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Packaging films are omnipresent in our daily life: wrapping of food, office supplies, clothing,
bags and sacks. They fulfill many market needs- convenience, portion control and overall
package materials reduction. Packaging is done to retain integrity and actively prevent food
spoilage. It enhances product attributes like look, taste, flavor, and aroma. It is helpful in
communicating product information, product history or condition to user. It also confirms
product authenticity and act to counter theft.
Busy lifestyles drive trends in food packaging. Consumer demands foods that are fresh, healthy and convenient. Packaging
film fight bacteria and help the environment. Bacterial growth during food transport and storage is a problem that may be
addressed with packaging materials that release anti microbial during food contact.
Packaging films are made of a wide range of materials including polyester, polypropylene, polyolefin, PVC, and vinyl.
Packaging also involves the use of plastic film, foils or papers. By combining the best qualities of these materials, packaging
offers a broad range of properties with their application in almost all the industries.
Packaging Films
Breathable Films
Breathable film has today emerged as a very popular packaging material. Breathable films are
produced by compounding a PP or PE resin with mineral filler. The film is then stretched mono or
bi axially to create micro pores in the cast film. In a subsequent process this breathable film can
be laminated with a nonwoven web using adhesive or a point-bonding calendar to produce a soft,
textile like composite. Breathable films, the ability of extruded films to allow the gases to escape,
but retain the larger water molecules, inhibiting the dehydration process.
Characteristics
Applications
They are widely used for roofing applications in the construction industry. They are also used for
sanitary articles. They are also required in the medical industry for bandages, wound dressings,
surgical drapes, and gown fabrication. They are also used in textile industry. They are utilized for
cost-effective tack bonding, combination tack bonding and lamination, for lamination, or for
surface modification.
These films reduce the fogging due to the improved drainage resulting in lower humidity
but they are not intended to prevent it water will always condense on the film surface if
there is moisture in the green house atmosphere and outside temperature is cold
enough. Condensation will be increased if the relative humidity is high. Ventilation or
heating is necessary to remove moisture from the green house. An anti fog film will only
change the way condensation moves or accumulates on the greenhouse cover.
These films are widely used in packaging of automotive parts, electronics and food. Anti-
fog films provide a approach to extend shelf life and control aging of the products.
Applications for anti-fog films include modified atmosphere packaging for cheese,
processed meats, lunch kits, fresh pasta, and other case-ready prepared foods. These
films are used to produce different packaging products like
• Packaging pouch
• Packaging bags
• Food Packaging Laminates
• Dairy Packaging Products etc.
Anti-Static Films
Anti static film is a single layer of non-amide polyethylene. These films
are build-ups of static. They are used to protect sensitive components inside packaging. They
protect package contents from the internal generation of static electricity. They are non-corrosive
films. They are available in the form of bags, tubing, and sheeting.
Antistatic films have some disadvantages also. They can be a major barrier to good
packaging machine performance, such as miswraps. High static levels on films can
attract dust and fines, resulting in poor appearance and seal contamination.
They are widely used in packaging of precise electronic parts. Anti static films are used
to make various packaging products like
• Packaging bags
• Packaging rolls
• Electronic Packaging
• Industrial Packaging etc.
Barrier films
Barrier films are multi-layer films that have been designed to be impervious to gas
migration and are often called gas barrier films. They are used for lamination and
protective system applications. The small size of the pores in these films prevents
penetration of liquid water, but the interconnected pore structure allows for transmission
of water vapor.
Barrier films are durable and flexible, having excellent compatibility with variety of
products. They extend the shelf life and improve the hygienic conditions for handling the
packaged products. They eliminate expensive and often inadequate cleanup. They are
easy to use and quick to install and remove.
Commercially significant materials used for making barrier films are aluminum foils,
glass-coated films, nylon resin, metallized film, cyclic olefin copolymer resin and films,
polychlorotrifluoroethylene resins and films, polytetrafluoroethylene, diverse polyolefins,
and precipitation-cast polyurethanes.
The number of layers, the selection of polymers, the layer configuration and the
thickness of individual layers depend on the intended film use.
Applications
Barrier films are used for applications in protective clothing and packaging. These are
also used as barrier against spills, as needed in carpet underlayments or baby seats.
They offer excellent resistance to a wide variety of chemicals for chemical resistant
clothing.
They are well suited in food packaging where moisture, oxygen and odor barrier is
essential. It is ideal for applications such as cheese packaging, sausage chubs, and
capliners. Some common examples for barrier films are found in grocery store. Bags
used for packaging potato chips and meat products are gas barrier bags. They can also
be laminated to other films and substrates for additional barrier functionality.
These films provide moisture protection in health care and pharmaceutical blister
packaging and other industrial applications. They are also valued in exotic military,
aerospace, aircraft, and electronic applications. Barrier films are used to make different
packaging products like
• Packaging bags
• Aluminum foil
• Aluminum sheet
• Packaging pouch
• Packaging rolls
Bopp Films
Bopp is a bi-axially oriented polypropylene film designed for flexible packaging and label
applications. OPP, oriented polypropylene, is a flexible material derived from melting and
orienting a polymer called polypropylene. This raw material, an oil by-product, is inert
and unaffected by most chemical agents occurring in daily life. Biaxially oriented means
that the polypropylene film is stretched in both the machine direction and across
machine direction.
Features
The main feature of BOPP films are improved stiffness, high tensile strength, excellent
optics and good water barrier properties. They range from 15 to 50 microns and are
most commonly 15 to 30 microns. These films can be monolayer or coextuded
structures, and transparent, opaque, or metallized. They also have the advantage of
being non-toxic and fully recyclable.
BOPP films are printed out of new printing technology, Indigo Omnius. They provide
excellent UV light protection, humidity, aroma and light barriers. They have superior
strength at low gauges, flatness, clarity and excellent printability. They can be treated
with acrylic and PVDC PVDC coatings for better sealability and barrier properties. The
films use mainly homopolymer PP and random copolymer PP.
