Creating value and sustainable solutions: Case studies on ...€¦ · Creating value and...

Creating value and sustainable solutions: Case studies on what’s possible in packaging design

Images used in this presentation are either owned by ExxonMobil or are used with permission.

Market needs from around the world drive innovation

OEMs

Packagers

Consumers Retailers

Brand owners

Converters

Value-added solutions

2

Packaging market needs

3

Cost savings Integrity/Durability Aesthetics Convenience Sustainability

Downgauging

Processability

Simplified solution

Toughness

Stiffness

Shrinkability

Transparency

Printability

High gloss

Package features

Ease of use

Single serving

Reduce waste

Resource efficiency

Recyclability

Overview

4

• Challenge reality of rigid packaging design

• When eXtreme Performance matters in flexible packaging

• Synergy solution of Exceed™ XP + ExxonMobil™ PP

Process performance

Pro

du

ct p

erf

orm

an

ce

ExxonMobil™ PP

Delivers consistent, high-quality products for high-performing applications. For almost 60 years, ExxonMobil has shown commitment to its customers with reliable supply, global support and technical expertise.

Achieve™ Advanced PP

Challenge reality and rethink what’s possible. Achieve Advanced PP offers a significant step beyond traditional PP performance by eliminating tradeoffs and unlocking new opportunities for customers.

ExxonMobil™ PP


ExxonMobil Chemical polypropylene business

5

Challenge reality and rethink what’s possible in packaging design with Achieve™ Advanced PP


Achieve™ Advanced PP high melt strength platform

High melt strength can bring value in thermoforming by enabling:

• Sheet sag resistance• Higher filler loadings• Higher recycle content• Uniform distribution• Wider process window

7

Data from tests performed by or on behalf of ExxonMobil

0

0.1

0.2

0.3

0.4

0.5

0 1 2 3 4 5

Pu

ll o

ff f

orc

e F

(N

)

Draw Ratio

Achieve™ Advanced PP6282NE2, 40.5 cN

ExxonMobil™ PP6272NE1, 6.9 cN

Reference high stiffness grade, 6.7 cN

17

20

23

Achieve™ Advanced PP6282NE2 Reference PP

Cy

cle

s/m

in

20

40

60

80

7 8 9 10 11 12

To

p L

oa

d, l

bf

Cup Weight, g

Achieve™ Advanced PP6282NE2

Reference PP

12% improvement


Case 1: Do more with less and faster! -16 oz clear cup example

Up to 17% lighter with excellent clarity

Reduce material and cost per part while maintaining stiffness and <6% haze

12% more productivity

Achieve Advanced PP eliminates the trade-off between productivity and downgauging.

Part weight reduced

8


0

4

8

12

Achieve Advanced PP PP6272NE1

Wa

ter

Va

po

r T

ran

smis

sio

n R

ate

,g

m-m

il/(m

2/d

ay)

Improved water barrier

0

100

200

300

Achieve Advanced PP PP6272NE1

Ox

yg

en

Tra

nsm

issi

on

Ra

te,

cc-m

il/(

10

0in

2/d

ay)

Improved oxygen barrier


Case 2: Improved barrier properties

37% Improvement

29% Improvement

ExxonMobil™ PP6272NE1 ExxonMobil™ PP6272NE1

Longer shelf life? Thinner barrier layers for cost savings?

9



Rethink what’s possible in rigid packaging design with Achieve™ Advanced PP

High stiffness AND

processability

12% more productivity

Improved processing window

Cost savings along value

chain

Up to 17% light weighting

>60% filler loading

New performance

standards and more

High melt strength

Non-phthalate catalyst system

Improved barrier

10

Exceed™ XP performance PE polymers

11

when eXtreme Performance matters

Introducing Exceed™ XP performance PE polymers

12

Processability

Me

cha

nic

al p

rop

ert

ies

LLDPE

LLDPE

blends LDPE

blendsLDPE

Exceed™

Enable™

Exceed™ XP

Exceed™ XP Exceed™

when eXtreme Performance matters

A new balance of toughness, sealing, and stiffness, combined with easier processing at lower energy

for superior toughness

Excellent mechanical performance for down-gauging/light-weighting, withoutstanding sealing properties

and best-in-class optics

Enable™

for optimum solutions

Combining excellent processing and bubble stability with toughness not realized in LDPE blends

Exceed™ XP, Exceed™ and Enable™ performance polymers

Product (for 25 µm mono film) MD Tear (g) TD Tear (g)

