BOPP FILM MANUFACTURE:-

EXTRUSION PROCESS
Bi-oriented polypropylene film (BOPP) has been used for decades in the
flexible packaging industry. It is widely appreciated for its low cost, excellent
optical and mechanical characteristics, and its outstanding gas barrier property
(particularly to water vapor).
The film thickness ranges from 15  to 60 micron, and is composed of at
least three layers: the middle layer is the thickest  and contributes almost
exclusively to the mechanical properties; the two outer layers lend various
properties to the film (i.e. heat-sealing properties).
Depending on what the final application the film is intended for, additives may
be added, in order to fully meet the application requirements.

 
1. Raw material feeding system
The main raw material, in the central layer, is the isotactic Polypropylene, a
semi-crystalline and thermoplastic material. Whereas, for the outer
layers, ethylene-propylene and/or ethylene-butane-propylene copolymers are
used. These materials are introduced inside the extruders by a hopper system.

2. Extrusion
Inside the extruders, the materials are melted and brought to 200-230°C and
then conveyed through the extrusion head, where they emerge in the form of
foil.
3. The foil cooling
The foil is then placed in direct contact with a cooled cylinder and immersed in
a water bath to quench the melt.

 
4. Machine direction orientation (MDO)
The film then passes over a series of rollers, which increase the temperature and
prearrange it to stretch longitudinally  (machine direction). The stretching is
achieved by passing the foil between the rollers that run at increasing speeds. As
a rule, the foil is stretched up to five times the initial length and, at this stage the
polymer chains are aligned. This stage allows the enhancing of the film's
mechanical properties, also, the thickness is reduced up to five times.
After stretching, the film is heated once again in order to neutralize the stress
accumulated during the stretching (annealing phase).
5. Transverse direction orientation (TDO)
Once out of the longitudinal stretching zone, the film is gripped on both edges
by a fast-moving chain of metal jaws (tenter clips). In the tenter, the film goes
into an oven, where its temperature rises before being stretched transversely by
the diverging rails (i.e. stretching in transverse direction up to 9 times its
original width).
At this stage, the macromolecules align, this time in transverse direction,
enhancing the film mechanical properties and reducing the thickness up to 9
times. Following the stretching stage, the chain and the film converge , so that
the film neutralizes the stress accumulated during the stretching (annealing
phase).
6. Thickness measurement and flame treatment
The film reaches a new processing stage where it takes the automatic
measurement of the thickness (along the entire width).
Afterwards, one of the faces is subject to the flame or corona treatment to make
the film suitable for the following conversion activities, namely, modifying the
surface, that is intended to anchor materials such as ink (printing process),
adhesive (lamination process), or metal (metallization process).  
7. Reel winding
The film is wrapped around a reel and is slit according to the requested
dimensions.

Film measurements
The main measurements the end product is subject to are the following:

 Thickness, grammage, density

 Tensile strength, elongation at break and elastic modulus
 Haze (opacity) and Gloss (sparkling appearance)
 Coefficient of friction between film-film and film-metal
 Sealing threshold and sealing strength °C
 Thermic stability (heat shrinkage)

 
Biaxially oriented polypropylene (BOPP) film refers to a thermoplastic
polymer used to manufacture product labels, laminations and packaging. It
is produced by stretching and flexing polypropylene film in both machine
direction (MD) and across machine direction (AMD). It exhibits various
advantageous properties, such as resistance to moisture and oil, high
durability and optical clarity. It also offers flex crack resistance, low-
temperature impact resistance, aesthetic shelf appeal, monolayer or
homogenous structure and sealing capabilities. As a result, it is widely
used in the packaging of food products, personal care products,
pharmaceuticals and electrical and electronics industry .
BOPP Films Market Trends:
The growing food and beverage industry, along with the increasing
requirement for efficient pharmaceutical packaging solutions, represents
one of the key factors creating a positive outlook for the market.
Furthermore, the widespread adoption of flexible packaging for ready-to-
eat food products, dairy and other beverages, such as coffee brews,
carbonated sodas, caffeinated drinks and mixed beverages, is also
contributing to the market growth. BOPP films are also used as a co-
extruded heat sealable and reverse printable film for packaging medicines
and drugs. They ensure that the nutrition, color and flavor of the contents
remain intact and facilitate prompt and secured transportation of products
in bulk quantities. Additionally, various product innovations, such as the
development of single-unit and chlorine-free variants, are acting as other
growth-inducing factors. In comparison to the traditionally used
cellophane, waxing paper and aluminum foil, these films are highly cost-
effective and have minimal effects on the environment. Other factors,
including increasing consumer preference for convenient packaging, along
with extensive research and development (R&D) activities, are anticipated
to drive the market further.

Key Market Segmentation:

IMARC Group provides an analysis of the key trends in each sub-segment
of the global BOPP films market report, along with forecasts for growth at
the global and regional level from 2022-2027. Our report has categorized
the market based on type, thickness, production process and application .

Breakup by Type:

 Wraps
 Bags and Pouches
 Tapes
 Labels
 Others
 

Breakup by Thickness:

 Below 15 microns
 15-30 microns
 30-45 microns
 More than 45 microns
 

Breakup by Production Process:

 Tenter
  Tubular
 

Breakup by Application:

 Food
 Beverage
 Tobacco
 Personal Care
 Pharmaceutical
 Electrical and Electronics
 Others
 

Breakup by Region:

 North America
o United States
o Canada
 Asia Pacific
o China
o Japan
o India
o South Korea
o Australia
o Indonesia
o Others
 Europe
o Germany
o France
o United Kingdom
o Italy
o Spain
o Russia
o Others
 Latin America
o Brazil
o Mexico
o Others
 Middle East and Africa
 

Competitive Landscape:
The report has also analysed the competitive landscape of the market with
some of the key players being Altopro S.A. de C.V., Amcor Plc, Ampacet
Corporation, Chiripal Poly Films Limited, Clondalkin Flexible Packaging,
Cosmo Films Limited, Futamura Chemical Co. Ltd., Innovia Films Limited
 (CCL Industries), Jindal Poly Films Limited, Mondi Plc, Polyplex
Corporation Ltd., Printpack Holdings Inc., Toray Industries Inc. and Uflex
Ltd.

Report Coverage:

Report Features Details

Base Year of the Analysis 2021

Historical Period 2016-2021

Forecast Period 2022-2027

Units US$ Billion

Segment Coverage Type, Thickness, Production Process, Application, Region

 Asia Pacific, Europe, North America, Latin America,

Region Covered
Middle East and Africa

United States, Canada, Germany, France, United Kingdom,

Countries Covered Italy, Spain, Russia, China, Japan, India, South Korea,
Australia, Indonesia, Brazil, Mexico

Altopro S.A. de C.V., Amcor Plc, Ampacet Corporation,

Companies Covered
Chiripal Poly Films Limited, Clondalkin Flexible
Packaging, Cosmo Films Limited, Futamura Chemical Co.
Ltd., Innovia Films Limited (CCL Industries), Jindal Poly
Films Limited, Mondi Plc, Polyplex Corporation Ltd.,
Printpack Holdings Inc., Toray Industries Inc. and Uflex
Ltd.

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