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1) Introduction: Requirements to film packagings
Advertising
• Optics
• Printability
- brand name
- attractivity
Protection Environment-
friendly
• Mechanical
• Water vapour • Production
• Gas ( O2, CO2, …) Processing
• Light
• Minimization of
• Aroma,taste
material requirement
• Seal integrity
• Disposal
Econimcs
• Cost effective
production
• Suitability for fast
packaging machines
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Improvement of properties by a stretching process
3500
CPP
BOPP 500 500 90
70
4 850
10
250 1500
560
160 160
1,5 5
60 200
50 100
30
MD TD MD TD H2O O2 CO2 N2
tensile - Elongation Haze Gloss
at break g 25µm cm³ 25µm
strength [%] [%]
[N/mm²] [%] m² d m² d bar
PVC
PA Raw- 1000 %
Others
Others material t/a Share
PS
PP 4.970 66,0
PET
PET 1.780 23,6
PS 480 6,4
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Classification of BOPP application areas
Market- Growth
share
Standard products:
Biscuit & cookies 31% 5%
Chips & Snacks 15% 7%
Candies 10% 6%
Noodles 8% 3%
Others 19%
Special products:
Labels 8% 8%
Ice cream 5% 10%
Others (new) 4%
Cut and stack and wrap around labels, posters, maps, shopping bags,
75-200 µm
business cards, calendars, banners
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Synthetic Paper
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Advantages of Synthetic Paper
Advantages
Mile High Eng Accuplot Outdoor posters, semi-gloss finish, needs pigment
Denver, CO inks to keep water proofing
NanYa Plastics Dura-Lite PP 3-layer with clay coating
50
45
40 2000 2005
35
30
[tpa]
25
20
15
10
5
0
BOPP HDPE others
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Production Capacity SynPa Worldwide
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Synthetic Paper Lines from Brückner
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Layer Structures of Synthetic Paper, examples
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Film Sample: 80µm 5-layer white opaque film – pearlized - heatsealable
A: 1,0 µm Terpolymer / Slip + Antiblock MB
B: 1,0 µm Homopolymer + slip/antistatic MB
C: 74,0 µm Homopolymer + White MB + Pearlized MB
D: 2,0 µm Homopolymer + White + Antistatic MB
E: 2,0 µm Terpolymer / Slip + Antiblock MB
Formulation Purpose
Increase in stiffness
1. PP with anorganic fillers
Opacity
Core layer
Density reduction of the
2. Chemically foamed PP-layer
stretched film
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Increasing possibilities by using 5-layer Technology
Excellent white film with high gloss: Film density and opacity are
functions of film thickness, orientation filler contents and type of
fillers. Five layer structures offer a broad spectrum in terms of film
density, gloss, opacity, whiteness and heatsealability.With three
layer strucure it is not possible to get:
for non heatsealable film:
High gloss, high opacity and low density
for heatsealable film:
High density, high opacity and high gloss
Worst Combination: High gloss, high opacity and low density
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Concept of a Synthetic Paper Line
Coextruder
• Twin screw extruders for all coextruders
• Screw for excellent melt quality
• Improved optical properties by moisture and
volatiles vacuum removal
• No predrying of moisture sensitive additives
• Controlled melt temperature
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LISIM® Principle
Linearmotor Simultaneous Stretching technology
Clips
Linear motors
Cast-film
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Comparison Sequential / Simultaneous Stretching Processes
Sequential LISIM®
Stretching ratio
5x9 8x8 10 x 5
(MD x TD)
MD 200 78 52
Elongation at
break [%]
TD 55 82 110
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4) Density reduction: Formation of vacuoles by incompatible additives
(Inorganic, organic e. g. PBT, -PP)
Y Vacuole
Z
Particle
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BOPP SYN PA Density as a function of the filler´s nature
BOPP-SYN PA
Density [g/cm3]
0.79
0.69
0.57
70 °C ~ 245 °C
+ T °C
Particle form
Density
Endfilm g/cm³ 0,68 0,91 DIN 53420
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Properties Unit „Pearlized film“ „Pearlized film“ Method
sequential simultaneous
Density
endfilm g/cm³ 0,75 0.73 DIN 53420
10 % CaCO3 20% CaCO3
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Other simultaneous stretched, density reduced systems:
PET/ PP/ CaCO3-blend: Thickness (120 µm), opaque (62%)
and stiff white film with a density of 0.97 g/cm3 (BOPET-film:
1.39 g/cm3), possible application as label or stiff synthetic paper.
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Properties Unit „Pearlized film“ blend PP/ breathable Method
simultaneous PA6/ CaCO3 film
Density
endfilm g/cm³ 0,73 0,46 0,52 DIN 53420
20% CaCO3 22% CaCO3 60% CaCO3
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Density reduction by foaming processes
Foamed
core
Skin layer
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Variation of endfilm properties by:
• Use of different matrix polymers and raw material formulations:
As matrix polymers we used:
polypropylene-homopolymers,
polypropylene-block-copolymers,
high crystallinity polypropylene grades,
long chain branched polypropylene grades to increase the
melt strength,
blends thereof
Terpolymer 1,1 µm
Homopolymer, CaCo3 12,7 µm
Adhesive Layer 0,5 µm
EVOH 1,4 µm
Adhesive Layer 0,5 µm
Homopolymer, CaCo3 12,7 µm
Terpolymer 1,1 µm
Gauge: 30 µm
Project coordination
Database Simulation
End user
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LISIM® pilot line for simultaneous stretching
Film types PET PP PA
Thickness range [ µm ] 1 – 150 3 – 60 5 – 25
Stretching ratio MD 3–6 6 – 10 3–5
Stretching ratio TD 3–5 5 – 10 3–5
Speed (max.) [m/min] 150 150 50
Net output (max.) [kg/h] 250 200 70
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Laboratory Stretching Frame
20,00
E44_S
15,00
E47_S
10,00
E44_N
5,00
E32_N
0,00
1 2 3 4 5 6 7 8
TD-Stretching Ratio [-] © Brückner
Upscaling Process
Method
Lab-Stretching Unit Evaluation of Process Window
Optimisation of Film Properties
Measurement of Stretching Forces
Simulation with FEM-Method
Upscaling to production scale
Pilot-Line
Production-Line
Advantages
Demonstration of the potentials of the
LISIM® - Technology
Basic R & D for film stretching
Development of new film types
Development of new components
Production of Sample Rolls for Pre-Marketing © Brückner
Path Forward and Conclusion
but…
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One Main difference between simultaneous and sequential
stretching: Significantly higher stretching speeds
during the sequential MDO-stretching:
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General Film Structure for Synthetic Paper
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