Exceed XP 8656 500 540

Exceed 1018 255 413

C8 ZN LLDPE (1.0, 0.920) 425 625

C8 mLLDPE (1.0, 0.916) 232 600


Step-out mechanical performance

13

Improving performance

Typical co-ex pillow

pack for liquids

Maximum limit of Dart A method

Typical co-ex

bag-in-box liner

High

performance plastomer-richbag-in-box liner

Exceed XP 8318

Exceed XP 8358

Exceed XP 8656,

50 µm – 1/3/1 structures

Imp

rovi

ng

per

form

ance

Exceed™ XP, Exceed™ and Enable™ performance polymers


Extreme Dart impact

Exceptional flex-crack resistance

Outstanding MD tear with high machine orientation

Exceed XP performance PE polymers enabled up to

30% downgauging

1.5 meter dropping

height

Empty bag

1kg MDS for frozen food packaging45 million food units processed per year~25% of the formulation or 150Ton of C8LL used in packaging

Frozen food package filling line

Additional value

• Reduce clean up labor

• Reduce product and packaging waste

• Lower customer complaint

• Reduce cross contamination risk

Up to

2.7kTonof CO2 reduction per year*


Case 3: Packaging integrity for food waste reduction

14

ExxonMobil solutionReference25% Exceed™ XP

performance PE polymer25% C8LL

Data from tests performed by or on behalf of ExxonMobil*Data based on Food LCA database developed by University of Michigan

Bag failure rate:

Food pack wasted/yr:

Up to

$700,000 total annual savings from food waste reduction

2%

900,000

0.096%

43,200

ExxonMobil solution

PE: 98 μm

100% Exceed™ XP performance PE polymer in core layer

Lamination: 100% PET, 12 mm

Up to 17% raw material cost savings from Exceed XP performance PE polymer

• Better drop

• Better seal strength

• Better tear resistance

• Matching stiffness as BOPA formulation

* Data based on ExxonMobil analysis


Case 4: Inter-material replacement for cost saving

15

Additional value

ReferenceLamination: 100% BOPA, 15 mm

PE: 98 μm

Lamination material unit cost (per ton)

BOPA ($4,800/ton*) PET ($1,800/ton*)1kg

liquid pouch

10

30

50

70

859095100105110115120125130

Cre

ep

TD

(%

)

Gauge (µm)

Exceed & Enable

37.5% Exceed 101838.5% Enable 200530% HDPE4.5% WMB

Exceed XP & HDPE

55.5% Exceed XP 835840% HDPE4.5% WMB

Exceed XP + ExxonMobil™ PP

75.5% Exceed XP 835820% ExxonMobil PP4.5% WMB

Note: HDS solution each layer might contain some additives, like anti-block, anti-UV, etc.

All data points shown passed drop test

Exceed™ XP, Exceed™, and Enable™ performance polymers


Outstanding creep resistance for heavy duty sacks

16Data from tests performed by or on behalf of ExxonMobil

> 25% Potential downgauge opportunityvs industry standard 125µm solution

-10

10

30

50

70

40 60 80 100 120 140 160

Sh

rin

kag

e M

D (

%)

Temperature (ºC)


High temperature performance

Lower creep at higher temperature and higher load

Exceed XP & HDPE

100µm

Exceed XP & ExxonMobil™ PP90µm

No shrinkage

Up to 140ºC

29%

70%


0.7kg 0.8kg 1.0kg

0

10

20

30

40

50

Cre

ep

TD

@ 5

hrs

(%

)

50ºC 60ºC 70ºC

0.8kg 0.7kg

Exceed™ XP performance polymers


Dart impact[0-1000g]

Elmendorf tear MD[0-750g]

Tensile at break MD[0-85N]

1% secant modulusMD

[0-900N]

1% secant modulusTD

[0-900N]

Creep at 1kg, 50ºC,TD

[50-10%]


Outstanding mechanical performance for heavy duty sacks

Reference

110µm

Exceed XP & HDPE

100µm

Exceed XP & ExxonMobil™ PP90µm

Exceed XP + ExxonMobil PP benefits:

• Higher dart impact

• Higher MD tear resistance

• Higher creep resistance

Derived benefits and value:

• Potential 20% downgauging opportunity

• Passed 2 meter bag drop test

• Improved heat and creep resistance


Exceed™ XP, Exceed™, and Enable™ performance polymers


Dart impact[0-15g/µm]

Elmendorf tear MD[0-10g/µm]

Elmendorf tear TD[0-20g/µm]

Puncture force[0-60mN/µm]

Tensile strength atbreak MD[0-50MPa]

1% secant modulusMD

[0-600MPa]


Post-industrial recycling

Exceed XP & ExxonMobil™ PP Virgin solution

Exceed XP & ExxonMobil PPRecycle reincorporation solution

Including 25% one pass regrind

Key findings:

• No degradation to film properties and no processing issue when incorporating recycled material

• No issues during pelletization

• PE and PP do not delaminate

Exceed™ XP performance polymers

Note: HDS solution each layer might contain some additives, like anti-block, anti-UV, etc. 19

Up to +21% more bags per roll!

