OUR MONO-PP SOLUTIONS

Making the packaging world more sustainable

 

PP Mono-Material Solutions

IMPROVED FLEXIBLE PACKAGING RECYCLING

WITH MONO-MATERIAL SOLUTIONS USING OPP FILMS

Numerous flexible packaging applications use multi-material laminates which are considered non-recyclable in Europe and can be converted to mechanically recyclable using polypropylene (PP) films. PP resins are light weight due to a very low density (0.9g/cm3) and are naturally easy to recycle (no cross-linking, no gels, no strong discoloration…) and very well suited for multiple re-extrusions, favoring its use in mechanical recycling operations.
OPP films provide the best balance of properties to maintain all the key essential packaging functions, such as stiffness, heat resistance, barrier, heat seal and optical properties. Specific OPP films are commercially available for the 3 main functionalities of flexible laminates: printability, barrier and heat sealability.

PRINTABLE WEBS

Replace paper or PET with OPP using a broad range of features

Some of the most demanding packaging formats and product segments are using paper, oriented PET films or other harder to recycle substrates in laminate forms. Papers and PET films are stiff, heat stable and tolerate high seal jaw temperatures allowing for a robust packaging operation.

To replace Paper or PET films, OPP films are available with a broad range of features. Commonly available in white or clear, matt or glossy, one or two-side processable, heat sealable or non-sealable, barrier or non-barrier formulations and usually compatible with most printing and lamination processes.

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PAPER can be substituted either with OPPalyte™ white OPP films either glossy (SHH) or matt (ORH), or with reverse printed Bicor™ clear OPP films with a matt look (CSRM).

Glossy or matte PET films can be replaced with Bicor™ clear OPP films (NND, NNH, CSRM) to deliver various functional features or visual aspects depending on the final use.

PAPER REPLACEMENT WITH BOPP FILMS

PAPER-LOOK ASPECT OPP FILM GAUGE (µm) HEAT SEAL* FILM DESIGN (OUT/IN) FEATURES
CLEAR

(REVERSE

PRINT)

MATT CSRM

GNR, GPR

18, 25

20, 30

NHS

HS

Matt/TRT

Matt/TRT

Good jaw release

O/O seal and lap (O/I) seal to PP

GLOSS OR PARTIAL

MATT OPV

NNH

MB666

MB866

20

20 to 40

21

NHS

HS

HS

TRT/TRT

Acrylic/Acrylic

Acrylic/PVOH

2-side treated; good jaw release

Aroma & MOH barrier

High gas, aroma & MOH barrier

WHITE

(SURFACE PRINT)

GLOSS OR PARTIAL MATT OPV SHH

MW647

MH647

28, 40

35-45

42-52

HS

HS

HS

TRT/TRT

Acrylic/Acrylic

Acrylic/Acrylic

Two side treated

High gloss; Aroma & MOH barrier

High gloss; Aroma & MOH barrier

MATT ORH 60-70 HS Matt TRT/Gloss TRT 2-side treated

Footnotes:  NHS = non heat sealable; HS = heat sealable; MO = barrier to mineral oils; * lap sealable to PP films;

Optionally clear barrier OPP films (MB890, MB866) are also available in various gauges for two-ply applications using reverse printing. Alternatively, white barrier OPP films (MW647, MH647) provide outstanding glossy white aspect with excellent barriers to aroma and mineral oils.

PET REPLACEMENT WITH BOPP FILMS

VISUAL ASPECT BICOR FILM GAUGE (µm) HEAT SEAL* BARRIER FILM DESIGN (OUT/IN) KEY FEATURES
CLEAR REVERSE PRINT GLOSS NND

MB400,GND

MB666

MB890

MB866

AO894

20, 25

15-50

20-40

16

21

16

NHS

HS

HS

HS

HS

HS

Aroma

Gas, aroma

Gas, aroma

H2O, gas, aroma

NHS/TRT

HS/TRT

Acrylic/Acrylic

HS/EVOH

Acrylic/PVOH

HS/AlOx

Non-sealable; Good jaw release

O/O & I/O seals with Cast or OPP

High gloss, MOH barrier; O/O seals

MOH barrier; O/O & O/I seals (PP)

MOH barrier; O/O seals (acrylic)

MOH barrier; Flexo print only

MATT CSRM

GNR, GPR

18, 25

20, 30

NHS

HS*

NHS/TRT

HS/TRT

Non-sealable; Good jaw release

O/O seal and lap (O/I) seal to PP

PARTIAL

MATT &

GLOSS

NNH

MB666

MB866

20

20-40

21

NHS

HS

HS

Aroma

Gas + Aroma

TRT/TRT

Acrylic/Acrylic

Acrylic/PVOH

Two side treated; Good jaw release

MOH barrier; O/O seals

MOH barrier; O/O seals (acrylic)

Footnotes: NHS = non heat sealable; HS = heat sealable; MO = barrier to mineral oils; * lap sealable to PP films;

To help replace PET films, Jindal Films recently developed tailored heat resistance OPP films for general outer web applications (MB100), or for more specific segments where extra heat processing is used such as retort or sterilization ( MR100 )

BARRIER WEBS

Replace Alu Foil or vacuum coated PET with OPP barrier films

For sensitive products, many barrier laminates still use thin Aluminum foils or vacuum coated PET films (clear coated or metallized) that are non-recyclable when combined with printable outer web or sealable inner web polyolefin films. Outstanding moisture, gas, light and aroma barriers can be delivered with OPP films and usually results in improved mechanical properties such as puncture or flex-crack resistance.

