Modul Blow Film Eng
Modul Blow Film Eng
Modul Blow Film Eng
Dow.com
Processing:
Resin • Blown Film Film or
• Cast Film laminate
• Coating
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Extruder Construction
Temperature
Gear Thermocouples
Reducer T T T T
T
p p
Pressure
Drive Transducers
Motor Heating / Cooling Zones
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Extruder Screw: Nomenclature
Flight Depth @ Feed (FD F) Flight Depth @ Metering (FD M)
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Extruder Screw: Basic Outline
Metering
Feed Zone Compression Zone
Zone
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Extruder: Smooth Bore & Grooved Bore
For a 30 L/D screw, following are general extruder configuration for different sections:
Smooth Bore Grooved Bore
Length of Feed Section 6 L/D 3 L/D
Length of Compression Section 10 L/D 17 L/D
Length of Metering Section 14 L/D 10 L/D
Compression Ratio 2.5 1.0
Drive for grooved 100
feed extruder - 90
OUTPUT 80
70
Output Rate, kg/hr
60
Smooth
50
Grooved
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
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Resin Feeding & Dosing
Resin is conveyed into the dosing unit via vacuum, and fills the hopper by
either gravimetric or volumetric feeding.
Additive
conveyance
Mixer
screw
Corona Treater
Stabilizing cage
Extruder
T T T T
T
Die
p p p p p Breaker
Plate
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Blown Film: Breaker Plate and Screen Mesh
• Breaker plate is located after the metering zone of the extruder, before the
adaptor leading into die entrance.
• It serves as support and holds a series of screen mesh (stainless steel).
• The series of screen mesh assists to build up the back pressure
in the extruder, and to filter foreign particles from entering the
die body.
Line Distance Line Distance
Mesh
(inch) (micron)
Flow of polymer melt
60 0.0098 250
70 0.0083 210
Required/fine Course screen
80 0.007 177
screen mesh mesh to provide
100 0.0059 149
for filtering and back-up and
120 0.0049 125
back pressure support in case
140 0.0041 105
build-up failure of fine
200 0.0029 74
screen
325 0.0017 44
400 0.0015 37
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Blown Film: Die
MD
CD
Draw-down Ratio (DDR) is an index
of MD orientation.
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Blown Film: Bubble Cooling – Air Ring
• Air ring is designed to direct an uniform air stream onto the exterior
circumference of the film bubble.
• For processing LLDPE, air should stream roughly parallel to the to the
bubble surface and remain in contact with the surface as long as possible as
it travels up away from the air ring.
• This is due to the low melt-strength of LLDPE, and the relatively thicker wall
extrudate from the larger die gap.
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Blown Film: Dual-lip Air Ring
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Troubleshooting in Blown Film
It is important to understand the root cause of process instability. Listed below are
recommended troubleshooting guides.
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Cast Film: Process
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Difference in Attributes
Machinery investment
Line output
Operation flexibility
Film cooling AIR WATER-CHILLED ROLL
Processing temperature
Film density HIGHER LOWER
Gauge variation
Physical of
Balance properties
orientation
Optical properties
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Typical Cast Film Applications and Attributes
Application Attributes
Lamination Film Very good optical properties and/or
thickness profile.
Surface Protective Film Usually consistent width, very high
MD tensile properties and very good
optical properties.
Stretch Cling Film High throughput, very good thickness
profile and optical properties.
Backsheet Flexibility for in-line MDO, good MD
tensile properties, flexibility on
surface modification, and high
throughput.
Bakery Film Very good optical properties, and high
throughput
Frozen Film Very low crystallinity for low
temperature toughness
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Typical Extrusion Coating T-Die
Die facade
Die profile
Manifold
Die Land
Lip Land
Polymer flow
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Chill-Roller
The speed determines the final film gauge –
by shifting the frost line further away from
the die in the rotational direction of the chill-
roller.
Typical construction: Thin-shelled, spirally baffled
Air Knife Edge pinning – due to neck in, both web edges
are thicker and tend to lift away from the chill-
Vacuum box roller. Static pinning, or high pressure air guides
are used to pin them onto the roller surface.
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Extrusion Coating Line - Layout
Deckle Plug
Deckle Plate
Substrate
Substrate
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Melt State Properties and Draw Down
Melt State
Properties: Effect of Typical die gap: 0.7mm
average molecular DIE
weight and MWD on
drawdown. MELT
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Varying Parameters in Extrusion Coating Line
Actions Observations
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Recommended Troubleshooting Step(s)
Observation Recommended Actions
Surface treatment
Increase die temperature
Increase air gap
Poor adhesion
Decrease line speed
Use/add functional co-polymer resin
Increase chill-roll temperature
Check for gel
Voids on molten web
Check moisture in resin
Check surface purity of substrate
Pinholes
Decrease draw ratio
Clean die lip
Gauge variation Varies the die nip temperature
Ensure all heaters in the die are working
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Recommended Troubleshooting Step(s)
Observation Recommended Actions
Check for any oxidized polymer or blockage in die edges.
