2010 14 10 Polypropylene Bl1

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Polypropylene blown film

Advanced Packaging



www.borouge.com

About Us

Borouge is a leading provider of innovative, value creating plastics solutions.

A joint venture between the Abu Dhabi National Oil Company (ADNOC),

one of the world’s major oil and gas companies, and Austria based Borealis,

a leading provider of chemical and innovative plastics solutions, Borouge

is a groundbreaking international partnership at the forefront of the next

generation of plastics innovation.

Borouge has its headquarters in the United Arab Emirates and Singapore,

employs approximately 1,600 people representing more than 40

nationalities and serves customers in more than 50 countries across the

Middle East, Asia-Pacific, Indian sub-continent and Africa.

Building on Borealis’ unique Borstar® technology and experience in

polyolefins for more than 50 years, Borouge provides innovative, value

creating plastics solutions for the infrastructure (pipe systems, and power

and communication cables), automotive and advanced packaging markets.

In 2010, Borouge tripled its annual production capacity in Abu Dhabi to 2 million

tonnes and an additional 2.5 million tonnes per year is scheduled for completion

by the end of 2013 to create the world’s largest integrated polyolefins plant.

Borouge is also investing in plants and logistics hubs in Asia and an Innovation

Centre in Abu Dhabi. Today Borouge and Borealis manufacture over 5.4 million

tonnes of polyethylene and polypropylene annually. Focused on Value Creation

through Innovation they ensure that their customers throughout the value chain,

around the world, can always rely on superior products and security of supply.

Borouge is committed to the principles

of Responsible Care® and together withBorealis proactively contributes towards

addressing the world’s water and

sanitation challenges through their Water

for the World™ initiative.

Visit www.borouge.com and see how

we are Shaping the Future with Plastics.



01

Contents

02 Your success is our motivation

03 Introduction

04 Types of polypropylene

05 Characteristic data

07 Processability of PP on conventional

PE blown film equipment with air cooling

09 Benefits of PP blown films compared to PE

11 Benefits of combining PP and PE in blown film

applications

12 Applications

14 Structures of Borouge PP films

15 Structures of Borouge PP/PE films

16 General troubleshooting guide for Borouge PP



02

Your success is our motivation

Borouge aims to provide added value beyond customer expectations.

Through interaction with our customers, and other key players in the value

chain, Borouge understands the needs and future trends in the film industry.

Our products in the film area are carefully designed to meet our customers’

demanding requirements, and we constantly focus on improving our products’

performance in order to fulfill the needs of the whole supply chain.

This brochure profiles how we view the film market, its challenges and what

we can do to help our customers’ businesses become even more successful.

If you have questions or require further information, please contact our sales

representative in your area. See www.borouge.com for contact details.




03

Introduction

Polypropylene (PP) is a semi crystalline material. Until now, PP films were

almost exclusively manufactured by cast film technology: the polymer melt

was poured onto a chill roll and was cooled instantaneously, which caused the

melt to harden quickly.

When PP was used in the traditional blown film process with air cooling there

were three main problem areas:

1. Poor bubble stability due to low melt strength

2. Film has poor machine direction (MD) tear due to linear molecular structure

of PP

3. Poor optical properties, mainly caused by the slow cooling

of the blown film process

New polypropylene developments regarding polymer structure

(new co-polymers) and special nucleation systems now make it possible to

use PP much more economically in blown film technology with air cooling.

This opens new property windows for blown film, e.g. soft to stiff, transparent

to matt, tough to brittle, heat resistant to easily sealable... which until now

could only be achieved in cast film extrusion.

Latest developments in coex technology support the use of full potential in

polymer development.

• The PP blown film process with a water contact cooling ring for

highly transparent packaging films (e.g. textile packaging)

• As a sealing or temperature resistant layer in multi-layer

composites, mainly with barrier materials/primers (EVOH, nylon,

EVA, etc) or with polyethylene as supporting layer

Figure 1: Blown film process

Winder

Flattening

Calibrating

basket

Frost line

Tube

forming area

ExtruderProcess controls

Figure 2: Molecular structure of PE (LDPE) vs PP

PE (branched polymer chain) PP (linear polymer chain)

CH3 H

C – C

H H

–

–

–

–

n

H H H H

C – C – C – C

H H H H

–

–

–

–

–

–

–

–

n



04

Types of polypropylene

PP homopolymers (homo, nucleated1) or non-nucleated) are characterised

by their high stiffness, excellent heat deflection temperatures, excellent H2O

barrier properties and good transparency, as well as high tensile strength for

film applications.

