Molecular structure & Morphology of BOPP-PP

Biaxially oriented polypropylene (BOPP) film, one major type of biaxially oriented
film, has been developed since the 1960s through the mass production of
polypropylene. This film is today widely used in commercial packaging because of
advantages that include high transparency, good moisture resistance, high
mechanical strength and dimensional stability, low density, environmental
friendliness, and printability. The production of BOPP film involves a sequential
biaxial stretching process, in which films are cold drawn in two consecutive steps at
two different temperatures. The temperatures of the orientation processes are
usually chosen in the vicinity of the melting point of polypropylene. With the
increasing commercial demand for BOPP film, wider and faster production lines have
been introduced to produce films of high quality and competitive manufacturing price.

Various investigations on BOPP film and optimization of its production conditions

have been extensively performed from many points of view, such as the effect of
temperature, draw ratio, and morphology on the properties of the final product. The
results indicate that the orientation processes can be optimized through varying the
starting morphology, stretching conditions, and polymer structure. For improving the
stretching process, various methods have been proposed, among which broadening
of the molecular weight distribution (MWD) and additional molecules with ultra-high
molecular weight has proven most successful. Consequently, the raw PP resin used
for BOPP film production today is considerably designed. As is known, isotactic
polypropylene (iPP) has a high tendency to crystallize when cooled from the melting
state or precipitated from its dilute solution. From a general melt crystallization
condition, iPP forms the so called α phase, which belongs to the monoclinic phase
based on its threefold helical conformation, and possesses the unit cell dimensions
of a=0.650 nm, b=2.096 nm, c=0.638 nm, β=99.3°. Similar to the crystallization
process of most other polymers, the development of polypropylene crystals is
determined by both nuclear formation rate and the subsequent several steps
segment movements, which is definitely dependent on the molecular weight and
structure.

Optical Microscope studies

Polarized light optical micrographs of two different PP samples (BOPP grade &
Injection molded grade) indicate that number of crystal nuclei of BOPP grade is
almost five times that of Injection molded PP within the same area. So the molecular
structure and molecular weight distribution of the both PP samples will be quite
different. Generally BOPP grade PPs have a small amount of ultra-high molecular
weight component, and also a considerable amount of very low molecular weight
part, while injection molded PP grades has a narrow molecular weight distribution as
compared to BOPP-PP. Therefore, the abundance of crystal nuclei from BOPP-PP
as shown in POM micrographs can be attributed due to the ultra-high molecular
weight molecules in this sample, because only these PP chains can nucleate at a

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temperature that is still too high for the remaining chains to form nuclei, which gives
rise to a large amount of nuclei as the sample cooled down from the complete
melting state. In contrast, low molecular weight polymers require a long time to
nucleate and finally result in a low number of large spherulites.

Polarized optical micrographs of BOPP and Injection Molded grade PP

TEM studies

If these two different PP samples are viewed under TEM, it can give better idea of
their crystal morphologies. Both the morphology itself and electron diffraction pattern
indicate that the BOPP-PP crystals are dentrite, while Injection-PP crystals more or
less develops into general spherulites.

TEM images of
BOPP-PP Injection-PP

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 Fig showing TEM bright image at higher resolution

The reason we always obtain dentrite structures from BOPP-PP is due to the
specially designed molecular weight distribution in the sample, in which a small
number of polymer chains with ultra-high molecular weight crystallize first, followed
by the crystallization process of the low molecular weight part, which attaches to the
possible defects at the main bones. However, the proportion of ultra-high molecular
weight component in the composite sample is so small that no complete backbone of
a spherulite can be built. As a consequence, a kind of crystal morphology dominated
by the uncompleted spherulites or dentrite structure is finally obtained. In contrast,
the common spherulites are observed in sample injection-PP owing to its uniform
molecular weight distribution, to which a classic crystallization process can be
applied.

