In a world of fast-changing lifestyles, consumers expect products to be lightweight, shatter-proof, aesthetically appealing, easy to handle and offer good protection. The only answer to all these pre requisites is plastics. Plastics have, in fact, revolutionized the whole world in the last three decades. They have become part and parcel in every walk of life.
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Flexible packaging materials like polyethylene, polyvinyl chloride, polypropylene and polyester films play a major role in almost all the industries, especially the food-packaging sector. Biaxially oriented polypropylene (BOPP) film is among the most favoured packaging material across the industrial spectrum. The BOPP film suitable for the food packaging industry is generally a co-extruded, heat-sealable film. The sector also uses non-heat sealable films. Co-extruded, heat-sealable films are used as a single web for packaging of products unlike polyester films which cannot be heat-sealed on its own and warrants a second web to be laminated.
MANUFACTURING BOPP FILMS
BOPP films are generally manufactured by the following processes:
a) Sequential Orientation:
Stenter Process Double Bubble Process
b) Simultaneous Orientation
Since sequential orientation by stenter is the most commercially employed process for the manufacture of BOPP films, the process needs to be looked at in greater detail.
Homopolymer polypropylene is processed with various functional additives like amides, ethoxylated amines, stearates etc, to reduce the film's co-efficient of friction and increase the static charge dissipation rate. It is also mixed with various fillers like talc and calcium carbonate and pigments like titanium dioxide to provide different shades to the film.
Polypropylene with the requisite additives, fillers and pigments are melt co-extruded as thick sheet. With the help of one or more satellite co-extruders, a random copolymer of polypropylene or other terpolymers are melt co-extruded on either one or both surfaces of the homopolymer sheet. The homopolymer core layer, which is generally between 70-90% of the total thickness, provides the mechanical strength, optical properties, reduction in density (in certain cases) and other relevant characteristics. The copolymer skin layers, which may contain the above-mentioned functional additives, may also contain anti-blocking additives. These skin layers render the film heat-sealable and improve its optical properties.
This sheet is later solidified by passing it over a chill roll kept in a water bath. The cast sheet is then passed over several heated, chrome-plated rolls, which pre-heat it. After achieving sufficient heat, it is passed over two or more pairs of rolls in which one set of rolls rotate at a speed faster than its preceding rolls. Due to the difference in circumferential speed, the film is oriented in the longitudinal direction. The orientation is generally to the tune of 4-7 times.
The mono-oriented film is then clipped by clippers, which carry them into a hot air circulated oven. The clippers are placed over a parallel chain track. After sufficiently heating and transverse direction orientation to the tune of about 7-10 times, the biaxially oriented film is then annealed to retain the oriented stresses and cooled to room temperature. While the unoriented gripped portions are trimmed, the final film is corona treated to enhance surface tension and wound in jumbo rolls .
PROPERTIES OF BOPP FILMS
Polypropylene (PP) has the lowest density of 0.905 g/cc of all the plastics available till now. In a special grade of pearlised BOPP film, the density is further reduced to 0.700 g/cc apart from providing a pearly aesthetic look and barrier to light. Owing to the low density of PP, the yield of the film is more than in other films and thus economical. The biaxial orientation of PP enhances various properties over conventional cast or tubular quenched PP films. The mechanical strength, dimensional stability, stiffness, non-terability, optical properties, barrier properties etc. are greatly improved owing to the biaxial orienting process. Table-1 provides a comparative analysis of the property details of various films.