They are widely used for gift and flower wrapping, paper lamination, textile packaging,
release film for melamine plates and plate film packaging. Also used as the anti-
counterfeit covering film on the packaging cases. Various packaging products like
packaging pouches, packaging bags, electronic packaging, industrial packaging are
produced by BOPP films. In fact aluminum foils and aluminum sheets have good
combinations of BOPP films to produce efficient packaging materials.
Properties
All films have excellent optical properties like gloss, sparkle and clarity. Shrink tightening
characteristics are incorporated into a number of films to ensure a tight wrap on the pack
in the market place. The film continues to tighten as it ages so that packs stay in
excellent condition. Shrink properties overcome the problem of thermal aging which can
make overwrap film begin to wrinkle after a time.
Applications
Overwrap films are used to enhance the shelf-appeal of audio and video
cassettes. The film gives an all round good performance, it enhances the
attractiveness of the product at the time of sale and works well on high
speed wrapping lines. They are printable for all over graphics. They are
designed to run at very high speeds while at the same time routinely
giving very strong seals for improved tamper evidence. They also have
differential slip characteristics that minimize film movement during packing
on high-speed packing lines. They are usually available in the form of packaging
pouches and packaging bags for easy storing of CDs and DVDs.
• Matte
• Clear
• Gel coated (Prepared)
Features
Such films are used for making packaging materials
because of their features like as follows:
• Optical clarity
• Lay Flat
• Printable
• Availability in variety of gauges
Coated Films
A coated film is a thermoplastic film which has a substantially continuous, adherent
coating on at least one surface, wherein the coating includes a polymeric binder and
nano-scale particles. In preferred embodiments, the coating includes a polymeric binder
and silicate particles formed on a base substrate layer that includes a polyolefin selected
from the group consisting of homopolymers, copolymers, and teropolymers.
• Electronic packaging
• Industrial packaging
• Food packaging laminates
• Pharma packaging products
Types of coating
Types of coating used in films are as follows:
• Acrylic coating offer an excellent surface for printing and exceptional gloss and
haze characteristics, combined with very good aroma protection.
• Low temperature sealing coating is a coating especially designed for
horizontal form, fill and seal lines, which allows machines to run at very high or
low speeds, while keeping constant seal temperatures.
• Polyvinyl chloride coating provides superior barrier properties and offers
excellent optics and good machine efficiency.
• Polyvinyl alcohol, with its excellent oxygen barrier is typically used to protect
food products that are sensitive to oxidation.
• Bacteriocin coated film slowed down significantly the microbial quality changes
of the packaged oyster and ground beef at both temperatures. These films have
shown a potential to be used as packaging films for extending shelf life of the
fresh chilled foods.
• Low temperature sealing coating is a coating especially designed for
horizontal form, fill and seal lines, which allows machines to run at very high or
low speeds, while keeping constant seal temperatures.
• Double Coated Film- These films have pressure sensitive adhesives coated on
both sides for instant bonding of two surfaces. They bond well to engineering
plastics and metals.
• Single Coated Film- These films have clear adhesives coated on one side of the
film. They provide a high bond level to many different surfaces.
Coextruded Films
Coextruded film is a multilayer film having peelable interfaces. The interfaces after
separation expose a clean non-stacky surface. These peelable layers are created by
multilayer polymer co extrusion. The structures can be made on conventional film
processing equipment. The peelable interfaces can serve as renewable surfaces,
removable coupons, tags, and cards, carrier webs, opening mechanisms and labels. The
multi layer co extrusion can be designed for one or two side printing, post converting
operation compatibility or for functionality. The layers can be pigmented or modified with
other additives. The bond between the layers can be adjusted from low to high.
History
In 1985, Golden Eagle introduced coextruded films to bulk bun bakers. Replacing
expensive cast films with co extrusions radically changed the industry, offering increased
shelf life, productivity, and profitability. Co extrusions, designed to provide lower
moisture vapor transmission rates allow the bakery products to retain freshness longer.
Features
Resins with custom additives enhance film performance to fit the end use as well as the
needs of converting and packaging systems.
• Packaging pouch
• Packaging bags
• Food packaging laminates
• Pharma packaging products
CPP Films
CPP or cast polypropylene film is a multilayer polypropylene film with co-polymer and
homo-polymer. It is used as a heat seal layer along with BOPP or polyester film in a
laminate for packing of food articles. CPP films have been known in the packaging field
to be the more elegant brother of polyethylene film, with higher gloss, greater
transparency and better heat resistance.
CPP films have higher gloss and transparency, higher strength, superior barrier
properties and excellent sealing strength. They are available with a polished or
embossed surface, gloss or matte finish, stiff or flexible, clear or colored, or in a
combination thereof. They are versatile and the most cost effective films.
Film Storage and Handling
Although CPP films are suitable for use within 4 months from the date of delivery, it is
advisable to rotate film stock. It is recommended that dry conditions at temperatures
below 35 degree C are used for storage of these films, otherwise a reduction in surface
treatment level may be experienced. On account of the elastic memory of thermoplastic
film, a prolonged period of storage may cause problems of profile and blocking. The film
should be kept in its original wrapping until it is used and should be kept at room
temperature 24 hours prior to processing. Films are very sensitive and any damage or
load on the CPP roll may cause blocking.
• Packaging rolls
• Packaging pouch
• Packaging bags
• Food packaging laminates
• Dairy packaging
• Cosmetic packaging
• Pharma packaging materials
Fiberglass Films
Fiberglass is finespun filaments of glass, which are available in a rope or
mat form. When used in a process with polyester resins, catalysts and
hardeners, can be formed or molded into pools, spas and related shapes. It
is a very tough and durable plastic material consisting of extremely fine
glass fibers, used in making various products, such as yarns, fabrics,
insulators, and structural objects or parts.
Properties
Fiberglass films have many unique and outstanding properties, which provide design
opportunities for the improvement of existing products and the developments of new
products. It resists most acids with the exception of hydrofluoric acid and hot phosphoric
acid. It has dimensional stability, will not shrink or stretch with change in atmospheric
conditions. Fiberglass film has low coefficient of thermal expansion and relatively high
thermal conductivity. It had high dielectric strength and relatively low dielectric constants.