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Alu foil and Met-PET can be replaced with Metallyte™ high barrier (MM288) or ultra-high barrier (MM883) OPP films – typically in 2-side processable form – or optionally with white metallized high barrier OPP films (MU842).

ALUMINUM FOIL & MET-PET REPLACEMENT WITH BOPP FILMS

BASE FILM TYPE METALLYTE FILM LAMINATE
TYPE
WVTR 38°C; 90%RH OTR 23°C; 0%RH Aroma & MOH Barrier ALU FOIL or MET-PET REPLACEMENT EXAMPLES
CLEAR 15MM288

16MM883

3-PLY 0.1

0.1

25

0.1

+

+++

Soluble drinks, instant coffee

Dry milk, roasted coffee

WHITE 28MU842

35MU842

28MH388ES

28UBWES

3-PLY

2-PLY

0.1

0.1

0.1

0.1

0.1

0.1

10

0.1

+++

+++

+

+++

Dry yeast

Baby food

Dry seasonings

Dehydrated soups

For transparent applications, Alox-Lyte™ films (AO894, AO893) or Bicor™ coated films (MB866, MB890) are suitable to either replace SiOx or AlOx vacuum coated PET films or to shift thicker barrier layers (EVOH) from coextruded PE or PP sealants to the middle or outer webs of laminates and results in improved PP mono-material composition for better recyclability.

CLEAR COATED PET REPLACEMENT WITH BOPP FILMS

BARRIER TECHNOLOGY BASE FILM ASPECT OPP FILM WVTR 38C 90%RH OTR 23C 0%RH Aroma & MO  barrier TARGET REPLACEMENT
ACRYLIC CLEAR

WHITE

20MB666 2-5 550 – 1000 +++ PET, Cellophane, PVdC-OPP, Paper
EVOH/PVOH CLEAR 16MB890

21MB866

5 0.5 +++ PVdC-OPP, EVOH coex PP or PE, dry applications
ALOX CLEAR 16AO894

16AO893

0.7 0.5 +++ PET-AlOx, PET-SiOx, PET-PVdC, PVdC-OPP

Footnotes: MO = barrier to mineral oils

Jindal Films is continuously improving its high barrier technologies with better tolerances as well as developing modified OPP films for more demanding applications such as for liquid packaging or for retort sterilized segments.

HEAT SEALANT WEBS

Replace PE films with enhanced seal performance OPP films

Most demanding packaging applications – such as for powdered products or those with MAP – use blown or cast polyethylene heat seal films that contribute to strong pack integrity. Cast PP or enhanced BOPP films can be used to shift the final laminate towards a PP mono-material composition, resulting in improved recyclability. OPP films provide enhanced mechanical properties (e.g. high stiffness, great puncture resistance) over most blown or cast films, to help to significantly down-gauge the sealant webs and provide additional features like easy tear propagation from a notch or from a crimp-seal.

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Jindal Films has developed specific Bicor™ or Metallyte™ OPP films with higher seal performance to partially close the gap with PE sealants. The latest generation of Bicor™ Ultra Seal films (MB344US) delivers 6 times higher seal strength than most standard coex OPP films, with exceptional hot tack window and often with lower seal initiation temperatures (SIT) than most cast PP films.

OPP FILMS WITH IMPROVED SEAL PERFORMANCE

MATERIAL REPLACEMENT HEAT SEAL PERFORMANCE OPP FILM BASE FILM ASPECT SIT (°C) SEAL STRENGTH WVTR 38°C 90%RH OTR 23°C;0%RH
Standard OPP applications Broad Seal Range

(low SIT)

HLD Clear 80 + **
STD White 80 + **
SVD White 100 Peelable **
MLB Metallised 85 ++ 0.25 40
MM398 Metallised 85 ++ 0.3 50
QFM White / Metallised 85 + 0.2 30
Extrusion coated
PE
ENHANCED SEAL MH388ES

UBWES

White / Metallised 75

80

+++ 0.1

0.1

10

0.1

PE & CPP ULTRA SEAL MB344US Clear 95 ++++ ** **

Footnotes: * There are different minimum seal strength thresholds for various technologies ** WVTR dependent on base film thickness;

In summary, PP mono-material solutions from Jindal Films provide numerous OPP film options – printable, barrier and heat sealable – to help brand-owners and converters launch their multi-material flexible packaging laminates on a journey towards a more sustainable future, feeding the PP recycling streams being progressively implemented across Europe.

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IN SUMMARY

In summary, PP mono-material solutions from Jindal Films provide numerous OPP film options – printable, barrier and heat sealable – to help brand-owners and converters launch their multi-material flexible packaging laminates on a journey towards a more sustainable future, feeding the PP recycling streams being progressively implemented across Europe.