Processing & Converting of Plastic PolymersExtrusion

Blown MethodCast Method

LaminationTHE LEADING EDGE IN PACKAGING

Processing & Converting of Plastic Polymers

EXTRUSION - BLOWN METHOD- is the manufacture of thin plastic film by extruding the polymer into a close circular bubble and expanding the bubble with air. By pulling the inflated bubble up and continuously adding more plastic resins, a continuous tube of film is created. - After the film is cooled, it is flattened in a collapsing frame and wound into rolls.- It can be wound up as a tube or it can be cut and sealed to make plastic bags. It can also be slitted and rolled as flat sheet film

THE LEADING EDGE IN PACKAGINGBlown Film

THE LEADING EDGE IN PACKAGINGVirgin Resin is mixed with specifiedRegrind and other Additives 2. The blended, heated mixture isPumped into the circular rotating dieDie HeadBlown Extrusion Process

THE LEADING EDGE IN PACKAGING3. A tube is drawn upward as it is beingextruded from the die4. Controlled air is blown into the tubeto create dimension and cool the bubbleas it is drawn up to the interior of the tower Blown Extrusion ProcessAir Bubble

THE LEADING EDGE IN PACKAGINGThe bubble is being collapsedas it passes through6. And over the nip rollersNip RollersBlown Extrusion Process

THE LEADING EDGE IN PACKAGING7. After it passed over the nip rollers,it will go down outside the tower into a final configuration of rollers where 8. It will either be slitted into sheets, wound into tube rolls, or cut and sealed to form into bagsBlown Extrusion Process

THE LEADING EDGE IN PACKAGINGProcessing & Converting of Plastic Polymers

Processing & Converting of Plastic Polymers

EXTRUSION - CAST METHOD

- The cast co-extrusion process combines several layers of different polymers into one film, benefiting from their different physical and chemical properties, thus providing the right solution to the specific packaging requirement of the food industry THE LEADING EDGE IN PACKAGING

Processing & Converting of Plastic PolymersLAMINATION- is the method to combine several polymer sheets using an adhesive to bond them together within a specified curing time

TYPES OF LAMINATING PROCESS 1. Dry Lamination

2. Wet Lamination

THE LEADING EDGE IN PACKAGING

Processing & Converting of Plastic PolymersDRY LAMINATION

Is a lamination method wherein 2 films are joined together using an adhesive and is made to pass through heated rollers to ensure that the 2 films will firmly stick together

WET LAMINATION

Is a lamination process wherein the newly extruded film which is still in its molten state is immediately stuck into another film and is cooled on chill rolls. In this process , adhesive is not required since the dry film will immediately adhere to the newly extruded wet film through the help of the rollers

THE LEADING EDGE IN PACKAGING

THE LEADING EDGE IN PACKAGINGLAMINATION PROCESS OPERATIONAL FLOW CHART

PREPRESS

CYLINDER MAKING

GRAVURE PRINTING

LAMINATION

SLITTING / BAGGING

CUSTOMERS

LAB & TECHNICAL SERVICE

Extrusion Lami

Metallizer

Dry Lami

CPP Film

Processing & Converting of Plastic PolymersMETALLIZATION- Vacuum metallizing is the process of depositing vaporized aluminium onto a film substrate in order to increase the barrier properties of the film

- It is a physical vapor deposition process, produces coating by thermal evaporation of aluminium which was heated to effect vaporization

THE LEADING EDGE IN PACKAGING

PLASTIC PACKAGING & ITS APPLICATION

THE LEADING EDGE IN PACKAGING

PLASTIC PACKAGING & APPLICATIONWhat is plastic packaging made of?

Base polymer specific resin to be extruded in either monolayer or multilayer form and

Additives - an ingredient that enhances the properties of the base polymer without altering its chemical structure- combination of food grade additives can be added into the resins during processing to meet the required film characteristics

THE LEADING EDGE IN PACKAGING

PLASTIC PACKAGING & APPLICATIONTypes of Additives:Antioxidants protect the resin from deteriorating during thermal processing. Plasticizer commonly used in PVC, to obtain flexibility and clinginessAnti-static additives reduce static accumulationAnti-bloc agent prevent film layers from blocking or sticking togetherSlip agents reduce frictional properties, allowing the film to slide smoothly over itself which improves high-speed packing and handling processesUV Stabilizers should be used with plastic that will have direct exposure to UV radiation Dyes, Pigment blended in as master batch color concentrates

