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PLASTIC PACKAGING - FLEXIBLE PACK
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Processing & Converting of Plastic PolymersExtrusion
Blown MethodCast Method
LaminationTHE LEADING EDGE IN PACKAGING
Processing & Converting of Plastic Polymers
EXTRUSION - BLOWN METHOD- is the manufacture of thin plastic film by extruding the polymer into a close circular bubble and expanding the bubble with air. By pulling the inflated bubble up and continuously adding more plastic resins, a continuous tube of film is created. - After the film is cooled, it is flattened in a collapsing frame and wound into rolls.- It can be wound up as a tube or it can be cut and sealed to make plastic bags. It can also be slitted and rolled as flat sheet film
THE LEADING EDGE IN PACKAGINGBlown Film
THE LEADING EDGE IN PACKAGINGVirgin Resin is mixed with specifiedRegrind and other Additives 2. The blended, heated mixture isPumped into the circular rotating dieDie HeadBlown Extrusion Process
THE LEADING EDGE IN PACKAGING3. A tube is drawn upward as it is beingextruded from the die4. Controlled air is blown into the tubeto create dimension and cool the bubbleas it is drawn up to the interior of the tower Blown Extrusion ProcessAir Bubble
THE LEADING EDGE IN PACKAGINGThe bubble is being collapsedas it passes through6. And over the nip rollersNip RollersBlown Extrusion Process
THE LEADING EDGE IN PACKAGING7. After it passed over the nip rollers,it will go down outside the tower into a final configuration of rollers where 8. It will either be slitted into sheets, wound into tube rolls, or cut and sealed to form into bagsBlown Extrusion Process
THE LEADING EDGE IN PACKAGINGProcessing & Converting of Plastic Polymers
Processing & Converting of Plastic Polymers
EXTRUSION - CAST METHOD
- The cast co-extrusion process combines several layers of different polymers into one film, benefiting from their different physical and chemical properties, thus providing the right solution to the specific packaging requirement of the food industry THE LEADING EDGE IN PACKAGING
Processing & Converting of Plastic PolymersLAMINATION- is the method to combine several polymer sheets using an adhesive to bond them together within a specified curing time
TYPES OF LAMINATING PROCESS 1. Dry Lamination
2. Wet Lamination
THE LEADING EDGE IN PACKAGING
Processing & Converting of Plastic PolymersDRY LAMINATION
Is a lamination method wherein 2 films are joined together using an adhesive and is made to pass through heated rollers to ensure that the 2 films will firmly stick together
WET LAMINATION
Is a lamination process wherein the newly extruded film which is still in its molten state is immediately stuck into another film and is cooled on chill rolls. In this process , adhesive is not required since the dry film will immediately adhere to the newly extruded wet film through the help of the rollers
THE LEADING EDGE IN PACKAGING
THE LEADING EDGE IN PACKAGINGLAMINATION PROCESS OPERATIONAL FLOW CHART
PREPRESS
CYLINDER MAKING
GRAVURE PRINTING
LAMINATION
SLITTING / BAGGING
CUSTOMERS
LAB & TECHNICAL SERVICE
Extrusion Lami
Metallizer
Dry Lami
CPP Film
Processing & Converting of Plastic PolymersMETALLIZATION- Vacuum metallizing is the process of depositing vaporized aluminium onto a film substrate in order to increase the barrier properties of the film
- It is a physical vapor deposition process, produces coating by thermal evaporation of aluminium which was heated to effect vaporization
THE LEADING EDGE IN PACKAGING
PLASTIC PACKAGING & ITS APPLICATION
THE LEADING EDGE IN PACKAGING
PLASTIC PACKAGING & APPLICATIONWhat is plastic packaging made of?