Random copolymers (nucleated and non-nucleated raco) are polypropylenes

with statistically incorporated C2 comonomers. These grades are soft and

have excellent heat sealing properties at low gate sealing points, extremely

low stress whitening and the best optical properties (gloss and haze) of allPP qualities. By using special nucleation systems, films with superior optical

properties can be produced in the blown film process.

Heterophasical copolymers (heco) have an ethylene propylene rubber as a

separate phase incorporated during polymerisation, which means that films

are characterised by a matt surface and low transparency. The high toughness

and good stiffness, as well as the extremely wide temperature range (from

freezing to sterilising) are the dominant properties of this material.

The newly developed Borsoft™ grades (rahecos) are random heterophasical

copolymers, which are a combination of both preceeding polymers, and

consequently also combine their properties. Films with high softness and

toughness can be produced from Borsoft. These polymers have much better

optical, heat sealing and stress whitening properties than hecos.

1) Due to nucleation, the spherulite construction of the film becomes finer,

which increases the stiffness and improves the optical properties

PP non-nucleated

PP nucleated

PP homopolymers A- A-A -A -A- A- A- A- A-A -A -A- A- A- A- A- A-A

PP random copolymers A- A - B- A -A - A- B - A- A -B - A- A - A- A -B - A- A - A

PP heterophasical copolymers A -A - B - B - B - B - A - A - A- B - B - B - A- A - A - A- A - A

PP random heterophasical copolymers A - A - B - B - B - A - A - B - A -A - B - B - B - A -A - B - A - A

A

= propylene monomer

B

= ethylene comonomer

Figure 3: Types of PP




05

Characteristic data

Typical polymer parameters Block copolymers

Properties Test

standard

Unit BHC 5012 Borsoft™

SA233CF

BA110CF

Melt Flow Rate - MFR 230/2.16 ISO 1133 g/10 min 0.3 0.8 0.85

Melt range ISO 3146 °C 162-166 138 - 142 162 - 166

Density at 23°C ISO 1183 kg/m3 905 905 905

Nucleation no no no

Film properties

Gloss (20°) ASTM % 3 3 3

Haze ASTMD1003 % 55 50 55

Tensile strength at break MD/TD ISO 527-3 MPa 75/45 55/45 70/45

Elongation at break MD/TD ISO 527-3 % 650/850 600/800 600/800

E-modulus MD/TD ISO 527-3 MPa 1,250/1,150 400/400 1,200/1,100

Dynatest - damaging force ISO 7765-2 N/mm 1,000 1,250 1,000

Dynatest - penetration energy J/mm 10 15 8

Typical polymer parameters Block copolymers

Properties Test

standard

UnitBorpact™ BC918CF

Melt Flow Rate - MFR 230/2.16 ISO 1133 g/10 min 3.0

Melt range ISO 3146 °C 164-168

Density at 23°C ISO 1183 kg/m3 905

Nucleation yes

Film properties

Gloss (20°) ASTM % 35

Haze ASTMD1003 % 14

Tensile strength at break MD/TD ISO 527-3 MPa 55/32

Elongation at break MD/TD ISO 527-3 % 640/480

E-modulus MD/TD ISO 527-3 MPa 1,550/1,350

Dynatest - damaging force ISO 7765-2 N/mm 1,000

Dynatest - penetration energy J/mm 7

Table 1

Table 2

Table 3

Table 4The specific film properties were evaluated on blown films with a thickness of 40 µm, which were manufactured

under standard internal conditions (BUR 3:1). In comparison to films, which were manufactured under

other conditions, the film properties depend very much on the manufacturing conditions.



Polypropylene blown film06 Polypropylene blown film

Typical polymer parameters Random copolymers

Properties Test

standard

Unit Borclear™

RB707CF

Melt Flow Rate - MFR 230/2.16 ISO 1133 g/10 min 1.5

Melt range ISO 3146 °C 143 - 147

Density at 23°C ISO 1183 kg/m3 905

Nucleation yes

Film properties

Gloss (20°) ASTM % 65

Haze ASTMD1003 % 7

Tensile strength at break MD/TD ISO 527-3 MPa 40/45

Elongation at break MD/TD ISO 527-3 % 750/850

E-modulus MD/TD ISO 527-3 MPa 900/950

Dynatest - damaging force ISO 7765-2 N/mm 870

Dynatest - penetration energy J/mm 5

Table 5

Table 6 The specific film properties were evaluated on blown films with a thickness of 40 µm, which were manufactured

under standard internal conditions (BUR 3:1). In comparison to films, which were manufactured under

other conditions, the film properties depend very much on the manufacturing conditions.



