Extrusion Lamination Model - Institute of Packaging Professionals
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The Dow Chemical Company
Extrusion Coating & Lamination
EMEA Market and Portfolio Overview
Carolina Gregorio Bernard Fehr
Market Manager Technical Service & Development Lead
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Global Extrusion Coating(2.108 kta, 2.7% Growth)
Blow Molding14%
Injection Molding10%
Pipe/Conduit9%
Extrusion Coating3%
Wire & Cable3%
Other Extrusion4%
Rotomolding2%
Other Non-Extrusion4%
Film52%
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Source: TPER & IHS
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
EMEA Extrusion Coating Market(880 kta, 2.6% growth – Regional : WE – 2.2%, EE – 2.7%, MET – 3.7%, Africa – 4.3%)
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By Region By Polymer
Source: TPER 2014, IHS 2016
Note: Numbers may not sum up due to rounding
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
EMEA Extrusion Coating Market(880 kta, Growth rates: WE – 2.2%, EE – 2.7%, MET – 3.7%, Africa – 4.3%)
4Source: AWA 2015Note: Numbers may not sum up due to rounding
Segment(Growth Rate2015-25)
Applications
FlexiblePackaging(2.2%)
Food:Bags and wrappers for cereals, confectionary, ice cream,retail. Pouches for meat, powdered foods, soups, sugar.Non-food: Bags and sachets for pet food, pharma, medical,fertilizers.
Liquid Packaging(3.0%)
Gable top and aseptic liquid cartons for beverages &semi-solid foods (purées, sauces, soups…)
Photographic(1.0%)
Color and monochrome prints, graphic arts
Commercial(3.2%)
Highly fragmented segment:1. 23% - Packaging boards: folding cartons for food
(frozen foods, detergents), tableware & ovenable2. 39% - Packaging paper: mil wrappers, ream wrapping,
industrial sacks, industrial wrappers (steel), envelopes3. 38% - Technical: medical/hygiene, release liners
(labels), Insulation facings, building membranes, cablewrap, wall coverings
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Key Markets Trends
Flexible Packaging
Beverage Packaging
Key Trends:•Stand-up Pouch Growth• Convenience•Light weighting•Extended shelf life•Opportunistic eaters
Key Trends:•Milk consumption•Energy drinks, beer consumption•Semi-liquid foods•Pouch fruit juices
European Beverage Market(‘13-’18) by Pack Type
Total Sweet & Savory Snack Market Growth (WE & EE)3.1-3.6% Growth YOY
0,00
500,00
1.000,00
1.500,00
2.000,00
2.500,00
3.000,00
3.500,00
2014 2015 2016 2017 2018 2019
Pack typeEastern Europe
2013-18 CAGR %Western Europe2013-18 CAGR %
Total Beverage Packaging 1.90 0.90
Metal 4.70 1.50
Rigid Plastic 1.50 1.40
Glass 1.60 -0.40
Liquid Cartons 0.80 1.20
Paper-based Containers 1.40 3.10
Flexible Packaging 1.20 1.40
5Source: Euromonitor
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.6
DOW
CONFID
ENTIAL -
DoNot
Share
With
Cost pressures on highvolume applications
Fully used equipmentcapability
LDPEs and New! AGILITY deliverfast coating and thinner gauges
Convenience drives demandfor takeaway foods, growing
demand for pouches andsmall cartons
Improve packagingintegrity - LLDPE in ECgrowing at 4% annually
ELITE™ & AFFINITY™ for highperformance sealing, improved
hot tack
Trend Impact Solution
Pouches for food andbeverages grow >8%
annually
E/C offers ease and speedof conversion for long runs
AMPLIFY™ TY & PRIMACOR™for long term adhesion in barrier
laminates
Specialty papers & someliquid cartons require higher
WVTR resistance/smoothsurfaces
HDPE in EC growing at 4.0%annually
New! DOWLEX 2006G offers higherbarrier and WVTR resistance and
good surface flatness
Market Trends Drive Our Industry Leading Portfolio
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Resin Trends
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High Melt Strength LDPEs makes up 77% of the PE use in E/C
- LDPE usage in extrusion coating growing at 2.5% annually
- Old autoclave plants -“newest” built in early 1960s- and no additional capacity planned
- Critical requirement for high melt strength resins which deliver low neck-in
High performance mLLDPEs usage is growing
- LLDPE usage in extrusion coating growing at 4.0% annually
- Improved seal performance driven by food safety and packaging machine efficiency
- Demand driven by both paper packaging and extrusion lamination
HDPEs growing use in blends
- Supports efficient use and costs optimization in conversion
- Offers higher temperature resistance and smooth surfaces
- Adhesion and seal initiation performance trade-off?