ADVANTAGES OF BOPP FILMS
The main advantages of using BOPP films are:
It provides a higher surface area per unit weight, which makes it cost effective; It has very low moisture transmission rate than other packaging films, which improves the shelf life and retains crispness of the food products sensitive to moisture; It has a combination of excellent slip and optical properties. The high gloss and excellent clarity provides good aesthetic appeal whereas controlled slop properties make it suitable to perform well on various form fill seal (FFS), overwrapping and converting machines in order to improve or maintain high productivity; High tensile strength, low elongation and thermal shrinkage render it suitable for processing on high-speed printing, coating/laminating and other converting machines. It can be tailor-made to suit various customer needs, which may be a combination of any optical/surface, optical/barrier and optical/mechanical properties etc; It is non-reactive or inert to its olefinic (hydrocarbon) nature, which makes it suitable for safe use in the food and pharmaceutical industries. It is also suitable for common methods of sterilization practiced presently in the industry; The co-extruded heat sealable films are preferred because they provide sealability in addition to barrier and better aesthetics without involvement of any additional coating or laminating operation, making the package cost effective; It is recyclable and does not emit hazardous gas while reprocessing.
ROLE OF BOPP FILM IN FOOD PACKAGING
The food packaging requirements are very stringent. BOPP films have many properties that are suitable and advantageous for packing food materials. The basic properties for packing food materials are as follows:
The package should be able to protect the nutritional properties of the food till final consumption. Therefore, it is desirable that the package should have sufficient barrier to moisture, gas and light. The package should be cost-effective. The package should be able to enhance the product's sales appeal on the shelf and also give all the statutory information. Hence, the pack should have good optical properties and printability. BOPP films have excellent clarity, transparency and gloss.
The consumption of food and beverage products in the U.S. has grown significantly over the years. Along with this growth has come an increased need for new food packaging solutions that can help extend shelf life while at the same time preserving the flavor and taste of these products. Plastic films are playing a huge role in the development of these new solutions.
So, what are the factors driving the growing demand for new and innovative flexible food packaging? Here are a few:
Increased spending by food and beverage manufacturers to bring new products to market
Desire by manufacturers to improve production efficiency due to the rising costs of labor, food ingredients, and transportation
Growing demand for case-ready packaging products that have improved shelf life
Growing consumer demand for simple, ready-to-eat and ready-to-cook packaged foods
Increased consumer sensitivity to food waste reduction
Think about it. Practically every food product a consumer purchases – whether from a local grocery store, a big box chain, or even online – is packaged in some way. And unless they work in the food and beverage industry, a consumer likely never thinks about how much the product packaging can affect the quality and safety of their purchase.
One of the biggest challenges with food and beverage manufacturing is spoilage. While there are lots of ways a manufacturer can try to limit food spoilage, there are many factors that can lead to it.
Light. When foods and beverages are exposed to light, whether it’s natural or artificial, bad things can happen. Food can become discolored, it can lose its vitamins and nutrients, and flavor can be affected.
Air. Oxidation is a chemical process that occurs when food is exposed to air. The effects can include changes in flavor, color, and vitamin/nutrient loss.
Temperature. When food is exposed to temperatures between 40°F-140°F, there is a greater chance for bacteria growth. In fact, certain foods can see double the amount of bacteria growth within just 20 minutes of increased temperature exposure.
Microorganisms. Bacteria is just one of the microorganisms that can cause food spoilage that can lead to food-borne illness. Other types include fungi like yeast and mold, viruses, and parasites.
Physical Damage. A food or beverage item that’s not packaged well can easily be damaged if it’s dropped or if the packaging rips. This can lead to food spoilage as well.
If spoilage is a concern for your food or beverage brand, there are ways to address it that can be more natural and more cost-effective than adding chemicals such as preservatives to your products.
The use of flexible food packaging solutions such as plastic films can not only help prevent food spoilage but also extend shelf life, which is a top priority for just about every food manufacturer these days.
The types of food products that can benefit from the right kind of food packaging are pretty much endless and can include:
Meats, poultry, and fish
Dairy products
Produce
Snack foods
Bakery products
Deli items
Frozen foods
Semi-solid or liquid foods
Dry foods
Pasta
Spices and powders
Extending the shelf life of products through innovative food packaging film is a win-win for both consumers and food manufacturers.
The consumer gets peace of mind knowing the items they purchase aren’t likely to spoil before they’re able to use them. They can also enjoy the convenience of food packaging that is easier to open, reseal, and even store.