A material with a unique molecular weight distribution will result in some special
characters of condensed state. Correspondingly, BOPP-PP possesses many unique
advantages for orientation processing. For example, a small amount of ultra-high
molecular weight polymer component can maintain stretching stability in the high
orientation procedure owing to the improved rheologic properties. Moreover, a rapid
crystallization process from the same component also results in a large number of
nuclei, which finally leads to small but uniform crystals in the product. On the other
hand, the low molecular weight part provides PP resin high mobility when it is
stretched at high temperature and contributes to a BOPP film with better “feel” owing
to its high crystallinity in the subsequent cooling process.

Morphology differences between the two crystals arise mainly for two reasons. First,
BOPP-PP exhibits smaller crystal size than injection-PP, and all these tiny crystals

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are connected by an amorphous phase. Second, more defects exist in the BOPP-PP
crystals than in Injection-PP crystals, in which long and complete lattices are
frequently observed. These differences are mainly attributed to the different
isotacticities between the two samples. The small number and random occurrence of
ethylene monomers along the PP chain in the BOPP-PP sample destroy the
intrinsically uniformed 31 helix structure of the isotactic polypropylene, which compel
PP molecules to introduce more disordered packing sites into their crystals.
Therefore, the obtained crystals possess many more defects and exhibit lower
crystallinity and smaller crystal size. However, these characteristic crystal
morphologies allow the final film product to exhibit high transparency to visible light,
which is the fundamental requirement for high-quality BOPP film.

These special morphological characteristics, e.g., unique dentrite crystals,

uncompleted spherulites, small crystal size, more defects in the crystal lattice, and
so on, all satisfy the fundamental requirements for producing high-quality BOPP film
and also make it more suitable for highly efficient processing in modern wide and
fast production lines.

There are two main principles for its production:

• The sequential manufacturing process is a two-step (1.longitudinal, 2. transverse) direction stretching process.

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The image given below shows the necessary machinery. 95 - 99 % of all biax stretching lines in the world are
sequential lines.

• The simultaneous manufacturing process is a one-step stretching process. The film is stretched (oriented) in
the longitudinal and transverse direction at the same time. The MDO and the TDO are combined to one unit. Because
of its multiple advantages DMT's simultaneous stretching system (MESIM) will be the leading system in future

BOPP film, a part of the flexible packaging industry has emerged as one of the
most popular, high growth films in the world. Lower costs and convenience has
added to the growth of BOPP in the past few years, along with other flexible
packaging materials. Moreover, the growth in demand for this film has been
substantial both in developed as well as emerging markets on account of its
recyclable nature and applications in a variety of non-food and food products.

The BOPP films are categorized into two different segments - commodity and
specialty films. Among the two categories, the commodity film comprises of
around 80% of the market, as this is categorized by low margins and price
competitiveness, while the specialty films which are mainly consumed in the
developed markets account for the remaining 20%. Recent years has seen the
consumption of BOPP in different markets such as food industry, tape/ adhesives,
tobacco, certain industrial products, among others.

The worldwide demand for BOPP film has been growing rapidly and since 2002,
the global BOPP film industry has expanded by 72% with China accounting for
the major production and consumption. Geographically, Asia was the largest
market for BOPP, followed by Europe, and North America region. In the last few
years, the emerging economies have witnessed an improved standard of living,
urbanization and increased per capita consumption, and this has led to an
increase in demand for BOPP films.

Although the BOPP industry has continued to witness growth on account of

favorable demographic and market factors, it continues to be plagued by the
problem of over capacity as well as raw materials prices, particularly PP resins

Jindal

Latest state-of-the-art production lines from leading global equipment suppliers…

(CAPACITY IN TPA)
BOPET BOPP Metalliser Polymer Coating
Location
Films Films Plants Chips Plant
Total Existing Capacity 127,000 180,000 45,000 111,600 4,500
Proposed expansions in
- - 8600 -
financial year 2010-2011
Proposed expansions in
60,000 66,000 31,700 - -
financial year 201-2012
Proposed expansions in 30,000 66,000 39,700 - -

5
 financial year 2012-2013
Total Capacity Post Current
217,000 312,000 125,000 111,600 4,500
Expantions

