v

Exploiting multilayer flexibility for high performance Polyethylene films

Cologne, 25-26 November 2008

Alberto Ronzani, SABIC EUROPE

Scope

Flexible packaging: current macro trends

Multilayer applied to non barrier films: technical and economic benefits

Conclusions

Converters are increasingly under pressure

ENERGY SUPPLIERS

CONVERTER FMCG Brand owners

Consumer Polymerssuppliers

Retailer

Economic of film production

Gross Margin 3,4%

Packaging 1,3%

Resin Price 70%

Overheads 9,4%

Utilities 4,3%

R&D 4,3%

Sales 5,1%

Labor 2,2%

Source: Maack Business Services

Blown film producer capacity 2,5kt/y

Converters are increasingly under pressure

International & NationalRegulation

Packaging taxesC02 reductionRecycling

Media interest in the environment & sustainable development

Corporate Social

Responsibility

Carbon & environmental footprints

Packaging scorecardsPackaging reduction

ENERGY SUPPLIERS

CONVERTER FMCG Brand owners

Consumer Polymerssuppliers

Retailer

Co-extrusion enables :

– New formulations concepts with contrasting film properties

– Down gauging & cost reduction with retained or improved film properties

– Reduced # of production steps per packaging structure

Monolayer, 100% LDPE

Blends of LDPE/LLDPE

Multi-layer of LDPE & LLDPE

1980

2010

Multi-layer including m-LLDPE

Multi-layer with diversity of base materials

monolayer

≥ 5 layers

Film Co-extrusion is nowadays a standard tool

Innovation by resins combination and more layers

Innovation will be realized by solutions based on the right combination of base resins rather than new enhanced resins

LDPE

LDPE

C4-LLDPE

C4-LLDPE

LDPE

m-LLDPE

EVA

EVA

C4-LLDPE

LDPE

m-LLDPE

EVAVLDPE PP

Bi-HDPE

HAO-LLDPE

HDPE

HAO-LLDPE

MDPE

Reclaim

Nu

mb

er of b

uild

ing

blo

cks/com

plexity

Inn

ova

tive

po

wer

/do

wn

gau

gin

g

PA

Converters with co-extrusion capability have a higher flexibility in using a wide raw materials variety

Inter material competition and increased flexibility allow to enhance performance at lower cost

Cost & quality improvement with 5 layers approach

Sabic PE based 5 layers vs. state of the art 3 layersfilms with improved:

1) Cost/quality ratio

– Diapers compression packaging

– Beverage collation shrink

2) Properties & functionalities

– Stand up and retortable pouches

Case 1: Diaper compression packaging

Use

Packaging of diaper ,insulation materials, rockwool, foams, textile articles & waste

Reduce transport and storage costs

Key features

Sealing properties

Puncture and tear propagation resistance

Creep and expansion

Case 1: Diaper compression packaging

•What:Replace 3 layers film by 5 layers structure

•Value proposition:Realize 20% downgauging of market reference film, with cost

competitive solution.

•Performance proposition Match market leader specs of 70μ with new developed 55μ film

•ApplicationDiapers compression film (Jumbo pack 72 diapers 7-18 kg baby)

Case 1: Diaper compression packaging

60% C6LL / 40% LD60% HDPE / 40% C6LL

60% C6LL / 40% LDPE

60% HDPE / 40% C6LL

80% LD / 20% C6 LL

Mat.l Grades used

C6LL Sabic 6118NE (0.918 / 1.0 )

LDPE Sabic 2201TH12 (0.922/ 0.85, Slip/AB)

HDPE Sabic F04660 (0.961/ 0.7 (2.16/190°C))

Ref. film 3 layers:thickness 70μ mLL, EVA based

5 layers alternative:thickness 55μC6 LL, HD, LD based

75% mLL/ 25% LD

70% mLL/30%EVA

75% mLL/ 25% LD 18

34

18

155

155

15

Case 1 Diaper compression packaging: SEAL Strength

Sealing strength on 4 bag plies is most critical property

P&G 50μ P&G 70μ

13 N 15,7 N

P&G 50μ P&G 70μ

28 N 34,8 N

Sabic 55μ

38N

Sabic 55μ

69N

Bags sealed, formed and tested by Lemo GmbH

Patent application filed

2.2

2.1

2.2

2.1

Case 1 Diaper compression packaging: results

Critical specifications for package type fulfilled (P&G Seal strength and mechanical properties)

Cost savings 5 vs. 3 Layers film*:

20 % thickness reduction

~ 60€/t raw material~ 6c€/m2 film saving

~ 1,5 M€/y Raw material per m2 film~ 144k €/y Raw material per KG film

*2008 PE delta prices, 300 working days/y, line 400kg/h

Use

Packaging of 6 bottles water packs,

or beer cans

400 kt/y in Europe, growth 2,5% p.a

Key features

Puncture and tear propagation resistance

Optical properties

Shrink force

Average thickness is around 50-55 μ

3 layers films technology enables ~40 μ

Unfulfilled market request down gauge below 40 μ

Case 2: Beverage collation shrink

Case 2: Beverage collation shrink

•What:Replace 3 layers film by 5 layers structure

•Value proposition:Realize 12 to 20% downgauging of market reference film,

with cost competitive solution.

