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Creating value and sustainable solutions: Case studies on what’s possible in packaging design
Images used in this presentation are either owned by ExxonMobil or are used with permission.
Market needs from around the world drive innovation
OEMs
Packagers
Consumers Retailers
Brand owners
Converters
Value-added solutions
2
Packaging market needs
3
Cost savings Integrity/Durability Aesthetics Convenience Sustainability
Downgauging
Processability
Simplified solution
Toughness
Stiffness
Shrinkability
Transparency
Printability
High gloss
Package features
Ease of use
Single serving
Reduce waste
Resource efficiency
Recyclability
Overview
4
• Challenge reality of rigid packaging design
• When eXtreme Performance matters in flexible packaging
• Synergy solution of Exceed™ XP + ExxonMobil™ PP
Process performance
Pro
du
ct p
erf
orm
an
ce
ExxonMobil™ PP
Delivers consistent, high-quality products for high-performing applications. For almost 60 years, ExxonMobil has shown commitment to its customers with reliable supply, global support and technical expertise.
Achieve™ Advanced PP
Challenge reality and rethink what’s possible. Achieve Advanced PP offers a significant step beyond traditional PP performance by eliminating tradeoffs and unlocking new opportunities for customers.
ExxonMobil™ PP
Achieve™ Advanced PP
ExxonMobil Chemical polypropylene business
5
Challenge reality and rethink what’s possible in packaging design with Achieve™ Advanced PP
Achieve™ Advanced PP
Achieve™ Advanced PP high melt strength platform
High melt strength can bring value in thermoforming by enabling:
• Sheet sag resistance• Higher filler loadings• Higher recycle content• Uniform distribution• Wider process window
7
Data from tests performed by or on behalf of ExxonMobil
0
0.1
0.2
0.3
0.4
0.5
0 1 2 3 4 5
Pu
ll o
ff f
orc
e F
(N
)
Draw Ratio
Achieve™ Advanced PP6282NE2, 40.5 cN
ExxonMobil™ PP6272NE1, 6.9 cN
Reference high stiffness grade, 6.7 cN
17
20
23
Achieve™ Advanced PP6282NE2 Reference PP
Cy
cle
s/m
in
20
40
60
80
7 8 9 10 11 12
To
p L
oa
d, l
bf
Cup Weight, g
Achieve™ Advanced PP6282NE2
Reference PP
12% improvement
Achieve™ Advanced PP
Case 1: Do more with less and faster! -16 oz clear cup example
Up to 17% lighter with excellent clarity
Reduce material and cost per part while maintaining stiffness and <6% haze
12% more productivity
Achieve Advanced PP eliminates the trade-off between productivity and downgauging.
Part weight reduced
8
Data from tests performed by or on behalf of ExxonMobil
0
4
8
12
Achieve Advanced PP PP6272NE1
Wa
ter
Va
po
r T
ran
smis
sio
n R
ate
,g
m-m
il/(m
2/d
ay)
Improved water barrier
0
100
200
300
Achieve Advanced PP PP6272NE1
Ox
yg
en
Tra
nsm
issi
on
Ra
te,
cc-m
il/(
10
0in
2/d
ay)
Improved oxygen barrier
Achieve™ Advanced PP
Case 2: Improved barrier properties
37% Improvement
29% Improvement
ExxonMobil™ PP6272NE1 ExxonMobil™ PP6272NE1
Longer shelf life? Thinner barrier layers for cost savings?