It also has low water absorption and high temperature resistance. It is used for harsh,
wet insulation jacketing application.
Filament Films
Filament is a fine or thinly spun thread, fiber, or wire, used for packaging. It is
economical with high-impact durable plastic construction. It is a transparent film
reinforced with continuous glass yarn filaments.
Properties
White Films
White films for packaging are white bop used for opaque packaging and multi color
printing. They are available in glossy and matte versions, and silver face stock creates a
shiny appearance.
Features
These films are ideal for cigarette packing, printing, lamination, and metallizing for food
and non-food packing applications, paper lamination, adhesive tapes, album and bag
making and general overwrap.
For light sensitive coatings of offset printing film, high contrast emulsions are used which
restrict the reproduction to only two values, white and black . The metal plate is used for
offset printing. This plate is covered with a light-sensitive coating, which in turn helps the
image to be transferred from the film. Offset white ink is very transparent, requiring two
hits of white. All offset printing films products have a clear UV flood coat to improve ink
resistance.
Applications
Offset Printing Films are used for
• Journaling
• Laser Printer
• Rubber embossing and stamping
• Architectural and engineering application
• Transfer Printing for textile industry.
Fluoroplastic Films
Fluoroplastic film is a group of plastic films where the molecules contain carbon and
fluorine. Carbon and fluorine dramatically change the properties to include very high
working temperatures, no stick characteristics, very high resistance to chemicals and
solvents, and very high electrical resistance.
Functional Properties
They are tough, durable and highly versatile. Impact is perfect for a wide range of
applications. They offer superior clarity, gloss, and sheen and are puncture resistant.
They are capable of using a wide range of materials.
Polyolefin
Polyolefin films are the workhorses of the packaging and agricultural industries. Their
good mechanical and durability properties as well as their excellent cost and
performance ratio drive their omnipresence.
Polypropylene
Polypropylene is one of the most versatile polymers that serve both as a plastic and as a
fiber the most important property of polypropylene is its versatility. Polypropylene films
for packing are produced using the latest technology and are particularly clear and
glossy. They have high mechanical properties, attractive appearance, and can store
products for a prolonged period of time. These are heat sealable films for flexible
packing and have high tensile strength.
Polyester
Polyesters are made from chemical substances found mainly in petroleum and are
manufactured in fibers, films, and plastics. The excellent combination of optical, physical,
mechanical, thermal and chemical properties of the polyester films is driving the growth
of the specialty films market. Superior dielectric properties make it the preferred film for
use in larger capacitors and also support its use in wire and cable insulation and electric
assembly.
It is used for outer packaging of a number of products including cooked foods, books,
magazines, stationery, office supplies, soaps, aerosol cans, detergent bars, video tapes,
CD, DVD, phones, calculators, etc. Also used for covering electrical connectors. Ideal for
multiple packaging of vitamins, medicines, puddings, jellies, juice, fats food, pastries and
sweets. These films are ideal to make packaging pouches, bags, food packaging
laminates, dairy packaging, cosmetic packaging materials etc.
Label Films
Label films for packaging are based on plastic polymers and their blends. They are used
to label a number of products offering high clarity images, scuff
resilience and water resistance.
Label films for packaging are resistant to mould and withstand retail
display. High definition graphics stand out on the shelf and increase the
perception of value. They have superior tensile strength and thermal
stability. Available in white, opaque and transparent. Design possibilities include “no
look” labels and reverse printed graphics that may be viewed through the container.
Labels are everywhere for displaying the contents of everything and helping to find a
particular product in the supermarket. In fact, it is hard to imagine a world without them.
The label is what makes a product stand out in a crowd, giving its unmistakable
appearance and visual appeal.
Materials Used
Polystyrene – Polystyrene label films provide an excellent print surface with consistent
lay flat characteristics making it ideal for label printers. They add UV protection
increasing the product shelf life.
Polypropylene – Polypropylene label films offer improved slip and anti-static properties.
They are non heat-sealable, with high gloss.
Polyester – Polyester label films are clear and white transparent tamper evident films.
They are thermally stable and flexible enough to suit various applications.
Label films add sparkle to packaging of beverages, CD, DVD, and other food
items. They are widely used in electronic industry, agriculture industry, and
pharmaceutical industry. They are used for low-shrink and non-shrink roll-fed label
applications.
Laminated Films
Laminating is a process of applying a film to either one side or both sides of a printed
document. Lamination adds luster to a printed product. It provides stability to the sheet,
allowing it to be more durable. Laminated documents are waterproof, tear proof, and
tamper proof.
Laminated films provide both decorative appeal and protective qualities. They are also
designed to increase the life of printed products. They give the printed products much
longer shelf life and help retain the pristine look of freshly printed work for longer.
Many of the films used for laminating are available in various thickness and finishes
ranging from clear gloss to delustered. The three main film materials are:
Types
Laminated films are of the following types:
• Pouch Laminating Films- Are like envelops and are sealed on one edge. They
come in many sizes to accommodate standard items such as letterheads or
business cards.
• Roll Laminating Films- Can consist of a layer of film that is applied to the front
side of the document or it can be two layers of film in which the document is
sandwiched between the layers and sealed.
Roll Laminating Films are further classified into the following:
o Clear Laminating Films- Clear is an everyday film that will adhere to
most ink lay downs.
o Matte Laminating Films- Matte is a high quality film that has a glare
finish. It has a slightly granular texture that is frosted to reduce glare.
o UV Laminating Films- It has an added advantage of UV protection.
o Pressure Sensitive Laminating Films- The film is applied by an
adhesive rather than a glue. It does not require heat.
Methods of Lamination
Thermal Lamination- Laminate usually consist of 2 plies with each ply made up of
overlaminate film and an adhesive. The document is placed between the two plies and
passed through the equipment where the dry adhesive is made tacky by heat. The
adhesive is then pressed onto the document under high pressure. After cooling, the
adhesive solidifies.
Cold Lamination- It is a process in which only one side of the document is laminated.