Edge tear Ensure the temperature at die edges are higher than other die sections.
Decrease draw ratio (reduced polymer stress)
Decrease draw ratio (reduced draw down)
Draw resonance
Decrease melt temperature
If blending of resins, check rheology
Orange peel / shark Proper purging
skin Check for uneven melt curtain temperature across the width
Increase die temperature
Decrease draw down
Collapse of molten
Decrease level of LCB
web
Use higher MI resin
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Thank
You
OVERVIEW OF DOW’S
POLYETHYLENE & ETHYLENE
COPOLYMER PRODUCT PORTFOLIO
FOR PACKAGING
A: C4 LLDPE (1.0 MI, 0.920 g/cm 3), B: DOWLEXTM 2045G (1.0 MI, 0.920 g/cm 3)
Values based on 2 mil films made using resins produced in a commercial train; typical values, not to be
construed as specifications.
Dow testing per Dow and ASTM standards. Complete protocols and test results available upon request.
Blown DOWLEX™ 2045G 1.0 0.920 Excellent toughness for general applications
Blown DOWLEX™ 2045LC 1.0 0.920 Excellent colour stability edition of DOWLEX™ 2045G
Blown DOWLEX™ 2038.68G 1.0 0.935 Excellent processability, balance of stiffness, toughness and optical property
Blown DOWLEX™ 2045.11G 1.0 0.922 Slip/AB additive edition of DOWLEX™ 2045G
Blown DOWLEX™ 2098P 1.0 0.926 Moderate stiffness with outstanding toughness
Blown DOWLEXTM 2645G 1.0 0.920 Hexene copolymer, Good toughness for general applications.
Blown DOWLEX™ 2645.11G 1.0 0.921 Hexene copolymer, Good toughness for general applications with slip/AB.
Blown DOWLEX™ 2645.11GY 1.0 0.921 Hexene copolymer, Excellent scratch resistance
Cast DOWLEX™ 2047G 2.3 0.917 Outstanding tear strength, impact strength, and toughness
Cast DOWLEX™ 2607G 2.3 0.919 Hexene copolymer, stretch cling film, diaper backsheet.
Cast DOWLEX™ 2636G 2.5 0.935 Good Stiffness films for overwrap, diaper backsheet.
Cast DOWLEX™ 2036P 2.5 0.935 High stiffness film application
Cast DOWLEX™2606G 4 0.920 Hexene copolymer, stretch cling film, diaper backsheet
Force (N)
0.65
0.50 10
0.35
5
0.20
Secant Modulus @2% (
Puncture Resistance 0.05 0
MD )
80 90 100 110 120
Temperature (oC)
6 Hot-tack
Secant Modulus @2% (
Tear TD @ 3200gm 5
TD )
A B 4
Tear MD @ 3200gm
Force (N)
3
A: 10% LDPE 640I + 90% DOWLEXTM 2045G density 0.920 g/cm3, 1 MI
2
B: 10% LDPE 640I + 90% ELITETM 5400G density 0.916 g/cm3, 1 MI
Values based on 2 mil films made using resins produced in a commercial train; typical values, not to be 1
construed as specifications. Dow testing per Dow and ASTM standards. Complete protocols and test results
available upon request. 0
80 90 100 110 120 130 140
Temperature (oC)
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ELITE™ EPE RESINS APPLICATIONS
❖ Food packaging
o frozen food film, fresh-cut produce, bag-in-box, lamination film, aseptic packaging
❖ Stretch wrapping
❖ Stretch hood & Shrink hood
❖ Liners
o liquid bulk container, < 1000L , flexi tank ~24,000L
o Geo-membranes
❖ Hygiene film
o Microporous Diaper backsheet (CaCO3), napkin wrapper
Blown ELITE™ 5400G 1.0 0.916 Low HSIT, high impact resistance
Blown ELITE™ 5401G 1.0 0.918 Slip/AB additive version of ELITE™ 5400G
Blown XUS 59999.110 1.0 0.918 Stable and low COF after lamination and heating
Blown ELITE™ 5500G 1.5 0.914 Very low HSIT, seal integrity, liquid packaging
Cast ELITE™ 5220G 3.5 0.915 Good stretchability and sealing performance
Cast ELITE™ 5220LC 3.5 0.915 Excellent colour stability edition of ELITE™ 5220G
Purpose
❖ Provide hot tack and strong seal over wide temperature window
❖ Provide hermetic seal by preventing channel leakers
❖ Provide low COF for film to flow over packaging surface
❖ Provide neutral taste and odour contribution
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ELITETM AT ADVANCED TECHNOLOGY RESINS
❖ Produced by solution process with advanced catalyst technology
❖ Broad sealing and excellent processability resin for high speed
Vertical Form Fill Seal (VFFS) applications
o High Hot-tack
o Low die built up and plate out performance
o Improved taste and odour
❖ Bulk Container liners/Flexi-tanks
o Improved Toughness/Softness
❖ Green house films
o Enhance toughness and transparency
o Lower processing temperatures
❖ Stretch hood applications
o Excellent toughness over EVA
o Excellent elastic recovery
o Much less sensitivity to BUR
•With S/AB
•High throughput with excellent bubble stability
•Good performance sealant
•Superior sealing characteristics:
ELITE™ AT 6410 0.85 0.912 ❖ Low HSIT
•Good processability
•Excellent stiffness improves bag making and ease of PE film
printing
ELITE™ AT 6900 1.2 0.969
•Ultra high moisture barrier
•Good processability
Values shown on above table are nominal values.