Source: TPER
Dow’s Portfolio
ELITE™ AT
Basics to Breakthroughs
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DOW™ LDPE
HDPEPro
du
ct
Fam
ily
Pro
posit
ion
s
Performance / Functionality Specialization
Butene CEFORTM
DOWLEX™
ELITE™
ATTANE™
AFFINITY™
PRIMACOR™
SARAN™ PVDC
AGILITY™
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Extrusion Coating Focus
INFUSE™ OBC
AMPLIFY™ TY
AMPLIFY™ EA
AMPLIFY™ IO
SEALUTION™Peel Polymers
COSEAL™Cold-Seal Adh
ROBOND™Waterborne Adh
MOR-FREE™Solventless Adh
ADCOTE™Adhesives & Coatings
ENGAGE™VERSIFY ™
LDPE and HDPEs for Sealing, WVTR & Stiffness
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Product Melt Index Density Applications
LDPE PG 7004 4.1 0.921 General paperboard coating
LDPE PT 7007 7.5 0.918 General purpose extrusion lamination
LDPE PG 7008 7.5 0.918 Versatile Extrusion lamination
LDPE 7010E 8.5 0.919 High-speed extrusion lamination and liquid paperboard packaging
DOW LDPE 770G 2.3 0.918 Blend partner for higher alpha-olefin copolymers
DOWLEX™ 2006G 8.0 0.962 HDPE for Stiffness, WVTR
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
laminate (aseptic)
25g/m² coatings at 100mpm on Kraft paper - Tset 320°C
High Performance Sealants & ESCR
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Product Melt Index Density Notes
ELITE™ 5811 8.0 0.919 Ready to use – general purpose abuse and sealant
ELITE™ 5800G 12 0.911 Ready to use – high speed sealant
ELITE™ 5860 22 0.908 Blendable – high speed sealant
AFFINITY™ PT1451G1 7.5 0.902 Ready to use – high performance sealing
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Heat Seal Strength [N/15mm] Hot-Tack Strength [N/15mm]
High Performance Sealants & ESCR
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®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Environmental Stress Crack Resistance (ESCR Bell Test )
PRIMACOR™ – EAA for Substrate Adhesion
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Product Melt Index Density % Comonomer
PRIMACOR™ 3002 9.8 0.936 8.0% AA
PRIMACOR™ 3003 7.5 0.935 6.5% AA
PRIMACOR™ 3004 8.5 0.938 9.7% AA
PRIMACOR™ 3330 5.5 0.932 6.5% AA
PRIMACOR™ 3440 10.0 0.938 9.7% AA
PRIMACOR™ 3460 20.0 0.938 9.7% AA
PRIMACOR™ 4608 7.7 0.932 6.5% AA
9.7% EAA - 180°T-PEEL TEST OF COMPOSITE SAMPLES
(> 10N/25mm) (4-10N/25mm) (<0.5 N/25mm)
ALUMINUM LDPE PP
STEEL EVA PET
GLASS PA PVdC
IONOMERS PAPER EVOH
mLLDPE PC
HDPE PS
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
AMPLIFY™ TY – Tie Layers
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Product MAHGraftLevel
MeltIndex
Density Adhesion Notes
AMPLIFY™ TY 1355 Low 6.0 0.920 PA, EVOH, PE,Paper
Ready to use for ext. coating
AMPLIFY™ TY 1052H High 1.3 0.870 PE, PP, PA,EVOH
Concentrate, most-versatilePA: 10-15% EVOH: 20-25%
AMPLIFY™ TY 1053H High 2.0 0.965 PE, PA, EVOH Concentrate, most-versatilePA: 6-15% EVOH: 12-20%
XZ 89893.00* Low 7.5 0.920 PE, PP, PET, PA,EVOH
Formulated , universal co-extrusionand extrusion lamination adhesive
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
*Developmental product of The Dow Chemical Company
The Case for Change
LDPE World capacity
----
5.000
10.000
15.000
20.000
25.000
30.000
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Autoclave
Tubular
-2% GR/A-0,15% GR/A
+2,78% GR/A
+2,24% GR/A
Units : -000-MT
200749% A/C
201242% A/C
P201735% A/C
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
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The Case for Change
Autoclave LDPE has been a stabletechnology
• Little to no innovation in the last 20-30 yrs
• Existing capacity is aged, no new capacityplanned
Emerging Markets Forecast
INDIA: 6.4%
MET: 3.6%
ASIA: 3.5%
AFRICA: 3.0%
Key Markets are Growing
• Lightweight, sustainable beveragepackaging driving liquid paperboard growth
• Global consumption of snacks/shelf-stablefoods growing in emerging markets
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Source: TPER & IHS
Introducing Our LatestBreakthrough….