This lamination is done when the ink or paper used for a document is too sensitive to
heat. The surface of the document is flooded with a water-soluble adhesive. It is then
sent through a set of rollers with the laminating film rolled onto the top of the adhesive
and the document. Pressure is applied to bond the film to the document.
Applications
Laminated Films are used for wrapping posters, maps, calendars, food labels, price
tags, membership cards, business cards, placemats, badges, covers, certificates and
many other. They perform a wide range of applications in industrial, food and agriculture
industry. They are used to make various packaging products like:
Lamination films are used to manufacture various packaging products like Blister packs,
Packaging pouch, Aluminum laminated foil, Aluminum laminated sheets, Packaging
rolls, Packaging bags, Medical Packaging, Industrial Packaging etc.
Cold Laminating Film provides a brilliant finish that boost color and offers crisp definition
to any image print. It provide an aggressive and permanent bond to image print.
Cold Lamination is a process in which only one side of the document is laminated. This
lamination is done when the ink or paper used for a document is too sensitive to heat.
The surface of the document is flooded with a water-soluble adhesive. It is then sent
through a set of rollers with the laminating film rolled onto the top of the adhesive and
the document. Pressure is applied to bond the film to the document.
• Floor Graphics
• Posters and banners
• Ideal for trade show graphics
• Packaging purposes
Laminate usually consist of 2 plies with each ply made up of overlaminate film and an
adhesive. The document is placed between the two plies and passed through the
equipment where the dry adhesive is made tacky by heat. The adhesive is then pressed
onto the document under high pressure. After cooling, the adhesive solidifies.
Standard Thermal Laminating Films - These are polyester films with a polyethylene
adhesive that requires temperatures between 210º-240ºF to bond. These are the most
popular films today, largely due to their low price. They can also be the most problematic
to work with.
Heatset (or Heat-Assisted) Laminating Films - These are usually PVC- or polyester-
based films with few exceptions. The adhesive, however, is thermoplastic and only
requires 170º-195ºF to bond to the substrate being laminated.
Glossy Clear Film - A film with a glossy, shiny surface and excellent optics. It is bi
axially oriented polypropylen film with uniformly extrusion coated with adhesives all
along the film surface. It shows excellent bonding with all kinds of printed paper
products.
Matt Film - A film with a matte surface, a surface that enhances the appearance of
laminated products. It is bi axially oriented polypropylen film with uniformly extrusion
coated with adhesives all along the film surface. It shows excellent bonding with all kinds
of paper products.
Laser Films
Laser films are designed to produce optimum image quality for use in computed
tomography, magnetic resonance imaging, digital subtraction angigraphy, and digital
radiography, ultrasound and nuclear medicine modalities.
They are used to package presentations, graphics, layouts, cards, menus, certificates
etc. Used for packaging products, holiday items, gift items, printing software.
Some packaging products made through laser films are:
• Electronic packaging
• Industrial packaging
• Pharma packaging materials
• Food packaging laminates
• Packaging pouches etc.
Metallized Films
Metallized films are based on aluminum attached to a flexible plastic film. These films
have one side metallized and one side sealable. They are designed to reflect the light
where one needs to control thrip and other pests that carry disease. They will support
combustion if ignited.
Metallized films use vacuum sputtering techniques to coat a dielectric film with a metal
composition. They also tend to be self-healing, in that a high voltage arc will vaporize the
metal deposit but will be contained by the dielectric, such that the damage remains
localized. They are made of neutral tones, therefore when anyone looking through these
films, gets true color perception. They offer higher heat rejection figures. They do not
fade or discolor with time.
Manufacturing
The film is drawn through a vacuum chamber with a hot metal ingot. An electromagnetic
field directs streams of ions toward the metal as the heat causes the metal to give up
particles, which then migrate onto the film’s surface. The result is a reflective layer with
very little mirror effect. Finally an ultra clear polymer layer is laminated on that and the
hard coating of materials like acrylic is applied. This finally gives out the quality
metallized films.
Aluminum Film
It has highly consistent optical density. It acts as a barrier to moisture and light, with
superior heat sealing properties. It is highly craze and crack resistant.
Nickel-Chromium Films
Nickel-Chromium Films films does not contain any dyes that can fade or turn purple.
These are clean looking neutral color films that are virtually invisible, blending well with
all exterior and interior color schemes. They are extremely durable and are resistant to
fading, cracking, peeling, delaminating and discoloration.
Nylon Films
Nylon film is a transparent, non-heat stabilized plastic film. it absorbs water. The higher
the moisture content , more flexible it becomes. At low moisture levels flexibility is
reduced. Their outstanding sealing characteristic helps maintain the quality of the
contents.
Features
Nylon films offer excellent thermal and chemical resistance, with high tensile strength,
flexibility and tear resistance. They are also abrasion and puncture resistant and are fully
recyclable. These films enable easy monitoring and act as effective microbial barrier.
Available printed with heat-sensitive inks that allow for immediate indication of
temperature reached during the autoclaving process. They also offer low oxygen and
odor permeability and strong cold temperature properties.
These films exhibit a lower elastic module while retaining its tensile strength and heat
stability. The clarity of the film optimizes visibility of contained products through the film.
They have good release qualities for ease of removal in curing applications.
These films are used as cast acrylic molds and bulk molding compound bags. They are
also used in the sterilization of medical and dental instruments. They can be used to
wrap electronic conductors on flat cables and printers. They are also found laminated to
LDPE films. Nylon films are used to produce various products like
• Packaging pouches
• Pharma packaging
• Aluminum foils
• Packaging bags
• Dairy packaging etc.
OPP Films
Holographic OPP films can be used exactly the same way as plain varnishing film. But in
addition to the protection benefit, holography brings its own refractive and kinetic effects
to enhance the visual appeal. As a cost-effective material, holographic OPP can also be
used to laminate to cardboard. It can also replace plain OPP film to make flexible
packages to boost the shelf appearance of products.
