N

Sealing Range > 10 °C 20 °C Creep 23°C < 10 % 5,0 % Creep 70°C < 15 % 4,2 %

Film Thickness

2-Sigma(<8%)

Stiffness (>250MPa)

Film Impact(>550g)

Delta Impact(<20%)

Fold Impact(>450g)

MD Tear(>10N)

Sealing range(>10°C)

Creep70(<15%)

Outside Friction (>0,45<0,65)

Creep23(<10%)

Film Thickness

2-Sigma(<8%)

Stiffness (>250MPa)

Film Impact(>550g)

Delta Impact(<20%)

Fold Impact(>450g)

MD Tear(>10N)

Sealing range(>10°C)

Creep70(<15%)

Outside Friction (>0,45<0,65)

Creep23(<10%)

Specification

80µm MDO Borstar

Specification

80µm MDO Borstar

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New MDO Application Opportunities

Shipping sacks

Candy Wraps

Compression Packaging

Magazine Wraps

Labels

Stand Up Pouches

Courier/security envelopes

Lamination films

Breathable films

…. And more

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Technology innovations and solutions A key technology driver for success

Unimodal Bimodal BorDry XFL0503

AC, Tub Himod EBA Stretch Hood

Standard Enhanced Differentiated

Borstar

BorPlus

Specialities

HDPE

LDPE

LLDPE

mLLDPE

High Clear XF0601

Borecene

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Thank you for your attention