FLEX INDUSTRIES LTD. FLEX INDUSTRIES LTD.

Presentation by :Presentation by : PIYUSH GUPTA, ASST. VICE PRESIDENT

MULTILAYER PACKAGING FILMS 200727-29 March 2007, Cologne, Germany.

Future of inFlexible PackagingFlexible Packaging

METALLIZED FILM

• A plastic film that

has been coated

on one/both sides

with a very thin layer of metal incorporating

the benefits of both metal and plastic films,

offering consumers much more versatility in

application.

VACCUM METALLIZATION

• Vacuum metallizing involves evaporating a metal, such as aluminum, silver or any other metal in a vacuum chamber, so the metal vapor condenses on the film.

METALLIZED FILMS – BUT WHY ?

• To form a Barrier for protection against Light, Water, Moisture, Gases etc.

METALLIZED FILMS – BUT WHY ?

• Its high gloss coupled with the outer Eye-catching packaging enhances the shelf appeal and life of the end product.

METALLIZED FILMS – BUT WHY ?

• Metallized films provide excellent machinability during Micro Slitting resulting in HIGHER PRODUCTIVITY.

HISTORY OF METALLIZERS

• First Metallizer of 650 mm width was put up in Italy in 1959.• There are over 1100 metallizers installed worldwide today.• An addition of 300-350 units is expected in the next 5 years.

• High Barrier Packaging had its beginning in Foil Substrates way back in 50’s when certain companies started to extrude PE and then laminate to foils.

HISTORY OF BARRIER FILMS

• It was the customers’ demand initially which brought barrier films to the forefront in the packaging market.

HISTORY OF BARRIER FILMS

MAIN DRIVING FORCES

Getting foods to the consumers in the freshest possible state

MAIN DRIVING FORCES

• With Flexible Packaging replacing metal cans, glass or rigid structures, the requirement of barrier materialsand coex structures was generated.

• Low cost of production

In the early 90’s, primarily 4 basic coating barrier materials

were there

• NYLON

• PVDC

• EVOH and

• Metallized films.

HISTORY OF BARRIER FILMS

The more flavourful, higher quality foods, generated the demand for more sophisticated packaging solutions

HISTORY OF BARRIER FILMS

• Meat packaging was one of the areas where “early action” in this field took place.

HISTORY OF BARRIER FILMS

• Once this technology was developed, other segments like snacks, cheese and confectionery items started being packaged in laminate structures using barrier films.

TODAY….

• Polyester and PP are most commonly used for the base substrate in high barrier packaging films.

TODAY….

• These are being used to build multilayer structures, depending on the end application.

TODAY…

• ALUMINIUM FOIL IS LAMINATED WITH POLYESTER AND PP FILMS

• IN ORDER TO PROVIDE REQUISITE BARRIER

TODAY….

• The art is in balancing the overall ratio of cost to performance

AL FOIL VIS A VIS

METALLIZED FILMS

NOW, AL. FOIL IS BEING REPLACED BY HIGH BARRIERMETALLIZED FILMS IN A BIG WAY – DUE TO VARIOUS

REASONS

AL FOIL VIS A VIS METALLIZED FILMS

METALLIZED FILM

• EASY TO PROCESS BECAUSE OF FLEXIBLE PROPERTIES.

• GETS BACK TO ORIGINAL SHAPE EVEN AFTER FOLDING

• CAN BE USED IN OUTER, MIDDLEOR INNER LAYER BECAUSE OF SEALING PROPERTIES

• EASY TO SLIT IN NARROW WIDTHS

ALUMINIUM FOIL

• DIFFICULT TO PROCESSBECAUSE OF RIGID AND BREAKABLE PROPERTIES

• DEAD FOLD PROPERTIES

• CAN ONLY BE USED IN MIDDLE LAYER OR SURFACE PRINTING

• DIFFICULT TO SLIT IN NARROW WIDTHS

AL FOIL VIS A VIS METALLIZED FILMS

COMPARISON OF BARRIER PROPERTIES

0.4-0.50.7-0.8<1.00WVTRGm/sq m-day

0.4-0.50.7-0.8<1.00OTRcc/sq m-day

PLASMA METALLIZED FILM (OD 2.7)

PLASMA METALLIZED FILM (OD 2.2)

NORMAL METALLIZED FILM (OD 2.2)

AL FOILPROPERTY

AL FOIL VIS A VIS METALLIZED FILMS

METALLIZED FILM

Can be available in both MATT and MIRROR FINISH

No such problem

AL FOIL

Available only in MATT FINISH

Usage results in Pin-hole defects

AL FOIL VIS A VIS METALLIZED FILMS

METALLIZED FILM

Comparable barrier with choice of Optical densityavailable

High shelf life

AL FOIL

Very good barrier properties but available in fixed Optical density

Low shelf life

AL FOIL VIS A VIS METALLIZED FILMS

AL FOIL• Easy to tear• High cost• Limited choice of

thickness range available (9, 12 mic)

• Fixed density (2.7)

METALLIZED FILM• Difficult to tear• Low cost• High choice of

thickness range available (9-50 mic)

• Density range between 0.9-1.4 available

PLASMA METALLIZED FILMS – a step further

The process of Plasma metallizationinvolves:

• An inline web treatment prior to metallizing to promote surface cleanliness and chemical modification, encouraging metal adhesion and improvements in barrier functionality.