Features
OPP films are very versatile, can be adapted for diverse uses and are suitable for many
types of packaging machines. These films are lightweight, bringing
extra advantage in terms of packaging and are environmentally
stable. They offer superior printability, machinability, and graphic
appeal and provide cost savings over other flexible packaging
materials. They are moisture resistant and durable.
640,
Economy level OPP.
700,
20 2000 Silver Good for gift-wrap, 90 - 100oC
780,
OPP101 and X'mas ornaments.
810, 880
700,
30 2000 Silver 90 - 100oC
1020
Professional level
640,
OPP. Good for hand
OPP200 20 2000 700, Silver 70 - 90
bags, folding boxes,
780, 810
stationery.
640,
OPP210 20 2000 700, 8 Colors - 70 - 90 ?
780, 810
Transparent laminates
2000, Transparent
OPP400 20 630, 785 to protect the printed 80 - 100 ?
4000 Coating
materials.
2000, Transparent
OPP600 20 780 - 80 - 100 ?
4000 Metallized
PET Films
Polyethylene terephthalate is a semi crystalline polymer used to produce films. Two
different film materials PET and PET2 are used to make this film.
PET films are biaxially oriented to stretch the polymer chains creating strength, then heat
quenched to lock in the structure with a small percentage of polymer crystallization. The
heat quenching conditions may leave a residue on the film that may be relieved with
later heat treatment. These films have good thermal stability. They can be post-
processed in the form of sheet or roll, to have better thermal dimensional stability. They
are subject to shrinkage over long periods of time due to stress relaxation.
They act as barrier to high oxygen, moisture, and aroma. They have one disadvantage
of getting degrade in sunlight unless they contain ultraviolet inhibitors. They exhibit good
water vapor and oxygen gas barrier properties.
The excellent thermal properties of PET allow processing and use over a wider
temperature range than most common packaging films. It is ideal for retort packaging,
dual ovenable lidding and ‘boil in the bag’ applications. PET film has the chemical
inertness and good gas barrier properties that are important for many medical,
pharmaceutical and food products. They can be used in the demanding steam, ethylene
oxide and radiation sterilization processes.
PET films are used to make various packaging products like packaging pouches,
packaging bags, aluminum foils, dairy packaging, pharma packaging etc.
PTFE Films
PTFE films are films of the polymer polytetrafluoroethane.
Polytetrafluoroethylene is one of the most important high insulating
organic polymer electret materials, which have been applied in many
fields such as sensors, generators and motors, dose-meters, and
air-filters at high temperature.
PTFE films are ultimate in durability, low stretch, high strength, high
temperature, non-stick protection for lamination lay ups and roll end
wraps. PTFE have several advantages related to both orienting properties and
processibility. They are easy to prepare, chemically inert, thermally stable, optically
transparent and of low cost.
Screen printing also called silk screen print also called serigraph was invented in the Far
East around 2000 years ago. No one knows exactly when or where. Originally silk was
used to make the screen printer's screen. A paper stencil was stitched onto the screen to
control the print area. Around a hundred years ago screen-printing was reinvented in the
west and it has become a common method of printing on textiles.
The screens used for screen-printing are made with a monofilament mesh.
Photopolymer emulsion is used to make the stencil. The silk screen is coated with the
liquid emulsion, and allowed to dry and harden. The emulsion is light sensitive. The
stencil is made in the "silk screen" by placing a positive of the print over the coated silk
screen then exposing the screen to light. The areas of the screen shielded from the light
remain water-soluble and can be washed out of the screen.
Screen print films are cast or calendered PVC film with permanent or removable
adhesives for solvent based inkjet printing. It is a specialty media for signage and
display.
Features
• High resolution
• High reduction capabilities
• Quick and accurate
• Exceptional print quality
• Offers durability
• Available in various thickness
• An actinic light source is needed for exposure of the film
• Easy to operate
• Widely used in printing and publishing industry
Plastic Films
Plastic is any material made of polymeric organic compounds and
additives that can be shaped by flow. This is the most common material
used to make high quality and highly significant films.
They do not have voids in the surface that allow an ink or coating to penetrate into it.
Certain plastics can be attacked or swelled by specific UV raw materials. These can be
matched up with the type of substrate and allow the ink to penetrate the film.
History
Plastics got their start with celluloid and the development of a replacement for ivory in
billiard balls. In 1868 John Hyatt mixed celluloid with camphor and alcohol to find a
substitute of billiard balls. Then came celluloid collars, cuffs, etc. After the turn of the
century, cellophane was invented. The major growth for cellophane and all plastic films
started during the late 1930s and after World War II when self-service shopping came
into vogue. Many packages required transparency because people wanted to see what
they were buying. Since then, many plastic films were added to the list of packaging
films.
Types
There are many material types used in films from single layer polymers to multilayer
polymers with tie layers and copolymers. A number of plastics are used in applications
such as nylon, polypropylene, cellophane, etc.
Polypropylene Films- These are heat sealable films for flexible packing and have high
tensile strength. The film can contain colorants, stabilizers, or other additives, and can
be coated for the improvement of performance properties.
Cellophane Films- Cellophane film is made by the viscose process, a physical process
for making regenerated rayon by treating cellulose with caustic soda, and with carbon
disulfide to form cellulose xanthate, which can then be spun into fibers and reconverted
to cellulose by an acid treatment.
Nylon Films- Nylon film is a transparent, non-heat stabilized plastic film. They absorb
water. The higher the moisture content the more flexible they become. They offer
excellent thermal and chemical resistance, with high tensile strength, flexibility and tear
resistance.
• Single-resin, single-layer packages, like the produce bags which are used to
carry fruits or vegetables.
• Multi-resin, multi-layer packages. They are like the boil-in bags.
• Multi-material packages: They represent blister packs.
Market applications for plastic film can be divided into the following categories: Plastic
film offers several packaging options. The films can be used to produce:
• Food packaging: Plastic films for packaging are available in the the form of
packaging pouch, packaging bags, packaging rolls, sheets, foils etc. Food
packaging includes bags for bread and rolls, in-store bags for produce and bulk
foods, candy wrap and bags, bag-in-a-box, carton liners for cereal and cake
mixes, wrappers for fresh food, wrappers for prepared red meat, poultry and fish,
milk bags, grocery bags.