Manufacturers benefit from less inventory waste since products can stay in the warehouse longer. They also benefit from expanded product distribution – since faster transportation methods that prevent spoilage may no longer be needed. Lastly, manufacturers can even expand their product offering thanks to flexible packing solutions that allow them launch products that weren’t possible before due to packaging constraints.
The types of films used in packaging for the food and beverage industry can be broken into segments such as polyethylene, polyester, polypropylene, among others.
At PennPac, we supply a wide variety of packaging films that are designed for direct food contact and meet or exceed FDA regulatory requirements and third-party audit needs for food safety.
Our high-performance BOPP films can be used in applications ranging from snack foods and frozen foods to pet food and treats.
We also carry a large inventory of Polyester (PET) film, which has food-safe properties that won’t contaminate food with chemicals or other materials.
Cast PP films can be a good option for food packaging because they are flexible and fatigue resistant which makes them tear or puncture-resistant.
Perhaps most suited for extending shelf life of food products is our inventory of Metallized films. These types of films offer a strong barrier against oxygen, water, and light.
Many of our Specialty films are commonly used for food and beverage applications and include Forming/Non-Forming films, Lidding film, Easy Peel film, and Sheeted film.
You’re guaranteed to get the best possible plastic films in food packaging when you partner with PennPac. Our facilities are AIB certified and our Manheim, PA location has earned SQF (Safe Quality Food) Certification.
Call 717-664- or us today to connect with one of our experienced team members. Ready to request a quote?
BOPP film is the most in-demand packaging material due to its flexibility and durability. Its strength, versatility, and outstanding mechanical properties make it the best among others. Moreover, what if the packaging material is also cost-effective and eco-friendly?
These are the added perks that make you inclined towards buying a specific packaging material. Amazingly, global BOPP film manufacturers facilitate you with these benefits.
Let’s have a look at the reasons for the popularity of polypropylene films!
Reasons
Amazing properties and benefits
Wide variety of BOPP film rolls
Compatible with countless industries
Decorative purposes
Printability
Edge over paper packaging
Distinctive polypropylene-based film
Environmentally Friendly
BOPP Films Properties & Advantages
They are flexible. Therefore, you can wrap them on various products.
They are water, heat, and chemical resistant.
Food-grade polypropylene films are safe for health.
Above all, they are recyclable and eco-friendly.
BOPP plastic films are lightweight and also easy to wrap.
Equally important, these films increase the shelf life of edibles.
To conclude, BOPP films are cost-effective, strong, versatile, and durable.
Figure 1 Food Grade BOPP Film
BOPP film rolls possess the following astonishing characteristics:
Heat sealable
Ideal surface gloss
Moisture-resistant
Anti-static
Low toxicity
Anti-fogging
Printable
Extended shelf life
Solvent & acid-resistant
Durable
Due to the increasing controversies against the use of plastic, plastic has become taboo. Authorities have banned single-use plastic. To overcome this problem, global BOPP film manufacturers use polypropylene as their raw material. Polypropylene emits the lowest carbon dioxide in contrast with other plastics.
BOPP film manufacturing process is also safe for the environment. This process uses less energy. As the emphasis on energy conservation is increasing, BOPP is taking over conventional (plastic) packaging.
Moreover, BOPP is among the recyclable materials. Therefore, BOPP film manufacturing process takes place without toxic emissions, halogens, or toxic wastes. Thus, causing no hazardous effect on the environment.
The Manufacturing Process of Bopp Film
BOPP is a multi-layer film having polypropylene at its core with several additional layers. When polypropylene is orientated in two directions, it guarantees that the resulting BOPP film has excellent mechanical properties and durability in both these directions
Layers of BOPP film may also contain a combination of appropriate functional additives and polymers that determine its barrier properties, whiteness, opacity, gloss, or matting. So, the manufacturer is in complete control of film properties.
A BOPP film can be produced by several methods but three processes are most commonly used. These include the Tubular process and Tenter Frame Sequential process.