• Surface of the web is prepared in-line with the Aluminium coating process.

• The plasma is formed when a gas, or combinationof gases are injected into an isolated treatment zone and ionized under vacuum conditions.

PLASMA METALLIZED FILMS

• Plasma interacts with the surface of the web in a variety of ways. In addition to removing moisture and other contaminants, it also acts to increase the number of nucleation sites through the introduction of polar groups, resulting in a coating with homogenous surface morphology and less defects.

PLASMA METALLIZED FILMS

• Better Metal Adhesion

An increase in the

surface energy of the

substrate as a result of

plasma treatment

leads to better

bonding of Aluminium

to the substrate. The

bond strength is

increased by 40%.

ADVANTAGES OF PLASMA METALLIZATION

ADVANTAGES OF PLASMA METALLIZATION

• Web Cleaning : The plasma cleaning process removes organic contaminants, dust particles, moisture etc. from the film substrates.

• Better barrier properties: Barrier properties of the film are enhanced substantially because of improved metal adhesion and web cleaning which leads to removal of unmetallized spots. OTR and WVTR are reduced by almost 30%.

ADVANTAGES OF PLASMA METALLIZATION

A WIN – WIN SITUATION…….AND A GREAT FUTURE

METALLIZED FILMS

METALLIZED FILMS

MAKING HEADWAY IN WORLDWIDE FLEXIBLE PACKAGING MARKET ESTIMATED TO BE US$ 60 BILLION

Source : FPA

GLOBAL METALLIZED FILM MARKETS

Metallized Film production worldwide : 450,000 tons/yearAbout 84% of metallized films are being used in FLEXIBLE PACKAGING.

• Expected growth rate : 7-8%

TODAY

GH BARRIER PACKAGING FILMS ARE BEING UTILIZED FOR VARIOUS APPLICATIONS IN FLEXIBLE PACKAGING

MILK POWDER / HEALTH DRINKS PACKAGING

“A GOOD EXAMPLE OF AL. FOIL BEING REPLACED BY METALLIZED FILMS”

TEA / COFFEE PACKAGING

METALLIZED FILM BEING EXTENSIVELY USED FOR:

AROMA RETENTION MOISTURE BARRIER

JUICE PACKAGING

Rigid containers and Pet bottles being fast eplaced by flexible

packaging.

Aluminium foil in flexible aminate being replaced by Metallized films.

SNACK FOODS PACKAGING

tallized films finding their way into snack food packagingoviding increased shelf life.

e to this, snack food industry is growing rapidly because e package can now reach far off places without losing the shness of the contents

LOW FAT SNACK FOODS

With the new “health concious”generation being on the rise, this is a new market segment that can look forward to a boom in the usage of metallized films.

LOW FAT SNACK FOODS

As the amount of fat in food is reduced, the flavour retention capabilities go down, hence better barrier propertiesare required to maintain the aroma and shelf life of the product.

ACKAGING OF BISCUITS AND OTHER BAKERY PRODUCTS

Metallized films are being added onto the biscuitand other bakery item packaging laminate to provide a better shelf life – to retain the freshnessfor a longer period.

PACKAGING OF PET FOOD

• With more and more varieties of pet food being launched in the market, this is another area which can look forward to a high demand of metallized/high barrier films.

CARTONS BEING REPLACED BY FLEXIBLE LAMINATED PACKAGING WITH METALLIZED FILMS FOR :

BETTER AESTHETICS

SECURITY

BRAND PROMOTION

PACKAGING OF LIQUOR BOTTLES

SHAMPOO – PORTION PACKAGING

METALLIZED FILMS BEING USED BY MAJOR MANUFACTURERS LIKE P&G IN SMALL SACHETS.

REASON: MOISTURE LOSS IS REDUCED. THE PRODUCTRETAINS ITS CONSISTENCY EVEN AFTER LONG PERIODS

TATOOS AND OTHER PROMOTIONAL MATERIAL

METALLIZED FILMS ARE BEING USED IN TATOOS, DECORATIVE STICKERS, GIFT WRAPS AND OTHER PROMOTIONAL MATERIAL FOR:

AESTHETICS BRAND PROMOTION

CONCLUSION

Success in business usually comes from finding ways to overcome barriers. But, in flexible packaging business, success is all about barriers, and in some cases, the higher the barrier, the better.

Metallized films are going to stay and will find increased usage in Flexible Packaging.

FLEX INDUSTRIES LTDFLEX INDUSTRIES LTD

Presentation by : PRADEEP TYLE - Sr. PresidentPresentation by :Presentation by : PRADEEP TYLE -- Sr. PresidentSr. President

THANK YOU.