• Non-food packaging: This include industrial liners which can be used for
everything from tote boxes to large drums to bubble packaging, shipping sacs,
mailing envelopes, dry cleaning bags, diaper overwrap, stretch wrap and more.
• Non-packaging application: This includes variety of stuff like trash bags, leaf
and yard waste bags, agricultural films, can liners, construction materials,
medical applications (e.g. sterile wraps, IV bags, biomedical waste bags) and
other consumer products, like household plastic wrap, diaper liners.
Polycarbonate Films
Polycarbonates are transparent thermoformable materials noted for their superior impact
resistance. This quality of the material makes them the ideal materials for protection
against vandalism or outside forces of nature. Remarkably, polycarbonate sheet is also
highly malleable.
Polycarbonate films are films based on polycarbonate and can be processed without
losing their original shape or durability. They are transparent with two glossy surfaces
and offer excellent thermal stability. They offer excellent dielectric properties and good
printing performance. They act as an easy substrate to print, giving excellent ink
adhesion without pre-treatment.
They are available in wide variety of finishes, textures and gauges. They offer high
transmittance, excellent surface uniformity and ease of processing. They offer superior
mechanical, electrical and optical properties for applications requiring high clarity,
improved heat resistance or reduced glare. They are hard and resistant to chemicals
and abrasion.
Surface Finishes
Polycarbonate films fall into three broad categories:
• Polished Grade Polycarbonate Film - They offer light transmission through all
gauges. These films are available in custom colors and the surface can be
embossed or selectively textured by a screen printing for aesthetic purposes.
• Textured Grade Polycarbonate Film - They are anti-reflective and control light
diffusion. They are easy to process and can also be embossed. They help to
conceal scratches.
• High Performance Grade Polycarbonate Film- They offer exceptional
resistance to attack by chemicals and to abrasion, making them suitable for a
wide range of applications. They feature a proprietary UV stable coating, which
brings long lasting outdoor performance to a wide range of graphics applications.
Polyester Films
Polyesters are made from chemical substances found mainly in petroleum and are
manufactured in fibers, films, and plastics.
Features
• Good oxygen barrier properties ensure that polyester films find demand in the
areas of flexible packaging and lamination.
• Polyester film features superior performance in printing, metalizing and cold seal
applications.
• The film shows excellent scuff resistance, machinability and temperature
characteristics.
• The adhesive can be clear or pigmented for ease of identification.
Types
• Solar Films- Are thin metallized polyester film that use an adhesive backing to
attach the film to the inside surface of existing windows. The performance
advantages of films include solar heat reduction, glare reduction, UV reduction,
increased shatter resistance and some improvement in insulation value.
• Oriented Polyester Films- Are rigid plastics that are strong, durable,
dimensionally stable, and have anti-curl properties. They are suitable for
graphics, packaging, electrical and industrial applications. Available in sheets
and rolls.
Polyethylene Films
Polyethylene is a thermoplastic material composed of polymers of ethylene. It is
normally a translucent, tough, waxy solid unaffected by water and a large range of
chemicals. It is made from petroleum feedstock also known as hydrocarbons. It is
molded to suit a range of applications in the form of sheets, films, rolls and bags.
Features
Polyethylene films for packaging have a very long life span. They are tough, chemical
and moisture resistant. They are also puncture resistant so that heavy or sharp edged
products do not damage them. They have good clarity and are easy to work with. They
are not affected by temperature extremes and are UV stabilized. These films are
available in clear, black, and a variety of colors, and they may be made from renewable
resources such as starch, cellulose, or degradable polymers.
Ecological Safety
Polyethylene films are environmentally friendly and not harmful to foodstuffs. No harmful
substances are used during the manufacturing and the preparation and there are no
vapors, which are hazard to health or drainage systems. These films are biodegradable
polymer films, which have a proprietary additive that allows oxidative degradation
breaking the long carbon chains down into smaller pieces. The oxidative degradation is
triggered by sunlight, heat, and mechanical stress. The film becomes brittle and the
molecular fragments are then further broken down by microbial action to carbon dioxide,
water, and natural substances.
Installation
Polyethylene films are manufactured in widths of upto 50 feet to suit an individual’s
needs. They have convenient folds that make them easy to transport and install. The
various folds are detailed on the back of each roll. The polyethylene rolls should not be
opened before installation. They should be installed taking care of each layer to be
placed.
They are also used for agricultural and technical applications. Designed for use in
overwraps, horizontal and vertical packaging applications. Other applications include
medical implants, bearings, box liners, bulk storage, gamma sterilization, pharmaceutical
storage, transport trays, precision parts, gas water filters, machinery covers, optical
parts, and printing plate storage and protection. Various packaging products made out of
polyethylene films are like packaging rolls, aluminum sheets, aluminum foils, packaging
bags, packaging pouches etc.
Printed Film
Hologram is a two or three dimensional photographic image produced by laser light. It
was discovered by Gabor. The term hologram was coined from the Greek words holos,
meaning "whole," and gramma, meaning "message." The process by which the image is
recorded is called holography.
A hologram contains information about the size, shape, brightness and contrast of the
object being recorded. This information is stored in a very microscopic and complex
pattern of interference. The interference pattern is made possible by the properties of
light generated by a laser.
Laser light is used more often because the light from a laser is of one color and leaves
the laser with one wave in perfect step with all others. Such a light that is highly
directional and of one colors is called coherent.
The hologram presents a true three dimensional recreation of the original object when
re-illuminated and viewed under normal light. For the observer, the perception of depth
is virtually indistinguishable from reality.
Holograms are available in assorted styles and types. Each hologram requires it's own
individual technique for production. Some holograms require a laser to view them, others
rely only on regular light. Some holograms show motion, and some change images as
you move by them. Holograms can be in full-color, change color and even project their
image out in space toward you when you view them.