1)Tubular Process
The company is the world’s best Printed BOPP Film supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
In this process, BOPP film manufacturers create the sheet by extruding a thick plastic tube. After that, the tube passes through the stretching heaters and inflates into a tubular bubble.
Then the bubble is compressed, and the lay-flat stretches and gives the sheet its required thickness. Nevertheless, this process is not as commonly used as the tenter frame process.
Figure 2 Tubular Process
2)Tenter Frame Process
In this BOPP film manufacturing process, a thick plastic sheet is softened at a low temperature. Then it is 300 – 400% stretched in two directions.
There are two methods for the biaxial orientation – simultaneous or sequential. In the tubular process and some new-technology tenter frame processes, simultaneous orientation forms BOPP sheets.
However, most commonly, BOPP film manufacturers use sequential orientation to form polypropylene films.
Figure 3 Tenter Frame Process
Polypropylene Film Types
BOPP is available in many types. Namely:
Clear BOPP Plastic Film
These transparent films are most commonly used for food packaging, for example, pulses, nuts, fresh fruits, vegetables & meat, cookies, etc.
Pearlized BOPP Film
Ideal for printing and is a perfect inner sealant for products like chocolate, ice cream, and labels for soda drinks.
BOPP Thermal Lamination Film
It is an ideal solution for two-sided printing. These films are usually used for brochures, shopping bags, textbooks, leaflets, etc.
Matte Polypropylene Film
This film is also suitable for printing. It is appropriate for cable wrapping, printed pouches, and strip packaging.
Printable White BOPP Film
White BOPP plastic film gives fantastic printing results. Also, the fast colors with accurate printing enhance the quality of pouches and labels.
BOPP Film for Adhesive Tape
The versatile properties of BOPP plastic make it adequate for coating and printing. Therefore, manufacturers prefer using these films to create self-adhesive tapes. Furthermore, you can custom-print these tapes as well.
Heat Sealing Film
These films are a perfect solution for applications that require solid and durable sealing. You may get variations in the sealing properties. Some may seal at low temperatures, while some may give you the flexibility to clinch a single side.
Figure 2 White BOPP Film Packaging
BOPP Films Applications
BOPP films are widely used in the packaging industry. If we see in a broad spectrum, they are suitable for:
Bags and pouches
Labels
Wrapping
Adhesive tapes
Let’s elaborate on these four categories. For instance, polypropylene films are functional for:
Packing personal care products
Tamper evident films
BOPP labels
Adhesive tape
Food and beverage packaging
Cigarette packaging
Medical packaging
Lamination
Decorative and industrial applications
Gift wrapping
Flower sleeves
Bagging
Figure 3 Flexible Packaging with BOPP Film
How to Print a BOPP Film?
BOPP films are incredibly versatile and that’s what makes them so good for printing labels. They can be simply white, clear, or transparent, and even metal-colored. With clear BOPP film, transparent labels can be easily created. These are ideal for businesses that want to show the contents of their products with clear containers. By using certain adhesives and inks, BOPP labels can be made waterproof.
The recommendations to print a polypropylene film are:
Flexography printing
Digital printing
Rotogravure printing
Lithography printing
Choosing a specific printing technique depends on your budget, material, design, and graphics.
King Chuan Packaging facilitates you with numerous BOPP plastic films. Therefore, you can choose the best-suited printing method to print your particular BOPP film roll.
However, the most common printing technique that gives you the best results is flexography printing.
Be creative! Print your BOPP Films Label to Captivate the Buyer’s Attention
Another reason behind the increasing popularity of BOPP film rolls is their printability. Beautifully printed BOPP labels are an ideal solution for brands to promote their name.
Purpose of Labels
Consequently, brands use BOPP labels to:
Promote their name
Showcase company’s contact details
Beautify the packaging
Captivate buyer’s attention
Provide you with the product’s specifications
Figure 4 Printed BOPP Labels
Types of BOPP Labels
These labels can be:
White
Metallized
Transparent or opaque
Flexible and squeezable (for tubes)
Not only labels, but you can get printed plastic bags, pouches, wraps, and tapes as well.