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AFFINITY™ POLYOLEFIN PLASTOMER (POP)
❖ Made by Dow proprietary INSITE™ technology- solution process
❖ 0.850 – 0.915 g/cm3 density
❖ Superior sealability (Heat seal, Hot-tack, Seal through contamination)
❖ Excellent toughness & softness (Impact, Puncture, Pin-hole resistance)
❖ Superior optics
❖ High bond & seal strength to PP film/sheet
❖ Excellent organoleptics (Taste & odor)
❖ High oxygen transmission rate
❖ High cling force
❖ Good processability (Motor load, blown bubble stability)
fossil equivalents and deliver the same Cracking & Films / packages
performance attributes in final application. Polymer producers
Manufacturing
❖ They meet food contact safety standards and do
not have an impact in packaging recyclability.
o Excellent hot tack and low heat seal initiation temperature COOH
COOH
Melt
Process Grade Ion Type Density (g/cc)
Index(g/10min)
Blown SURLYN™ 1706 Zn 0.7 0.95
Blown SURLYN™ 1707 Na 0.9 0.95
Blown SURLYN™ 1601 Na 1.3 0.94
Blown SURLYN™ 1650 Zn 1.6 0.95
Cast SURLYN™ 1605 Na 2.8 0.95
Cast SURLYN™ 1652 Zn 5.2 0.94
Cast SURLYN™ 1705-1 Zn 5.5 0.95
Coating SURLYN™ 1702 Zn 14.0 0.95
APPEEL®
APET CPET PP PS PVC PE BAREX ACLAR Itself
Grade
With recent addition of DuPont’s Ethylene Co-polymers portfolio, Dow’s combined capabilities in adhesives, resins and specialty solutions will be
unparalleled in the industry.
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Structure - Property Relationships
in Ethylene-Based Polymers
Major Types of Polyethylene
• HDPE
• No or little short
chain branches
(comonomer) Crystal
• LLDPE
• Short chain
branches
(comonomer)
• LDPE
• Long & short
chain branches
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General Polyethylene Attributes
General
Positives Negatives applications
Polyethylene • Stiff
• Dense (good barrier) • Brittle
• High load carrying • Hazy
HDPE capability (HMW)
• Higher T resistance
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Ethylene monomer to Polyethylene
“Homopolymer”
•Solution
Ethylene •Gas Phase
High Density Polyethylene HDPE
•Slurry
(1) CH2 CH2 CH2 CH2 CH2 CH2 CH2
•Solution
Ethylene •Gas Phase
Linear Low Density Polyethylene LLDPE
•Slurry
(2) CH2 CH2 + CH2 CH2 CH2 CH2
comonomer
Co-monomer
“Co-polymer”
LDPE
Ethylene Low Density Polyethylene
•High Pressure
(3) CH2 CH2 CH2 CH2 CH CH2 CH2
Free radical
initiator CH2
“Homopolymer”
CH2
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Types of Co-monomers
LLDPE is made by polymerized ethylene monomer and an “a-olefin co-
monomer” to make an “ethylene/a-olefin co-polymer”, which is ZN,
Chrome, or Single-site catalyzed
1-Butene 1-octene
-(CH2-CH2)-CH2-CH-
CH(-CH2-CH2)-(CH2-CH2)- -(CH2-CH2)-CH2-CH
CH-(-CH CH2)-(CH2-CH2)-
CH2-CH
CH2 CH2
CH3 CH2
CH2
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5 Variables that Define Polyethylene
SCB (comonomer
LCB
Incorporation)
MWD
Inter-molecular
SCBD (comonomer
distribution)
Mw
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Molecular Weight and MWD
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Melt Index (ASTM D1238/ISO 1133)
I10/ I2 ratio MWD i.e. the greater the I10/I2 the broader the MWD
(assuming no long chain branches or polar side groups)
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MWD is Measured by GPC (Gel Permeation
Chromotography)
1MI, 0.920g/cc resins
16 18 20 22 24 26 28
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Melt Index Effects on Performance
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Short Chain Branching and SCB Distribution
Short chain branching (SCB)
• Density/Crystallinity
indicates branching content
• # of branches on the chain
determines density
• Branches = butene (C4),
hexene (C6) or octene (C8)
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Density (Crystallinity) Ranges in Polyethylene
Density, g/cm3
0.85 0.86 0.87 0.88 0.89 0.90 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1.00
Pure amorphous PE Pure crystalline PE
LDPE
ZN catalysts
ULDPE LLDPE HDPE
(ATTANE*) (DOWLEX*)
Elastomeric Plastomeric
ENGAGE* and AFFINITY* AFFINITY*
c − a
Wt% Cryst. = Where a=0.855 g/cc and c=1.00 g/cc
c − a
• All solid properties are affected by density in general.