Properties of Holograms
Applications of Holograms
PRINTED FILMS
• Art, science and technology
• Used on certain product packaging • Polypropylene Printed Films
• Used for labelling • Polyester Printed Films
• Embellishment on printed media • PVC Printed Films
• On credit cards and driving license to help • Polyolefin Films
stop counterfeiting • Printed Cellophane Films
• Used in airplanes to provide the pilot with • Lamination Films
critical information • Lacquered Polyester Films
• Also used for artistic expression • OHP Films
• Security applications
• Laser Print Films
Know More About Holograms
A film is a synthetic resin adhesive, with or without a film carrier fabric, usually of the
thermosetting type, in the form of a thin film of resin, used under heat and pressure as
an interleaf in the production of bonded structures.
Printed film used for packing, is a film with a display of printing, lithographing,
embossing, stickers, seals, or other written, printed or graphic matter. These are leak
proof films.
Specifications
Packaging products require a specific range of coefficient of friction (COF) to allow
automatic packaging operations to run unhindered and to prevent the package from
sliding during storage.
When an ink or coating is applied to a film, the COF of the printed film usually is higher
than the film itself. The printed film COF will drop over time as the slip agents distribute
themselves within the film and ink layer. If the printed film has retained solvent, this will
cause a higher COF. As the ink dries, the COF will drop. The presence of retained
solvent also can increase the migration of slip agents.
The consumption of printing films is growing for stretch and heat shrink sleeve labels,
which make attractive and low-cost-temper evident seals.
Applications
Protection Films
Protection films are films with self adhesive polymer films on one side. They are the films
used for protection of a specific product from all hazards. They are optically clear and
extremely thin films. They are available in a variety of colors and are conceived for both
outdoor and indoor applications. Available in a wide range of colors, thickness and
adhesive strengths, as well as a choice of backing, in different widths. Moreover, they
can be reverse wound and printed, to the final touch for a quality presentation.
They can be transparent as well as translucent. They guarantee resistance to ultra violet
radiation and weathering conditions. They are resistant to wrinkle and abrasion. They
are simple to apply, offering high adhesion and high performance, even over long
periods, and easy to remove cleanly, without leaving any residues, from plastics, glass,
metals, wood, fiberglass, vinyl, leather and other textiles. They also have tamper evident
property.
Features
Materials
Protection Films, are manufactured from a variety of materials including light
polyethylene, vinyl chloride, and air permeating papers. Bonding agents are made of
rubber, acrylic, or polyolefin materials, each with a different bonding strength.
Applications
Polymer Films are suitable for covering a diverse range of applications and substrates.
Ideal for protecting damage prone areas of automobiles boats, without diminishing the
natural aesthetics of the vehicles. They are perfect for high visibility areas such as
vehicle hoods where sheet metal is less curved, thus allowing for easier installation.
They are ideal for painted and coated applications. They provide an effective shield for
high value, quality craft. They are widely used in shipping industry to secure the product
during transportation. They ensure an excellent appearance on completion or redelivery
to the owner. These films are a complement to the marine craftsman’s toolbox.
PVC Films
With good printability and cost advantage, holographic PVC is a favorite
material for making Christmas decoration items, stickers, stationery, and posters, ...etc.
Holographic PVC is also a great material for glitter and sequin.
History
The worlds most versatile plastic had a rather humble beginning. A rubber scientist
during the early 1920s stumbled onto a new material with fantastic properties during his
search for a synthetic adhesive. Waldo Semon was intrigued with his finding, and
experimented by making golf balls and shoe heels out of versatile material called PVC.
After then with the advent of packaging the vinyl films were formed with better material
properties.
Features
PVC films provide controlled oxygen and water vapor transmission. They operate
satisfactorily on high speed packing machines. They offer exceptionally good stretch and
are easily heat-sealed. They limit excessive moisture build-up while preventing the meat
from dehydrating.
PVC films are temperature sensitive, developing a tendency to shatter and split at cold
temperatures and shrink back or block when exposed to high temperatures. The color
may also change to yellow when exposed to heat.
Types
• Rigid PVC Films- Has excellent printing capabilities and is used for various
applications including door panels, stationary, lampshades, ceiling foil, and
cooling tower. They are also used for blister packaging.
• Semi-Rigid PVC Films- Has excellent printing capabilities and is used for a
variety of applications including bookbinding and packaging.
• Flexible PVC Films- Are unplasticized PVC with plasticizers blended into it.
They offer excellent lay-flat, a large selection of opaque colors and prints. They
are used for bookbinding, pool liner, graphics, and water bed.
Some technical applications of PVC films include print-carrying substrates, credit cards,
adhesive tapes, office equipment, furniture frontage, pipe insulation and recycling films.
Features
The film gives a wonderful presentation to the product. They give a glossy appearance.
Have superior transparency and high burn out resistance. They offer excellent stiffness
and stability. They are environmentally friendly films. They have excellent sealing
shrinkage, elasticity, and memory properties. The film remains tightly sealed around the
product after storage, transport, and conveyance to store. The film has anti-fog
properties, which prevent droplets from condensing inside the package, maintaining a
clear wrap and prolonged shelf life. They can be printed on both sides. They are less
expensive, even when printed with high-quality, multi-color UV flexo and rotary screen
graphics. Great for both plastic and metal containers. Shrink films can be applied at high
speeds. They are available in a variety of materials such as white, opaque, clear, and
metallic films.
Types
Shrink film can be of various types. They are made of various materials that offer good
shrink capabilities.
• PVC shrink Film - PVC shrink film feature excellent sealability without
unpleasant fumes. They offer high shrink capabilities at low temperatures and
high tear resistance. Has excellent shrinkage rates and are available in different
shrinkage ratios. They are used widely for food and non-food applications.
• Pallet Stretch Film - It offers maximum comfortability, cling, and strength. This
film has extremely high puncture resistance and a very high holding force and is
ideal for the most demanding applications.
• Polyolefin Shrink Film - They enhance the display effects of merchandise with
excellent material properties and fine finish given by shrink property. They are
the best selection for foodstuffs, pharmaceuticals, convenience goods, etc.