07

Processability of PP on conventional

PE blown film equipment with air cooling

Processing

Borouge PP may be processed on all conventional equipment for

manufacturing films with suitable tooling.

Screw configuration

Borouge PP film grades should be processed using screws with a shear and

a mixing part and a length of 25 - 33 D. Screw lengths < 25 D are in principle

also suitable, but not recommended.

Processing temperature guidelines

It must be remembered that Borouge PP have higher melting temperatures

than Polyethylene (PE), hence it is important to ensure that the feed zone

is hotter to promote sufficient polymer melting. However, this temperature

cannot be too high, otherwise, surging can occur and the bubble may dance.

Melt temperature

In general, the melt temperature depends on the MFR of the processed

material. The lower the MFR, the higher the temperature required in the

extruder (figure 5). It has to be considered that this temperature can vary

depending on the screw design and the layout of the extruder.

Die gap/Blowup ratio

For PP we recommend die gaps in the range 1.2 and 2.0 mm. Narrow die gaps

support higher tear resistance in MD. According to experience, the blowup

ratio should be between 2:1 and 3:1.

Cooling

To achieve the best film properties (best optical properties and toughness)it is required to cool the film as quickly as possible.

Other processing recommendations

Too high melt temperatures could cause thermal damage and impair

material properties. It should be ensured that there is adequate ventilation

during processing. The addition of processing aids or master batches can

influence the properties of the final film. Films made from Borouge PP may

be processed with customary welding equipment if international and national

regulations are followed. Again, adequate ventilation of the workplace is

essential as for all PO conversions in general.

Figure 4: General blown film extrusion guidefor Borouge PP

Figure 5: Processing temperatures of PP

grades as a function of MFR

Notched feeding section, Barrier screws, L/D > 28

Chilled internal +

external cooling air

(recommended 10 - 15°C)

BUR 2:1 to 3:1

Die gap 1 - 2 mm

190

200

210

220

230

240

0.3 – 0.5 0.8 – 1.8 2.0 – 3.0

MFR 230/2,16 [g/10´]

Extrusion temperature:

Typical temperature profile for RB707CF

/ BC918CF :

Barrel Adapter Die Head

190-220°C 215-220°C 225°C



Polypropylene blown film08



09

Benefits of Borouge PP blown films

compared to PE

Compared to PE, PP provides the following advantages:

High stiffness of Borpact™ BC91BCF or Borclear™ RB707CF

grades, in pure blends or as co-extrusion layer

Benefits

Excellent water vapour barrier of Borpact™ BC918CF

Benefits

• Improved heat resistance

• Widens sealing window

• Downgauging potential

• Very good conversion on packaging equipment

• Good planarity/layflat (punching quality)

• Downgauging potential

• Substitution of other materials such as PE blends, PVC, PET, nylon

• New applications possible (e.g. cereal packaging etc.)

Figure 6: Stiffness of various PP and PE blown

film products

Data based on 40 µm films

Extruder parameters: Ø 90/25 D, BUR = 3:1,

output: 85 - 125 kg/h

Figure 7: Water vapour permeability of various

PP and PE blown film products

Data based on 40 µm films.

Extruder parameters: Ø 90/25 D, BUR = 3:1,

output: 85 - 125 kg/h

Borsoft™

SA233CF

HDPE bimod

(0.945)

Borpact™

BC918CF

Borclear™

RB707CFLDPE

(0.924)

T e n s i l e m o

d u l u d

[ M P a ] I S O

5 2 7 - 3

Borpact™

BC918CF

Borclear™

RB707CFBorsoft™

SA233CF

HDPE bimod

(0.945)

LDPE

(0.924)



10

Borclear™ RB707CF/

Borpact™ BC918CF/

Borclear™ RB707CF

Borclear™ RB707CF LDPE/LLDPE(Density 0.924)

Higher heat deflection temperature of polypropylene

Benefits

Good optical properties of film

specially nucleated racos Ú mainly adjustable by coextrusion.

Benefits

• Sterilisable (depending on individual PP grade and conditions)

up to 145°C

• Semi and fully retortable for 35 minutes at 135°C

• Advance into hot fill applications possible

• High temperature gradient possible for coextrusion solutions

• Good surface gloss

• High transparency

Figure 8: Heat deflection temperature

Evaluated on 4 mm injection moulded

specimens (standard B)

Figure 9: Data based on 40 µm coex films.