Production
Cosmo Films has multi-location manufacturing facilities in India with an annual capacity of
56,000 MT in BOPP and 22,000 MT in thermal lamination.We have the most advanced
BOPP equipments from DMT and Brueckner, as well as high speed slitters from Atlas and
metallizer from Gallileo.We are adding a new line in Baroda of 40,000 MT per annum
capacity in March 2009. The company has an installed capacity of 22000 MT of extrusion
coated films, which are made in state of the art extrusion coating machines. The company has
recently acquired a PVDC and Acrylic coating plant from France and has started making
inroads in the high barrier packaging material as well as coated Label segments. Certified for
ISO 9001 and ISO 14001, our products are popular in domestic and overseas markets. By
following the principle of “Quality First, Customer Supreme”, Cosmo Films Ltd is devoted to
being a world class packaging as well as thermal lamination film supplier. We have has our
own captive power plant of 8 MW capacity in Aurangabad to ensure uninterrupted ,stable
power supply to our production lines which is essential to get consistent quality of production
as well as to meet committed deliveries to our esteemed customers. At Cosmo, we are very
much concerned with the environment. At Baroda, we have opted for natural gas as power
source.

Bopp Films Features

The main feature of Bopp films are improved stiffness, high tensile strength, excellent optics and good water
barrier properties. They range from 15 to 50 microns and are most commonly 15 to 30 microns. These bopp
packaging films can be monolayer or coextuded structures, and transparent, opaque, or metallized. They also
have the advantage of being non-toxic and fully recyclable.

In films, it is common to add antistatic, slipping and anti-blocking agents to avoid powder attraction, as well as the
adhesion of one surface to another once the film is coiled and to facilitate their handling in processes that are
performed after the extrusion.

BOPET FILMS

BIAXIALLY ORIENTED POLYETHYLENE TERAPTHALATE FILMS

FLEXPET™

Engineering Innovated Films,

Customised for Your Applications
Flex Films produce over 1,60,000 MT/Annum (350 Million Lbs)
of BOPET Films on its seven state-of-the-art plants.

RANGE 8 - 75 MICRONS AVAILABLE IN :

PLAIN, ON-LINE CORONA TREATED, CHEMICALLY PRIMED, MATT, HEAT SEALABLE, METALLIZABLE,
ENVIRONMENT FRIENDLY, CLEAR, EXTRA CLEAR VARIETIES

6
FLEXPET™ Performing Properties
1. Superior mechanical properties
2. Improved resistance to chemicals
3. Good barrier against oxygen
4. Dimensional stability at elevated temperatures
5. Good optical clarity
6. Excellent surface treatment & primer coatings
7. Excellent surface smoothness
8. Resistance to abrasion
APPLICATIONS

1. Printing & Lamination

2. Metallizing
3. Industrial Coating
4. Thermal Lamination
5. Encapsulation
6. Hot Stamping
7. Cable Wrapping
8. Metallic Yarn
9. Electrical & Thermal Insulation
10. Pressure Sensitive Tapes
11. Heat sealable films
12. Lidding (Dairy products)
13. Release Film
14. Retort Applications
15. Silicon Coating
16. Extra clear film for Embossing & Holograms and many more

BOPP Films

BIAXIALLY ORIENTED POLYPROPYLENE FILMS

FLEXOPP™

Engineering Innovated Structures,

Customised for Your Applications
Flex Films produce over 72,000 MT/Annum (160 Million Lbs) of FLEXOPP™ on
three state-of-the-art PLC controlled lines.