Applications
Shrink films are widely used in a number of industries including food industry,
automotive, agriculture, etc. They are used to wrap CDs, videos, picture frames, paper
plates, wrapping paper rolls, software packages, toys, stationery, promotional
multipacks, biscuits, pizzas, chocolate boxes, bread, egg trays, pastries, really any
products where presentation counts.
These films are used for tray packing which were developed for packing of dairy foods
such as perishable foods, box lunches, prepared foods and etc.
Shrink Labels
Labels are defined as the symbol of manufacturer reputation. Shrink label is described
as a film label printed on an oriented plastic sheet or tube. When heat is applied to the
label, it conforms to the contour of the container that it surrounds. They represent a high
growth segment in the product decoration. They tie a knot between product packaging
and decorative labeling. This increases brand identity, through the use of the containers
resembling the products they represent, packaging with built-in hand grip and measuring
cups, and eye catching exotic shapes.
Types
There are two types of shrink labels:
Materials
The most common material used for shrink labels is PVC. Other materials are also used,
such as polyester, glyco-modified polyester, and oriented polystyrene. OPS have been
made with higher shrink ratios and hence are selected for making the labels. PVC
remains to be the material of choice because of its lowest cost and numerous sources,
both domestically and off-shore. They come in a wide range of shrink ratios and it has
the widest window of shrink temperature.
Film Thickness
Once the type of film has been determined, thickness is the next
consideration. Generally, shrink labels are made from 40 micron
and 50 micron film, with 50 micron being the dominant thickness.
There are, however, labels from 30 micron and 70 micron film.
Perhaps the most important selection factor is what thickness is required for the
application process. Machine manufacturers have certain stiffness requirements and
other processing factors that directly impacts the film thickness that is used.
Applications
Shrink labels grace cans, bottles and jars, attracting consumers to products as diverse
as baby foods, air fresheners, coffee and shaving cream. They are used for both
automatic and manual applications. From household supplies, cosmetics, and the food
and beverage markets, these labels have set their place in the spot light. The world of
promotional products has also found a home for shrink labels. The advantage lies in its
ability to be removed from a product once the promotion is complete, revealing the
brands original label underneath.
Skin Films
Skin films are one of the most important components of the skin
packaging process. It is the film that holds the product on the board.
The film also reinforces the board and provides a glossy surface for
enhancing graphics.
Skin packaging films are known for their clarity, high gloss, puncture
resistance, versatility, adhesion and shorter cycle time. They have
excellent opacity and a lustrous satin appearance. They are best suited for high profile
items, have low shrink force to minimize board curl. They absorb and dissipate heat
quickly for highest possible production speeds.
Skin Packaging
Skin packaging is an inexpensive, effective way to display any product. It is extremely
versatile because one piece of plastic can be drawn around almost any shape, size or
weight product. The plastic protects the product and the card backing from wear and
tear. And since the product is immobilized, it cannot shift and multi-component products
will not lose any of its pieces.
Skin packaging can be used to replace blisters, poly bags and folding cartons. In the
industrial products protection segment, skin packaging can replace peanuts, cellulose
wadding, bubble wrap, foam-in place, shredded paper and die cut corrugated. It provides
product protection, product visibility and tamper evidence.
Applications
Skin films are used for almost all automatic packaging machines for thermoforming, flow
pack and transwrap systems as well as machines for bags sealing. They are also used
for packaging of a wide range of products including meat, poultry, ready meals, fish,
cheese, bread, medical products. The films are available in different reel widths adapted
to the needs of all packaging machines. They are available in the form of packaging
pouches, packaging bags, packaging rolls etc. They are also used in shipping rooms
and industrial applications.
Stretch Films
Stretch films are films that can be stretched in two directions, ideal for wrapping and
securing palletized and irregular shaped loads. They offer strength, protection, reliability,
economy and versatility. They are tear and puncture resistant. They prevent movement
in transit and are available in clear and black films. They offer excellent clarity and
transparency, and appropriate clingability.
Stretch Wrapping
In stretch wrapping, one or more flat films are placed under mechanical tension and
wound helically around the item to be packaged. Depending upon the shape and weight
of the package contents, the stretch material used should be PE or plasticized PVC film
of a thickness of 0.01 to 0.05 mm, with stretch packaging only being suitable for light
weight and firmly consolidated items. The ends of the film web are sealed or coated. The
cargo unit is held together by the tension of the film. Sharp edged items should only be
stretched wrapped using edge protectors, as the film may tear during the stretch
operation. Stretch wrapping provides protection from dust and moisture in indoor storage
only if an additional cargo cover sheet is used. It provides a physiological barrier to theft.
Applications
They are used in various applications. They are most suitable for use in deep freeze
storage areas. They are used for automatic machines and hand pallet wrap for manual
use. They are used in supermarkets and grocery stores, usually in conjunction with a
plastic or fiber tray, to package individual cuts of fresh meat, poultry, fish and other food
products. They are widely available as packaging pouches and packaging bags.
Meat packaging represents one of the largest applications for stretch films, as they have
enough oxygen permeability to allow the formation of oxyhaemoglobin, which, gives the
desired fresh red look to the meat.
Water-Soluble Films
Water soluble films for packaging are films made by evaporation of a solution of alginate
or by extrusion of an alginate solution into a non-solvent which mixes with water, such as
acetone or ethanol. Water soluble films provide a convenient, safe and economical
means of packaging a wide range of products. They also help to reduce the freight
costs. By shipping highly concentrated liquid and dry formulations in water-soluble films,
it is easier and safe for consumers to purchase and use the products.
Materials
The film is made of polyvinyl alcohol or cellulose nitrate nitrite. Films made of cellulose
nitrate nitrite are cold water soluble films. They are prepared by dissolving bleached
sulfite pulp in a solution of nitrogen dioxide in dimethylformamide at room temperature
and heating the solution at 70 degree C for about 3 hours. They have higher crystallinity,
lower moisture absorption, and lower permeability.
The other film could be cast from cyanoethylated polyvinyl alcohol with a degree of
cyanoethylation between 5 and 10 mole % which were readily soluble in cold water.
Features