A ( Ø 65/25 D)/B ( Ø 90/25 D)/C ( Ø 65/25 D),

BUR = 3:1, output: 300 kg/h


Borpact™

BC918CF

Borclear™

RB707CFBorsoft™

SA233CF

HDPE bimod

(0.945)

LDPE

(0.924)



11

Benefits of combining PP and PE

in blown film applications

Due to its different chemical and polymer construction, PP offers different

film properties.

Benefits of PP and PE combinations

The combined use of PP and PE in blown film makes it possible to combine

typical advantages of PP like:

with typical advantages of PE like:

Possibilities of combining PP with PE

• high stiffness

• high heat resistance

• high H2O-barrier

• broader sealing window

Borsoft™

• high tear resistance in MD

• good sealability

• broad sealing window

• high gloss, good optical properties, easy printing

• Blending / compounding

Can be used on monolayer extrusion lines as well as on multilayer

extrusion lines.

• Coextrusion

Combining pure PP with pure PE layers in a multilayer film typically

requires a modifier, e.g. plastomers to prevent interlayer delamination.

This will be a lower cost alternative versus extruding a tie layer

comprising of a polar material, e.g. EVA or compounded PP/PE.

Figure 10: Property window

of PP and PE blown film



Polypropylene blown film12

Stiff packaging film

e.g. for textiles, cigarettes, food, lamination

• High stiffness

• Excellent appearance (gloss, haze)

• Substitute for laminates g cost savings

• Good heat sealing properties

Stand up pouch

• Balanced film properties for both stiffness and toughness

• Good optical properties (display window) – high gloss, low haze

• Downgaugingg cost savings

• Substitute for glass/aluminium containers g cost savings

• High seal strength

• Broad sealing window

• Increased heat resistance

• Low taste and odour

Label film

• Good planarity/layflat

• High gloss/matt surface possible

• Good punching quality, die cutting

• Good printability

• Monomaterial solution with PP bottles/containers possible

Food packaging film / Form-Fill-Seal (FFS)

e.g. snack, food, frozen food, hygiene films, dry food

• Good barrier properties

(H2O and O

2 in combination with barrier materials)

• Good optical properties (especially gloss)

• Good planarity/conversion

• Broad sealing window• Downgauging g cost savings


• Allow hot fill

• Low taste and odour

Applications



13

Lidding Film

• Good optics

• Low taste and odour• Stiffness

• Retortable at 135°C

• Good mechanical properties

• Downgauging

Heavy Duty Shipping Sacks

• Increased stiffness

• Improved creep resistance

• Good mechanical properties

• Downgaugingg cost savings

Retortable Films

• Space savings vs. cans

• Lighter weight

• Retortable at 135°C

Industrial Films

e.g. protective films, shrink film

• Release layer

• High clarity Film

• Anti-tacky layer


Applications

Hygiene films

e.g. diaper films

• Soft touch/embossing

• Softness

• High tenacity

• Good mechanical properties/downgauging



14

Structures of Borouge PP films

Typical structures, where the benefits of PP are useful:

As a heat resistant outer layer

As a high stiffness, high transparency film with good heat sealing properties

As a highly tenacious, sterilisable transparent film

As a tough, stiff film with good heat sealing behaviour

Borclear™ RB707CF or

Borsoft™ SA233CF as

substrate

Borpact™

BC918CF for

stiffness


Borsoft™ SA233CF for

high tenacity


Borpact™ BC918CF

for a balanced ratio

between stiffness

and tenacity

Borpact™ BC918CF

Borclear™ RB707CF

for good optical and heat

sealing properties

Borclear™ RB707CF

for good optical,

sterilising and heat

sealing properties

Borclear™ RB707CF

Borpact™ BC918CF for

stiffness and high heat

deflection temperature

with the aim of achieving

temperature gradients of

up to 40°C




15

Structures of Borouge PP/PE films

Typical structures, where the benefits of PP and PE are useful:

Combining water vapour barrier with good transparency

and excellent heat seal properties

Combining heat resistance with high tenacity

Combining anti-lamination effect and good shrinking properties

Combining high stiffness and excellent gloss

Gas barrier layer

(e.g. PA, EVOH,…)

Blend Borclear™ RB707CF

or Borsoft™ SA233CF

with Borstar® Enhanced PE

for extremely high tenacity

EVA as tie layer

Borpact™ BC918CF or

Borclear™ RB707CF and

metallocene LLDPE or a

combination for highest

stiffness

Borpact™ BC918CF or

Borclear™ RB707CF

Borpact™ BC918CF

for high heat resistance

Metallocene LLDPE

for extremely high gloss

and low haze

Tie layer

(e.g. g-MAH)