THE LEADING EDGE IN PACKAGING

PLASTIC PACKAGING & ITS APPLICATIONS

THE LEADING EDGE IN PACKAGING

COMMON PLASTIC FILM

HDPE

High Density Polyethylene

LLDPE

Linear Low Density Polyethylene

LDPE

Low Density Polyethylene

PA

Polyamide / Nylon

PP

Polypropelene

PET

Polyester / Poly(Ethylene Terephthalate)

PS

Polystyrene

EVA

Ethylene- Vinyl Acetate

EVOH

Ethylene - Vinyl Alcohol

PVC

Poly (Vinyl Chloride)

PVDC

Poly (Vinylidene Chloride)

PC

Polycarbonates

EPS

Expanded Polystyrene

PLASTIC PACKAGING & APPLICATIONTHE LEADING EDGE IN PACKAGING

Plastic Polymer Application

Material

Strength

Weakness

Polyetylene (PE)

HDPE

High melting point

Poor gas & oxygen barrier. Easily sctratch

Excellent moisture barrier

and abraded.

LDPE

Good clarity. Good moisture

Poor oxygen & gas barrier. Poor grease

barrier. High impact strength,

barrier. High dust attraction

elongation and flexibility

LLDPE

More flexible. Excellent heat

Poor oxygen & gas barrier. Poor grease

seal property. Good clarity.

barrier. High dust attraction

Good moisture barrier

Polystyrene (PS)

Hard with fairly high tensile

Intrinsically brittle. Poor water barrier.

strength. Softens at 90-95 C.

Good dimensional stability.

Superior opticals. Good chemical

resistance to food acid. Good

printability

PLASTIC PACKAGING & APPLICATION

THE LEADING EDGE IN PACKAGING

Plastic Polymer Application

Material

Strength

Weakness

Polyester (PET)/

High tensile strength

Lacks heat sealability

Polyethylene

High melting point. Excellent

Poor machine performance

Terephthalate

grease/oil barrier. Good gas,

Generates static

moisture permeability. Good

Low elongation

printing characteristic. Wide

temperature range. Excellent

dimensional stability

Polyamides (PA)/

Tough material with high tensile

Poor water barrier. Poor sealability

Nylon

strength able to resist abrasion

Cracks when repeatedly flexed. Poor

High melting point

slip properties. Generates statis electricity

Retains flexibility even at low

temperature. Resistant to grease,

oil and other chemicals

Good barrier against oxygen,

nitrogen and carbon dioxide

Good printability

EVA

Forms tough film

Poor gas & water barrier

Solvent resistant

Good stress crack resistance

PLASTIC PACKAGING & APPLICATION

THE LEADING EDGE IN PACKAGING

Plastic Polymer Application

Material

Strength

Weakness

Polycarbonates

Tough plastic with clear glass

Not resistant to strong acid. High cost

Resistant to weak acids. High

material

impact strength and high melting point.

Cellulosics

Clear. Superior depth fold

High cost

properties and machinability

Less static

Polyvinyl

High impact strength

Chloride

Good dimensional stability

(PVC)

Good opticals

Excellent grease and oil barrier

Good gas & moisture barrier

Suitable for sterilization

Polyvinylidene

Good gas & water barrier

Chloride (PVDC)

Good opticals

Not stable when heated for any length

Good grease/oil chemical

of time over 60 C

resistance. Can be heat sealed

PLASTIC PACKAGING & APPLICATION

THE LEADING EDGE IN PACKAGING

Plastic Polymer Application

Material

Strength

Weakness

Polypropylene

Excellent grease resistance.

Low tensile and impact strength

(PP)

Resistant to fatigue when flexed.

Poor gas barrier

Superior optical properties

Cold fractures at freezer temperature

Excellent moisture barrier

Good dimensional stability

Good heat seal strength

High melting point

Ethylene Vinyl

Excellent gas & oxygen barrier

Poor water barrier. Soft and dense

Alcohol (EVOH)

Hard to co-extrude

Expensive

Surlyn

Tough, clear film. High melt

Not resistant to acid

strength. Excellent heat seal

bond. Can seal even through

contamination

PLASTIC PACKAGING & APPLICATION