9
Data from tests performed by or on behalf of ExxonMobil
Achieve™ Advanced PP
Rethink what’s possible in rigid packaging design with Achieve™ Advanced PP
High stiffness AND
processability
12% more productivity
Improved processing window
Cost savings along value
chain
Up to 17% light weighting
>60% filler loading
New performance
standards and more
High melt strength
Non-phthalate catalyst system
Improved barrier
10
Exceed™ XP performance PE polymers
11
when eXtreme Performance matters
Introducing Exceed™ XP performance PE polymers
12
Processability
Me
cha
nic
al p
rop
ert
ies
LLDPE
LLDPE
blends LDPE
blendsLDPE
Exceed™
Enable™
Exceed™ XP
Exceed™ XP Exceed™
when eXtreme Performance matters
A new balance of toughness, sealing, and stiffness, combined with easier processing at lower energy
for superior toughness
Excellent mechanical performance for down-gauging/light-weighting, withoutstanding sealing properties
and best-in-class optics
Enable™
for optimum solutions
Combining excellent processing and bubble stability with toughness not realized in LDPE blends
Exceed™ XP, Exceed™ and Enable™ performance polymers
Product (for 25 µm mono film) MD Tear (g) TD Tear (g)
Exceed XP 8656 500 540
Exceed 1018 255 413
C8 ZN LLDPE (1.0, 0.920) 425 625
C8 mLLDPE (1.0, 0.916) 232 600
Exceed™ XP performance PE polymers
Step-out mechanical performance
13
Improving performance
Typical co-ex pillow
pack for liquids
Maximum limit of Dart A method
Typical co-ex
bag-in-box liner
High
performance plastomer-richbag-in-box liner
Exceed XP 8318
Exceed XP 8358
Exceed XP 8656,
50 µm – 1/3/1 structures
Imp
rovi
ng
per
form
ance
Exceed™ XP, Exceed™ and Enable™ performance polymers
Data from tests performed by or on behalf of ExxonMobil
Extreme Dart impact
Exceptional flex-crack resistance
Outstanding MD tear with high machine orientation
Exceed XP performance PE polymers enabled up to
30% downgauging
1.5 meter dropping
height
Empty bag
1kg MDS for frozen food packaging45 million food units processed per year~25% of the formulation or 150Ton of C8LL used in packaging
Frozen food package filling line
Additional value
• Reduce clean up labor
• Reduce product and packaging waste
• Lower customer complaint
• Reduce cross contamination risk
Up to
2.7kTonof CO2 reduction per year*
Exceed™ XP performance PE polymers
Case 3: Packaging integrity for food waste reduction
14
ExxonMobil solutionReference25% Exceed™ XP
performance PE polymer25% C8LL
Data from tests performed by or on behalf of ExxonMobil*Data based on Food LCA database developed by University of Michigan
Bag failure rate:
Food pack wasted/yr:
Up to
$700,000 total annual savings from food waste reduction
2%
900,000
0.096%
43,200
ExxonMobil solution
PE: 98 μm
100% Exceed™ XP performance PE polymer in core layer
Lamination: 100% PET, 12 mm
Up to 17% raw material cost savings from Exceed XP performance PE polymer
• Better drop
• Better seal strength
• Better tear resistance
• Matching stiffness as BOPA formulation
* Data based on ExxonMobil analysis
Exceed™ XP performance PE polymers
Case 4: Inter-material replacement for cost saving
15
Additional value
ReferenceLamination: 100% BOPA, 15 mm
PE: 98 μm
Lamination material unit cost (per ton)
BOPA ($4,800/ton*) PET ($1,800/ton*)1kg
liquid pouch
10
30
50
70
859095100105110115120125130
Cre
ep
TD
(%
)
Gauge (µm)
Exceed & Enable
37.5% Exceed 101838.5% Enable 200530% HDPE4.5% WMB
Exceed XP & HDPE
55.5% Exceed XP 835840% HDPE4.5% WMB
Exceed XP + ExxonMobil™ PP
75.5% Exceed XP 835820% ExxonMobil PP4.5% WMB
Note: HDS solution each layer might contain some additives, like anti-block, anti-UV, etc.
All data points shown passed drop test
Exceed™ XP, Exceed™, and Enable™ performance polymers
Exceed™ XP performance PE polymers
Outstanding creep resistance for heavy duty sacks
16Data from tests performed by or on behalf of ExxonMobil
> 25% Potential downgauge opportunityvs industry standard 125µm solution
-10
10
30
50
70
40 60 80 100 120 140 160
Sh
rin
kag
e M
D (
%)
Temperature (ºC)
Exceed™ XP performance PE polymers
High temperature performance
Lower creep at higher temperature and higher load
Exceed XP & HDPE
100µm
Exceed XP & ExxonMobil™ PP90µm
No shrinkage
Up to 140ºC
29%
70%
Note: HDS solution each layer might contain some additives, like anti-block, anti-UV, etc.
0.7kg 0.8kg 1.0kg
0
10
20
30
40
50
Cre
ep
TD
@ 5
hrs
(%
)
50ºC 60ºC 70ºC
0.8kg 0.7kg
Exceed™ XP performance polymers
17Data from tests performed by or on behalf of ExxonMobil
Dart impact[0-1000g]
Elmendorf tear MD[0-750g]
Tensile at break MD[0-85N]
1% secant modulusMD
[0-900N]
1% secant modulusTD
[0-900N]
Creep at 1kg, 50ºC,TD
[50-10%]
Exceed™ XP performance PE polymers
Outstanding mechanical performance for heavy duty sacks
Reference
110µm
Exceed XP & HDPE
100µm
Exceed XP & ExxonMobil™ PP90µm
Exceed XP + ExxonMobil PP benefits:
• Higher dart impact
• Higher MD tear resistance
• Higher creep resistance
Derived benefits and value:
• Potential 20% downgauging opportunity
• Passed 2 meter bag drop test
• Improved heat and creep resistance
Note: HDS solution each layer might contain some additives, like anti-block, anti-UV, etc.