Reference solution:4.6 mil/117 µm

Exceed XP + ExxonMobil™ PP synergy solution:3.8 mil / 97 µm


Case 5: Value creation in HDS downgauging

20

• Hot fill capability

• Better creep resistance

• Passed bag drop test

• Sustainability: resource efficiency

Additional value 3,263

Bags per 300 kg roll

3,964

701 extra bags

when eXtreme Performance matters in flexible packaging

21

Introducing Exceed™ XP + ExxonMobil™ PP synergy

Downgauging

Unlock new markets

Performance & reliability

Increased stiffness

High temperature resistance

Reduced deformation(creep resistance)

Collaborating with the value chain

22

Equipmentsuppliers

Converters Brandowners

Packagers Retailers Consumers

@XOM_chemical

linkedin.com/showcase/exxonmobil-chemical

www.exxonmobilchemical.com/HDS

exxonmobilchemical.com/HDSexxonmobilchemical.com/HDS

https://twitter.com/XOM_Chemical

https://www.linkedin.com/showcase/exxonmobil-chemical/

http://exxonmobilchemical.com/HDS

http://exxonmobilchemical.com/HDS

Copyright 2019 ExxonMobil. ExxonMobil, the ExxonMobil logo, the interlocking “X” device and other product or service names used herein are trademarks of ExxonMobil, unless indicated otherwise. This document may not be distributed, displayed, copied or alteredwithout ExxonMobil's prior written authorization. To the extent ExxonMobil authorizes distributing, displaying and/or copying of this document, the user may do so only if the document is unaltered and complete, including all of its headers, footers, disclaimers and otherinformation. You may not copy this document to or reproduce it in whole or in part on a website. ExxonMobil does not guarantee the typical (or other) values. Any data included herein is based upon analysis of representative samples and not the actual product shipped.The information in this document relates only to the named product or materials when not in combination with any other product or materials. We based the information on data believed to be reliable on the date compiled, but we do not represent, warrant, orotherwise guarantee, expressly or impliedly, the merchantability, fitness for a particular purpose, freedom from patent infringement, suitability, accuracy, reliability, or completeness of this information or the products, materials or processes described. The user is solelyresponsible for all determinations regarding any use of material or product and any process in its territories of interest. We expressly disclaim liability for any loss, damage or injury directly or indirectly suffered or incurred as a result of or related to anyone using or relyingon any of the information in this document. This document is not an endorsement of any non-ExxonMobil product or process, and we expressly disclaim any contrary implication. The terms “we,” “our,” "ExxonMobil Chemical" and "ExxonMobil" are each used forconvenience, and may include any one or more of ExxonMobil Chemical Company, Exxon Mobil Corporation, or any affiliate either directly or indirectly stewarded.

Test Method based on

MI (Melt Index) ASTM D-1238

Density ASTM D-4703 and ASTM D-1505 / ISO 1183

Melt Flow Ratio (MFR) ASTM D-1238

Flow behavior- Capillary and Oscillatory Rheology EMC methods

Tensiles tests ASTM D-882

Dart Impact ASTM D-1709 (procedure A)

Elmendorf tear ASTM D 1922-09

Puncture resistance EMC method

Puncture needle test CEN 14471 (probe diameter = 0.8 mm)

Holes after flex EMC method (Gelbo device)

Shrinkage tester: Betex EMC method

Shrink force measurement by Retratech ISO14616

Lab aging test(Tensile test/Carbonyl test) ISO 4892-2 at Norner (ISO527-3/Norner method M730849)

Melt Strength ExxonMobil - RHE04-4.2, 190°C

Flex Modulus 0.05 in/min ASTM D790A, 1% secant

Oxygen Transmission Rate ExxonMobil PLSL-650.002, Mocon Ox-Tran®

Water Vapor Transmission Rate ExxonMobil PLSL-652.002, Mocon Permatran-W®

Inverted Top Load ASTM D2659, test completed at 3rd party labs

Haze ASTM D1003-13, test completed at 3rd party labs

Test methods

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