•Perfomance propositionMatch 45μ film properties with newly developed of 35μ

•ApplicationCollation shrink for 6 bottles (1,5L) pack

Case 2: Beverage collation shrink

5 layers alternative:thickness 35μLD, HD , C4 LL based

85% C4 LL / 15% LD

50% HDPE / 50% LD

70% LDPE / 30% HDPE

50% HDPE / 50% LD

85% C4 LL / 15% LD

Reference film 3 layers:thickness 45μ mLL, LD based

5

4

17

4

5

Type Grade used

C4LL Sabic 726N (0.926 / 0.7 )

LDPE Sabic 2600TC00 (0.926 / 0.3)

HDPE Sabic F04660 (0.961/ 0.7 (2.16/190°C) )

9

27

985% mLL/ 15% LD

80% LD/20% HD

85% mLL/ 15% LD

Case 2: Beverage collation shrink, results

Cost savings 5 vs. 3 Layers film:23% thickness reduction

~ 120€/t raw material~ 2,5 c€/m2 film

~1,8 M€/y Raw material per m2 film~345 k€/y Raw material per KG film

Reference film specifications matched (Shrink % & force, tensile & optical properties)

First shrink tunnels trials successful

Case 3: Stand up pouches

Use

Food, Petfood, Beverages, retortable

230 kt/y (180 PE, 50 PP) in Europe, 12% yearly growth.

Key features

Balanced mechanicals (High stiffness and good toughness)

Good sealing and hot tack strength

Easy tear characteristics along the perforation

Good organoleptic properties and FDA/ food contact approval

Special requirements:

Sterilisable at 121°C - 30 min

Increased barrier to Water vapour, easy tear

Case 3: Stand up pouches•What:

Develop new multilayer film structure for SUP

•Value proposition:Add extra film functionalities, without lamination step

•Perfomance propositionIncrease barrier to WVTR, easy tear, heat resistance andtransparency

•ApplicationStand up pouch for food packaging, transparent & retortable

Case 3: Stand up pouches better WVTR barrier

Barrier improvement thanks to thin functional HDPE layer

Alternative film:5 layers, 65μ and 70μ:

80% mLL/ 20% LD

60% LD / 20% mLL20% HD

80% mLL/ 20% LD

80% C6 LL / 20% LD

100% HDPE SABIC F04660

80% LD / 20% C6 LL

100% HDPE SABIC F04660

80% C6 LL / 20% LD

Reference film 3 layers, 70μ:

Case 3: HDPE SUP, WVTR and Tear resistance

Full HDPE layers enable increased WVTR and easy tear opening

20 % HD in 5 layers equals WVTR of 70% HD in 3 layer

8,6

4,44,0

2,83,9

8,0

0

1

2

3

4

5

6

7

8

9

reference 2X 5μ HD 2X 7,5μ HD

WV

TR

(g/m

².d

ay)*

0

9

Tear

MD

g/μ

*38°C, 90% R.H.

Case 3: Stand up pouches, retortable

Retorting thanks to functional layers of PP Raco

5 layers film alternative:

80% mLL/ 20% LD

80% LD / 20% mLL

80% mLL/ 20% LD

PP Raco 680K40% C6LL/ 40% mLL/ 20% LD

70% C6 LL / 30% LD

40% C6LL/ 40% mLL/ 20% LD

PP Raco 680K

Reference film 3 layers:

Case 3 Stand up pouches: seal curve after sterilization

0,0

5,0

10,0

15,0

20,0

25,0

30,0

110 120 130 140 150 160 170

Seal bar temperature [°C]

Se

al

forc

e [

N/2

4m

m]

1h at 121°C Reference

Addition of PP Raco enables seal integrity after sterilization

Brüger seal/Zwick tensile test conditionsSeal bar pressure: 0.3 N/mm², Dwell time: 1.0 secSeal bars width/length (mm): 10 , 150Sample width/length (mm): 24, 50Deformation speed: 200mm/min

Case 3: Stand up pouches, conclusions

Properties profile extension main driver to apply 5 layers to SUP film

Additional layers enable lower WVTR (HDPE) and heat sterilization (PP).

PP/PE lamination step can be avoided in some cases

Conclusions

➨A multilayer approach brings clear advantages to film producers also for non barrier films

➨Cost reduction and properties profile extension can be achieved by a more rational and specific raw materials use

26

Visit us at our conference table top