Exceed™ XP, Exceed™, and Enable™ performance polymers
18Data from tests performed by or on behalf of ExxonMobil
Dart impact[0-15g/µm]
Elmendorf tear MD[0-10g/µm]
Elmendorf tear TD[0-20g/µm]
Puncture force[0-60mN/µm]
Tensile strength atbreak MD[0-50MPa]
1% secant modulusMD
[0-600MPa]
Exceed™ XP performance PE polymers
Post-industrial recycling
Exceed XP & ExxonMobil™ PP Virgin solution
Exceed XP & ExxonMobil PPRecycle reincorporation solution
Including 25% one pass regrind
Key findings:
• No degradation to film properties and no processing issue when incorporating recycled material
• No issues during pelletization
• PE and PP do not delaminate
Exceed™ XP performance polymers
Note: HDS solution each layer might contain some additives, like anti-block, anti-UV, etc. 19
Up to +21% more bags per roll!
Reference solution:4.6 mil/117 µm
Exceed XP + ExxonMobil™ PP synergy solution:3.8 mil / 97 µm
Exceed™ XP performance PE polymers
Case 5: Value creation in HDS downgauging
20
• Hot fill capability
• Better creep resistance
• Passed bag drop test
• Sustainability: resource efficiency
Additional value 3,263
Bags per 300 kg roll
3,964
701 extra bags
when eXtreme Performance matters in flexible packaging
21
Introducing Exceed™ XP + ExxonMobil™ PP synergy
Downgauging
Unlock new markets
Performance & reliability
Increased stiffness
High temperature resistance
Reduced deformation(creep resistance)
Collaborating with the value chain
22
Equipmentsuppliers
Converters Brandowners
Packagers Retailers Consumers
@XOM_chemical
linkedin.com/showcase/exxonmobil-chemical
www.exxonmobilchemical.com/HDS
exxonmobilchemical.com/HDSexxonmobilchemical.com/HDS
Copyright 2019 ExxonMobil. ExxonMobil, the ExxonMobil logo, the interlocking “X” device and other product or service names used herein are trademarks of ExxonMobil, unless indicated otherwise. This document may not be distributed, displayed, copied or alteredwithout ExxonMobil's prior written authorization. To the extent ExxonMobil authorizes distributing, displaying and/or copying of this document, the user may do so only if the document is unaltered and complete, including all of its headers, footers, disclaimers and otherinformation. You may not copy this document to or reproduce it in whole or in part on a website. ExxonMobil does not guarantee the typical (or other) values. Any data included herein is based upon analysis of representative samples and not the actual product shipped.The information in this document relates only to the named product or materials when not in combination with any other product or materials. We based the information on data believed to be reliable on the date compiled, but we do not represent, warrant, orotherwise guarantee, expressly or impliedly, the merchantability, fitness for a particular purpose, freedom from patent infringement, suitability, accuracy, reliability, or completeness of this information or the products, materials or processes described. The user is solelyresponsible for all determinations regarding any use of material or product and any process in its territories of interest. We expressly disclaim liability for any loss, damage or injury directly or indirectly suffered or incurred as a result of or related to anyone using or relyingon any of the information in this document. This document is not an endorsement of any non-ExxonMobil product or process, and we expressly disclaim any contrary implication. The terms “we,” “our,” "ExxonMobil Chemical" and "ExxonMobil" are each used forconvenience, and may include any one or more of ExxonMobil Chemical Company, Exxon Mobil Corporation, or any affiliate either directly or indirectly stewarded.
Test Method based on
MI (Melt Index) ASTM D-1238
Density ASTM D-4703 and ASTM D-1505 / ISO 1183
Melt Flow Ratio (MFR) ASTM D-1238
Flow behavior- Capillary and Oscillatory Rheology EMC methods
Tensiles tests ASTM D-882
Dart Impact ASTM D-1709 (procedure A)
Elmendorf tear ASTM D 1922-09
Puncture resistance EMC method
Puncture needle test CEN 14471 (probe diameter = 0.8 mm)
Holes after flex EMC method (Gelbo device)
Shrinkage tester: Betex EMC method
Shrink force measurement by Retratech ISO14616
Lab aging test(Tensile test/Carbonyl test) ISO 4892-2 at Norner (ISO527-3/Norner method M730849)
Melt Strength ExxonMobil - RHE04-4.2, 190°C
Flex Modulus 0.05 in/min ASTM D790A, 1% secant
Oxygen Transmission Rate ExxonMobil PLSL-650.002, Mocon Ox-Tran®
Water Vapor Transmission Rate ExxonMobil PLSL-652.002, Mocon Permatran-W®
Inverted Top Load ASTM D2659, test completed at 3rd party labs
Haze ASTM D1003-13, test completed at 3rd party labs
Test methods
24