PE sealant layer

with low SIT

(e.g. PE based EBA copo)

Borstar® Enhanced PE and

LDPE because of balanced

shrinkage

Borclear™ RB707CF as

anti-lamination layer with

good shrinkage at low

temperatures

Tie layer



16 Polypropylene blown film

General troubleshooting guide for

Borouge PP

Problem Reason Solution

Melt fracture Too low melt temperature Change to a more narrow die gap 1.2 - 1.5

Poor Microstructure Too wide die gap or Add PPA (~1%) Polybatch P AMF 905 or similar

Oxidation in the die head Remove and clean the die insert

Stripes in the film Check the height of the calibration basket

Increase the temperature on the die head

Creases/Wrinkles in Too low temp at nip rolls Increase the output or lower distance betweenMD / TD and A- frames the die head and nip rolls.

Higher the melt temperature

Delaminating Common problem when Add > 30% mLLDPE in all layers for improved

contributing PE / PP adhesion

Poor bubble stability Too much air cooling or Reduce the air or adjust air flow / design

too high melt temp

Too wide die gap Lower melt temperature

Change to a more narrow die gap 1.2 - 1.5

Blocking Too high temp Decrease melt temperature

Modify additive package (slip + AB)

Poor optical Too high FLH and air temp Lower the FLH

Old product left in the extruder Purging of the extruder can take approx. 30 min

Use refrigerator air



Disclaimer The information contained herein

is to our knowledge accurate and reliable as

of the date of publication. Borouge extends

no warranties and makes no representations

as to the accuracy or completeness of the

information contained herein, and assumes

no responsibility regarding the consequences

of its use or for any printing errors. It is the

customer’s responsibility to inspect and

test our products in order to satisfy himself

as to the suitability of the products for the

customer’s particular purpose. The customer

is also responsible for the appropriate, safe

and legal use, processing and handling

of our products. Nothing herein shall

constitute any warranty (express or implied,

of merchantability, fitness for a particular

purpose, compliance with performance

indicators, conformity to samples or models,

non-infringement or otherwise), nor is

protection from any law or patent to be

inferred. Insofar as products supplied by

Borouge are used in conjunction with third-

party materials, it is the responsibility of the

customer to obtain all necessary information

relating to the third-party materials and ensure

that Borouge products, when used together

with these materials, are suitable for the

customer’s particular purpose. No liability can

be accepted in respect of the use of Borougeproducts in conjunction with other materials.

The information contained herein relates

exclusively to our products when not used in

conjunction with any third-party materials.

Borstar is a registered trademark of Borealis

group.

Shaping the Future with Plastics, Borclear,

Bormod, Borsoft and Borpact are trademarks

of Borealis group.

Borouge Film specialises in supplying innovative plastics polyolefin’s for the manufacture

of film, fibre, coating and thermoforming solutions through introduction of technologies

and solutions such as Borstar®, Borclear™ and Bormod™. Together with Borealis, Borouge

benefits from over 50 years of experience in the film markets across Europe, Middle East

and Asia. Borouge believes that customer-driven innovation is the only way to achieve and

sustain progress.

In the film industry, Borouge has pioneered the development of innovative solutions.

Borclear polypropylene for blown PP film with higher heat stability, stiffness and

excellent optical properties has opened up new opportunities for blown film producers on

conventional air cooled production lines. For cast polypropylene film applications, Bormod

has set a new standard of stiffness benefiting multiple packaging end uses.

Through foresight and focus on customer needs, Borouge continues to provide innovative

PP and PE solutions for the film industry that add real value throughout the value chain.

We also know the high value that our customers in the film industry place on product

consistency and processability. We pride ourselves on the performance of our products,

and through ongoing investment in upgrades and new plant programmes, we continue

to set new records for output efficiency and product reliability. Borouge believes that

responsiveness is the foundation of fruitful customer partnerships. Borouge ensures this

through highly skilled and experienced technical, marketing and product development

people located in Australia, New Zealand, India, China, Hong Kong, Singapore and Abu

Dhabi, as well as a diverse sales and agent network around the World.



w w w . b o r o u g e . c o m

Borouge Pte Ltd 1 George Street | #18-01 | Singapore 049145

Tel +65 6275 4100 | Fax +65 6377 1233 | www.borouge.com

B o r o u g e © 2 0 1 0 1 0 F F B R 2 0 0 Y G B B R G

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2010 14 10 Polypropylene Bl1