The market is witnessing the growing trend of BOPP packaging and the use of PP Filler Masterbatch in its productions. Let’s delve into the details!
BOPP packaging is getting more and more popular in the market. Many manufacturers choose this material for their products due to durability, printability, and environmental benefits.
In BOPP packaging production, PP Filler Masterbatch is one of the crucial ingredients, guaranteeing high-quality products and helping manufacturers save production costs.
This article will provide an in-depth insight into BOPP film, its growing trend, and how PP Filler Masterbatch plays a role in its production.
Follow along!
1. Understanding BOPP Packaging
BOPP packaging refers to packaging made from a plastic film called “Biaxially Oriented Polypropylene” (BOPP). This film is used in many applications, including food and beverage packaging, labeling and branding, laminating, tamper-evident films, personal care product packaging, medical packaging, adhesive tape, and agricultural films.
BOPP film is renowned for its superior transparency and strong tensile strength since it is made from PP plastic polymers and additives, such as PP filler masterbatch. Because of its low density of 0.90 g/m3, it is sometimes referred to as a thin film and has a thickness of 10–40 microns.
The material is becoming more and more popular. According to FactMR, the market size of BOPP packaging is expected to reach $25.9 billion in 2024. Besides, the worldwide sales of BOPP film are forecasted to grow at a CAFR of 5.6%. Experts also predict its market value will reach $44.6 billion in 2034.
Many reasons drive this market-growing trend:
- The BOPP packaging, with its high tensile strength, printability, and clarity, has become a preferable choice for many manufacturers.
- It can be used in many sectors, including food and beverages, healthcare, and consumer products, leading to market expansion.
- Thanks to the development of production technology, BOPP packaging can be customized to meet the aesthetic and functional requirements of individuals.
- BOPP film is recyclable and suitable for the growing concern about the environment.
The BOPP packaging production process includes 8 steps:
- Step 1. Raw material feeding
Isotactic Polypropylene, a semi-crystalline, thermoplastic polymer, is the primary raw material in the center layer. The outer layers, however, are made of ethylene-propylene copolymers and/or ethylene-butane-propylene copolymers. These ingredients are added to the extruders using a hopper mechanism.
- Step 2. Extrusion
Before the ingredients are fed into the extrusion head, where they form a foil, they are melted and heated to 200–230°C within the extruders.
- Step 3. The foil cooling
After that, the foil is placed directly in touch with a cooled cylinder, which is then immersed in a water bath to cool the melt.
- Step 4. Machine direction orientation (MDO)
BOPP film undergoes longitudinal stretching by being passed over rollers. Here, the temperature is increased to prepare for the machine’s direction.
After stretching up to five times its initial length, the polymer chains align, enhancing the film’s mechanical properties and enabling a five-fold decrease in thickness.
The film is then heated during the annealing process to release the tension produced during the stretching phase.
- Step 5. Transverse direction orientation (TDO)
Once the film leaves the longitudinal stretching zone, it is grabbed on both edges by a chain of metal jaws. After being heated in an oven, the film is stretched transversely by diverging rails. It improves the mechanical properties of the film and reduces its thickness by up to nine times by aligning macromolecules in a transverse orientation. The BOPP film is able to balance the stress from the stretching phase when the chain and film converge after stretching.
- Step 6. Thickness measurement and flame treatment
In this step of BOPP packaging production, the thickness of the film is automatically measured throughout its breadth in a new manufacturing phase. To get it ready for conversion procedures like printing, laminating, or metallization—where it alters its surface to act as an anchor for materials—one surface is treated with flame or corona.
- Step 7. Reel winding
The film is wrapped around a reel and then chopped to the required lengths.
- Step 8. Film measurements
The major metrics that the finished product is subject to are as follows:
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- Density, thickness, and grammage
- Tensile strength, elongation at break, and elastic modulus
- Gloss (sparkly look) and Haze (opacity)
- Between films and between films and metals, the coefficient of friction
- Sealing strength and °C threshold
- Stability of temperature (heat shrinkage)
The thickest layer of the three layers, which range in thickness from 15 to 60 microns, is mostly in charge of the mechanical qualities of the BOPP film. The outer layers have the ability to seal heat. Depending on its intended purpose, additives may be added to the film to satisfy application criteria.
Read more: BOPP Film: A Complete Guide to Its Properties and Uses
2. PP Filler Masterbatch: The Game Changer in BOPP Packaging Production
2.1. What is PP Filler Masterbatch?
PP Filler Masterbatch is made of polypropylene (PP) resin, calcium carbonate (CaCO3) powder, and other additives. The material offers toughness and durability, allowing it to be applied in different types of packaging, including food packaging, animal feed packaging, seeds packaging, fertilizers packaging, chemicals packaging, etc.
2.2. Benefits of PP Filler Masterbatch in BOPP Packaging Production
PP Filler Masterbatch is a common material in BOPP packaging production since it offers several advantages, including:
- Reduced cost: PP Filler Masterbatch replaces a large portion of expensive PP virgin resin, leading to a lower production cost. Yet, at the same time, it maintains the quality and functionality of the final products.
- Enhanced mechanical properties: BOPP film will have better tensile strength, stiffness, and tear resistance due to the use of PP Filler Masterbatch. Therefore, the packaging is also more durable.
- Improved dimensional stability: The material can reduce wrapping and shrinkage, allowing consistent dimensions of the packages.
- Better printability: If you need BOPP packaging with clearer printed designs, this filler masterbatch is a great help. It can improve the surface of BOPP film, offering better ink adhesion.
- Opacity: Certain BOPP film require a certain level of opacity. Using the appropriate type of PP Filler Masterbatch can help manufacturers adjust the BOPP packaging production process to meet the desired requirements.
- Eco-friendliness: Using PP Filler Masterbatch instead of some amount of virgin resin can benefit the environment and support sustainable development.
3. EuP Egypt – The World’s Leading PP Filler Masterbatch Manufacturer
EuP Egypt is proud to introduce one of our flagship products, the PP Filler Masterbatch. With 20 years of manufacturing and supplying filler masterbatch for thousands of companies worldwide, we’ve gained the trust of all our clients.
Our PP Filler Masterbatch offers strong breaking strength, improves several properties of end-products (such as brightness, opacity, shrinkage reduction, etc.), and enhances product elongation. It’s suitable for extrusion, blow film, and injection molding. Since the PP Filler Masterbatch can cool quickly, it enhances extruder productivity and decreases processing time. Thanks to the CaCO3’s great thermal transmission ability, the material saves energy and lowers production costs for companies.
Contact us now for an all-function-in-one and cost-saving solution!
4. Conclusion
BOPP packaging, made from polypropylene resin, is a popular choice in many industries, including food, consumer goods, cosmetics, etc. The BOPP film is stretched in machine and transverse directions, aligning the polymer chains and providing it with unique features.
Thanks to its outstanding properties and versatility, BOPP film is expected to be more widespread in the packaging industry.