FLEXOPP
RANGE 8 - 75 MICRONS AVAILABLE IN:
PLAIN, HEAT-SEALABLE, METALLIZABLE, MATT, PEARLISED, CAVITATED, OVERWRAP, WHITE OPAQUE,
SPECIALTY FILM GRADES

FLEXOPP™ Performing Properties:

7
 1. Good mechanical strength
2. Good chemical resistance
3. Good dimensional stability
4. Excellent barrier against water
5. Superior optical clarity
6. One or both side heat sealable
7. Good stiffness
8. RResistance to tear and abrasion
Applications

1. Packaging & Conversion

2. Metallizing
3. Industrial Coating
4. Printing and Lamination
5. Photo Albums
6. Encapsulation
7. Overwraps (CDs, Cigarettes)
8. Synthetic Papers
9. Holography
10. Adhesive Tapes
11. Textile Bags
12. Hot & Cold Antifog
13. Cables over wrap
14. Reams/Sheets wrapping
15. Confectionery packaging
16. Biscuit/Sandwich over wrap
17. Inner wrap
18. Embossing
19. Anti-fog (Food products)
20. Thermal Lamination
21. Shrink wrap and many more

CPP FILMS

Cast Polypropylene Films

FLEXCPP™

Engineering Innovated Films, customized for your applications

Engineering Innovated Films,
Customised for Your Applications.

FLEXCPP™ is a highly dynamic and versatile film with exceptional gloss, excellent transparency, heat sealability,
good twisting property and excellent tear strength. Flex Film’s Cast Polypropylene film line has a capacity of

8
16,000 MT / Annum (35 Million Lbs) and can be supplied in widths upto 3000 mm, thickness range of 18-200
microns. The film can be offered with corona treatment on either one or both sides.

FLEXCPP™ RANGE 18 - 200 MICRONS

AVAILABLE IN :
PLAIN, HEAT-SEALABLE, METALLIZABLE, POLISHED, MIRROR, EMBOSSED SURFACE, GLOSS / MATTE
FINISH, STIFF, FLEXIBLE, CLEAR, OPAQUE VARIETIES
FLEXCPP™ Performing Properties:

1. New aesthetic possibilities for enhanced shelf appeal

2. Good gloss, transparency and heat sealability
3. Versatile structural properties
4. Good oxygen and moisture barrier
5. Customisable for special applications
Applications

1. Packaging & Conversion

2. Food Wraps
3. Lamination
4. Anti-fog
5. Candy/confectionery Wrap
6. Garment Bags
7. Retort Packaging
8. Stationery Packaging
9. Vacuum Metallization
10. Deep Freeze Application
11. Over Wrap
12. Floral Wraps, and many more

Metallized Films

BOPP, BOPET & CPP Films

FLEXMETPROTECT™

Engineering Innovated Barriers for your Applications

FLEXMETPROTECT™ high barrier metallized films is the ultimate solution for packaging a wide variety of
products that require extended shelf life apart from host of applications in the textile and capacitor industries.
Armed with seven state-of-the-art metallizers, with Plasma treatment facilities for better metal to film adhesion,
Flex Films is producing over 45,000 MT (100 Million Lbs) of Barrier Metallized films per annum with optical
density ranging from 0.4 to 3.5 upto a width of 2,850 mm.

FLEXMETPROTECT™ RANGE
8-75 microns for BOPET 8-75 microns for BOPP 18-200 microns for CPP

9
APPLICATIONS

1. Converting and Laminating

2. Synthetic Zari & Metallic Yarn
3. Electronic Goods Packaging
4. Insulation Ducting
5. Decorative Applications
6. Lidding Applications
7. Embossing & Holograms
8. Sandwitch Lamination
9. Twist Wrap & Confectionery, and many more

Blown film versus the cast film process

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Modified: Friday, 09 January 2009 02:55 PM by mcurenton - Categorized as:

Consultants Corner

» Blown film versus the cast film process

[X] » Blown film versus the cast film process

Blown film versus the cast film process Vol. 22 #3, December 1995

Blown Film:

1. Better balance of film physical properties (MD vs TD): This is especially true of
linear polyolefins like HDPE and even LLDPE. The monoaxial drawdown in the
cast film process coupled with the web neck-in tends to give very splitty cast film
from resins like HDPE. Physical properties of most resins, such as tear strength
and elongation, tend to be more balanced in the blown film process thus
promoting better dart drop impact strength.