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
AGILITY™ EC Introducing the Performance LDPE’sfor Fast & Light Coatings
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• AGILITY™ EC 7000 – Fast & Light Coatings
• New AGILITY™ EC 7220 – High Performance Blending partner inELITE blends for Fast & Light Coatings with Improved SealPerformance
• New AGILITY™ EC 7080 – Very Fast and Light Coatings
• Dow has developed a new extrusion coating LDPE based on Dow’s patentedAGILITY™ technology
• AGILITY™ EC is designed to meet the industry’s needs for higher line speeds andthinner coat weights
Dow’s AGILITY™ EC 7000 Benefits
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
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Fast coatings for improved productivity
Thin coatings for improved efficiency
Meets highest industry standards
Broad ramp up and steady stateprocess window
Robust neck in and draw dawn behavior
Long term supply security for improvedflexibility
Processing Performance
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0
25
50
75
100
125
Specific Rate[g/RPM]
Adapter Pressure[bar]
Neck-In [mm]25[g/m²] @100[m/min]
Neck-In [mm]25[g/m²] @300[m/min]
Draw Down[m/min]
Paper adhesion -Mullen [%]
AGILITY™ EC 7000
DOW LDPE PG 7008 / PT 7007
DOW LDPE 7010E
DOW LDPE PG 7004
mono @ 320° set temperature /25 [g/m²] and 100 or 300 [m/min]line speed on 60 [g/m²] Kraft Paper
LDPE 7008 (7.7 MI, 0.918)
LDPE 7004 (4.1 MI, 0.922)
LDPE 7010E (8.5 MI, 0.919)
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Packaging Performance
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Seal Initiation[°C]
Seal Strength[N/15mm]
COF(Ctg to Ctg)
CoatingTensileStrength
at Break [MPa]
CoatingElongation
at Break [%]
CoatingElemendorfTear [cN]
FlexuralModulus [MPa]
Haze[%]
AGILITY™ EC 7000
DOW LDPE PG7008 / PT 7007
co-ex @ 290° settemperature /25 [g/m²] and 100[m/min] line speed1 coated paper2 film from webcurtain
1
1
12
2
2 2
2
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Similar Neck-in Performance
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0 20 40 60 80 100 120 140 160
10 [g/m²]650 [m/min]
25 [g/m²]300 [m/min]
25 [g/m²]100 [m/min]
AGILITY™ EC 7000
DOW LDPE PG 7008 / PT 7007
DOW LDPE 7010E
«Neck-In» of coating web in [mm]
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
AGILITY™ EC = High Speed
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Our customers experience:
• Speed of 650 m/min OK
• Gauge of 7μm OK
• Speed improvements of20-30% achievable
• All possible within a safeprocessing window
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
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Source: DOW PackStudios Lab
~ Performance advantages combination:
~ ELITE™ high seal performance for improved packaging hermeticity
~ AGILITY™ improved conversion output for conversion efficiency
~ AGILITY™ EC 7220 is key to run a stable high speed conversion inELITETM rich blends for improved sealant performance and optimalmaterial use
~ Benefits for converter
~ Blends result in 40% material usage reduction in sealant layervs a 100% LD pure layer!! – Up to 5% in total final package
~ Up to 5% cost saving due to material reduction
~ Up to 30% conversion efficiency improvement derived ofincreased productivity (more sqm produced)
~ Conversion energy savings per sqm
~ Benefits for packer
~ Improved sustainability profile packaging
~More packs produced with same roll weight
AGILITY™ EC 7220 – Benefits of ELITE™ blending
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
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Source: DOW PackStudios Lab
Neck-In Draw Down
Blended with 70% ELITETM 5860 in all cases
Low Neck-In in ELITETM EPE rich blends with improved draw down vs autoclavestandard alternatives for Fast and Light Coatings with Improved PackagingHermeticity
AGILITY™ EC 7220 – Blend Partner for Fast & LightCoatings with Improved Seal Performance
Looking ahead!
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
What’s next?
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• New! Improve process efficiency and seal integrity with High PerformanceSealant (cleaner, improved processability, improved seal performance)
• New! Versatile interlayer adhesive with new AMPLIFYTM TY (retort Al-PP)
• Proven high aluminum adhesion with PRIMACORTM
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow.
Building on the Unique In-HouseEngineering Capabilities
HORGEN
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• Single station
• Feed-block1 co-extrusion
• Line speed: max. 1000 m/min
• Web width: max. 800 mm
• Fully process controlled
• Dow data acquisition system
1Dow proprietary technology for market relevant structures
Thank You