Customized BOPP Labels
Do you want customized prints on the BOPP labels?
It is not a big deal. BOPP film manufacturers facilitate you with the opportunity to have custom-made labels.
You can have your brand name, product details, and contact information on the label. As a result, this label is a promotional tool for your brand.
Difference between Paper and BOPP Film Packaging
There are two types of BOPP film manufacturing processes – tubular or tenter frame process. In both methods, the BOPP film manufacturers stretch the film in two directions to make it strong, tensile, and durable.
On the other hand, paper is not as flexible and robust as plastic.
Secondly, polypropylene film is resistant to water, oil, and chemicals. In contrast, paper cannot resist fluids.
A BOPP film is scratch and wear-resistant, unlike paper.
Is Bopp Film Recyclable?
Yes, the Biaxially oriented polypropylene film is recyclable. They have a low density yet excellent stiffness that allows for thin yet durable BOPP films. While recycling, it doesn’t degrade as much as other films. BOPP films can be easily recycled by mixing them in a polypropylene recycling stream. Almost every product made from polypropylene (including BOPP) can be recycled into polymer pallets that can be used for a variety of industrial and commercial applications.
Advantages of Choosing Our Recyclable Packaging Films:
It Protects the Environment: Our recyclable BOPP film packaging is good for the environment as it helps in preserving our precious natural resources. Not only can recyclable BOPP films meet your financial goals, but they can also help you contribute to the environment.
Ensures That the Packaging Is Free of Toxins and Allergens: Traditional packaging materials are manufactured from chemical-laden and synthetic materials that are unhealthy for the consumers as well as harmful for the manufacturers. Our BOPP film packaging is completely non-toxic and free of all types of allergens.
Stunning, Durable, and Eco-Friendly Bopp Films Can Lead to Increased Sales: The demand for eco-friendly products has been growing for the last few decades. Today’s environmentally conscious consumers prefer eco-friendly products that do not harm their health and the environment in any way. Choosing stunning and durable BOPP films for your packaging needs can help you attract more customers to your business.
BOPP Packaging Films Are Flexible and Versatile: Eco-friendly BOPP films are some of the most versatile packaging options out there. They can be easily recycled to be used in many other industries. Whether you want a perfect film for medical packaging or personal care product packaging, there will be a suitable BOPP film to meet your packaging needs.
Our Highest Quality BOPP Films Can Help Enhance Your Brand Image: Having high-quality eco-friendly packaging material like BOPP films on the products can help you create a good brand image for your business. This will also show the customers that they are dealing with a responsible company that cares about the environment.
Upcoming Trends for BOPP Films
The rapidly growing packaging industry is increasing the demand for packaging material.
Because of its extraordinary qualities, BOPP plastic film is taking over traditional packaging materials (metal and paper).
Furthermore, the packaging industry prefers using polypropylene films as they are easy to use and lightweight.
According to recent research, the international market demand for BOPP film was $24.2 billion in . It is projected that, by , it will grow to $31.4 billion.
Hence, these statistics show that investing in the plastic industry is profitable. Indeed, your business will get a boost by dealing in eco-friendly BOPP plastic film rolls.
For example, if you are related to food packaging, BOPP is an appropriate solution for you. Highly sterilized BOPP films are food safe. Additionally, they prevent food from contamination.
These easy to wrap films are widely used for pet food, baby food, frozen meals, etc. Briefly, your investments are secure while dealing with polypropylene films.
Figure 5 Food Packaging with BOPP Film
Final Verdict
As mentioned, BOPP films cover all the aspects of life, so it is eventually the best choice! We are positive that now when you know a long list of benefits of polypropylene film, your next choice in business or daily chores will be BOPP films. Get started right away, and don’t miss out on these fantastic compensations.
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