2. Denser film, stiffer, with better barrier properties: The lower cooling rate in the
blown film process allows more crystallite formation and a higher film density.
This generally promotes higher film modulus and lower rates of moisture and gas
transmission for the same polymer.

3. Less trim, regrind: Because of the tendency to edge bead and because many
cast film line dies are fixed slot width, the amount of edge trim that must be
taken is a much higher percentage of the total web. This becomes less so as the
cast film line is wider. The bubble diameter in a blown film line can be adjusted
to give just the right size for mini mum edge trim.

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4. Lower investment per annual pound for equipment: Because the line speed for
a cast film line running the same lb/ hr. width and thickness is twice that for a
blown film line, the takeoff drive system is more sophisticated and expensive.
The web handling and winding systems are designed for much higher speeds,
are more sophisticated, and more expensive. Automatic gage control is almost
mandatory for cast film and adds about $200,000 to the price of a cast film line.
Typical machinery investment numbers for blown film lines are 14 to 28 cents
per annual pound of film production and for cast film lines is 25 to 50 cents.

5. Short runs are less expensive: Because the width is easily changeable on a
blown film line, short runs are less ex pensive as less changeover scrap is run
and less trim is taken during the run.

6. Thinner films can be made: Because the drawdown occurs in two directions
(MD and TD), a thinner film can be made from the same resin on a blown film
line than can be made on a cast film line. In addition, the web handling is easier
because two thicknesses are transported to the winder at a slower line speed
instead of one at a higher line speed.

7. 100% LLDPE does not have the drawdown instability problems with blown film
that it has in cast film (draw down resonance).

Cast Film:

1. Better gage uniformity: The slot die can be adjusted from one point to the
next and the adjustment can be made automatically by a computer control
system.

Typical operating gage control for LDPE on a cast film line is within + or - 2%.
Typical blown film gage uniformity is within + or- 10%, which can be reduced to
= or - 5% with a good TD automatic gage control system. The viscosity of the
melt in a cast film line is usually much less than that in a blown film line because
of the resins used and because cast film generally is done at higher melt
temperatures, (475 deg. F vs 375 deg. F).

2. Better optical properties: The quench rate at the casting roll contact area of a
cast film line is much higher than the cooling rate in an air cooled blown film
bubble. This tends to delay the crystallization and tends to make the film more
amorphous with less haze and more gloss. Because of this, the transparency
(see through) of cast film is much better. This is especially true for homopolymer
polypropylene.

3. Better embossing quality: The embossing that can be done at the casting roll
surface can be much finer in definition and have more retention with heat and

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time exposure than that which is done on blown film after the collapsing process.

4. Higher rates of production per total inch of web width are achieved in the cast
film process because the cooling at the casting roll surface is so much more
effective. Typical numbers for the blown film process are 10 to 20 lb/hr per inch
of layflat tubing or 5 to 10 lb/hr per inch of bubble circumference, depending on
resin and film thickness. Typical rates for cast film are 15 to 30 lb/hr per inch of
web width, usually three times that for blown film. For a given width of take off,
the cast film line will usually run 50% more pounds per hour than a blown film
line (the blown film line makes two thicknesses for one web width of production).

5. Lower density, softer film: The same characteristic cited as a disadvantage for
cast film in item 2. under blown film can sometimes be an advantage, especially
if soft drapable film is desirable.

6. Allows some resins not readily runnable on blown film to run: A good example
is polypropylene homopolymer. In the air cooled blown film process,
polypropylene homopolymer produces a very hazy splitty film because the
crystallites are so large. Rapid quenching in the cast film process produces a
clear, soft film that is very useful for dry goods packaging and photo album
pages. Note: some tubular water or mandrel quench processes exist that can run
PP homopolymer film. The cast film process
Blown Film Extrusion - An Introduction can run resins with low melt strength,
By: Cantor, Kirk © 2006 Hanser (typically higher melt index) whereas the
Publishers blown film process requires those with
higher melt strength. LLDPE is an exception
here and must be modified to prevent drawdown resonance.

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