Base polymer specific resin to be extruded in either monolayer or multilayer form and
Additives - an ingredient that enhances the properties of the base polymer without altering its chemical structure- combination of food grade additives can be added into the resins during processing to meet the required film characteristics
THE LEADING EDGE IN PACKAGING
PLASTIC PACKAGING & APPLICATIONTypes of Additives:Antioxidants protect the resin from deteriorating during thermal processing. Plasticizer commonly used in PVC, to obtain flexibility and clinginessAnti-static additives reduce static accumulationAnti-bloc agent prevent film layers from blocking or sticking togetherSlip agents reduce frictional properties, allowing the film to slide smoothly over itself which improves high-speed packing and handling processesUV Stabilizers should be used with plastic that will have direct exposure to UV radiation Dyes, Pigment blended in as master batch color concentrates
THE LEADING EDGE IN PACKAGING
PLASTIC PACKAGING & ITS APPLICATIONS
THE LEADING EDGE IN PACKAGING
COMMON PLASTIC FILM
HDPE
High Density Polyethylene
LLDPE
Linear Low Density Polyethylene
LDPE
Low Density Polyethylene
PA
Polyamide / Nylon
PP
Polypropelene
PET
Polyester / Poly(Ethylene Terephthalate)
PS
Polystyrene
EVA
Ethylene- Vinyl Acetate
EVOH
Ethylene - Vinyl Alcohol
PVC
Poly (Vinyl Chloride)
PVDC
Poly (Vinylidene Chloride)
PC
Polycarbonates
EPS
Expanded Polystyrene
PLASTIC PACKAGING & APPLICATIONTHE LEADING EDGE IN PACKAGING
Plastic Polymer Application
Material
Strength
Weakness
Polyetylene (PE)
HDPE
High melting point
Poor gas & oxygen barrier. Easily sctratch
Excellent moisture barrier
and abraded.
LDPE
Good clarity. Good moisture
Poor oxygen & gas barrier. Poor grease
barrier. High impact strength,
barrier. High dust attraction
elongation and flexibility
LLDPE
More flexible. Excellent heat
Poor oxygen & gas barrier. Poor grease
seal property. Good clarity.
barrier. High dust attraction
Good moisture barrier
Polystyrene (PS)
Hard with fairly high tensile
Intrinsically brittle. Poor water barrier.
strength. Softens at 90-95 C.
Good dimensional stability.
Superior opticals. Good chemical
resistance to food acid. Good
printability
PLASTIC PACKAGING & APPLICATION
THE LEADING EDGE IN PACKAGING
Plastic Polymer Application
Material
Strength
Weakness
Polyester (PET)/
High tensile strength
Lacks heat sealability
Polyethylene
High melting point. Excellent
Poor machine performance
Terephthalate
grease/oil barrier. Good gas,
Generates static
moisture permeability. Good
Low elongation
printing characteristic. Wide
temperature range. Excellent
dimensional stability
Polyamides (PA)/
Tough material with high tensile
Poor water barrier. Poor sealability
Nylon
strength able to resist abrasion
Cracks when repeatedly flexed. Poor
High melting point
slip properties. Generates statis electricity
Retains flexibility even at low
temperature. Resistant to grease,
oil and other chemicals
Good barrier against oxygen,
nitrogen and carbon dioxide
Good printability
EVA
Forms tough film
Poor gas & water barrier
Solvent resistant
Good stress crack resistance
PLASTIC PACKAGING & APPLICATION
THE LEADING EDGE IN PACKAGING
Plastic Polymer Application
Material
Strength
Weakness
Polycarbonates
Tough plastic with clear glass
Not resistant to strong acid. High cost
Resistant to weak acids. High
material
impact strength and high melting point.
Cellulosics
Clear. Superior depth fold
High cost
properties and machinability
Less static
Polyvinyl
High impact strength
Chloride
Good dimensional stability
(PVC)
Good opticals
Excellent grease and oil barrier
Good gas & moisture barrier
Suitable for sterilization
Polyvinylidene
Good gas & water barrier
Chloride (PVDC)
Good opticals
Not stable when heated for any length
Good grease/oil chemical
of time over 60 C
resistance. Can be heat sealed
PLASTIC PACKAGING & APPLICATION
THE LEADING EDGE IN PACKAGING
Plastic Polymer Application
Material
Strength
Weakness
Polypropylene
Excellent grease resistance.
Low tensile and impact strength
(PP)
Resistant to fatigue when flexed.
Poor gas barrier
Superior optical properties
Cold fractures at freezer temperature
Excellent moisture barrier
Good dimensional stability
Good heat seal strength
High melting point
Ethylene Vinyl
Excellent gas & oxygen barrier
Poor water barrier. Soft and dense
Alcohol (EVOH)
Hard to co-extrude
Expensive
Surlyn
Tough, clear film. High melt
Not resistant to acid
strength. Excellent heat seal
bond. Can seal even through
contamination
PLASTIC PACKAGING & APPLICATION