• Melt properties are not affected by density (there is no crystallinity in
the molten state).
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Long Chain Branching (LCB) Content
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Putting It Together! Summary of PE Chain Structures
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Polymer Melt vs. Solid State
PE Is Semi-crystalline…So It Can Melt!
Heat
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Melt Properties
• CHAIN ENTANGLEMENTS!
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Flow Curves Of Different MWD Having the Same MI
LOG APPARENT VISCOSITY
NARROW MWD
MEDIUM MWD
BROAD MWD
I10
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Dynamic Shear Viscosity
I2
13,000
10,000
8,000
0.01 0.1 1 10 100 1,000
Shear Rate, 1/sec
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Summary of Melt State Properties
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But…We Usually See Solid PE
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Solid State Properties
Solid state properties depend on Composition AND Morphology
including:
• Percent Crystallinity (Density → Stiffness)
• Amount of Short Chain Branching
• Tie-chain Concentration (Toughness)
• Short Chain Branching Distribution
• Molecular Weight
• Orientation
• Molecular Weight Distribution
• Long Chain Branching
Morphology Evolution of LLDPE
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DSC Second Heat
Sample: DOWLEX 2045 TM 2045 File: C:\DSC\Dat4.179
Sample: DOWLEX
Size: 6.8280 mg
Method: STDCOOLHEAT
LLDPE Resins
Comment: 199802759-9C / CMH
DSC Run Date: 26-Jul-99 03:30
119.92oC
122.60oC
Heat of Fusion = 142.0 J/gm
1.2
@ 23 oC
Wt% Crystallinity = 142.0/292*100
@ 23 oC = 48.6 wt% 110.82oC
0.6
23.00oC
-20.00oC 133.05oC
0.3 142.0(146.2)J/g
4.197J/g
0.0
-40 -20 0 20 40 60 80 100 120 140
Exo Down Temperature (oC) Universal V2.5H TA Instruments
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Modulus vs Density of PE
10 5
Young's Modulus (Psi)
10 4
10 3 Single-site Polym.
LLDPE & VLDPE
mLLDPE
Regression
10 2
0.84 0.86 0.88 0.90 0.92 0.94 0.96
Density (g/cc)
Log(Modulus) = -130.0787+270.267*den-134.832*den*den, r2=0.99
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Decreasing the Crystallinity (Density)
• Is accomplished by...
• Increasing the amount of short chain branching by adding
comonomer
• Advantage of octene co-monomer - effectively incorporate into the
polymer
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Solid State Properties
Solid state properties depend on Composition AND Morphology
including:
• Percent Crystallinity (Density)
• Amount of Short Chain Branching
• Tie-chain Concentration (Toughness)
• Short Chain Branching Distribution
• Molecular Weight
• Orientation
• Molecular Weight Distribution
• Long Chain Branching
Semi-Crystalline Morphology
INTERFACE
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Increasing Tie Chain Concentration
• Is accomplished by
• Optimizing Short Chain Branching Distribution (SCBD)
• Increasing the molecular weight
• Advantage of octene co-monomer - versus hexene and butene,
octene’s longer carbon chain provides greater entanglement for
enhanced film performance properties
• Increases…
• Toughness
– Impact
– Tear (needs balance of tie chain & high dens)
• Environmental Stress Crack Resistance (ESCR)
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Relative Tie-Chain Concentration Model Calculations
0.08 Mw=50,000
Mw=99,000
0.06
0.04
0.02
0
0.86 0.88 0.9 0.92 0.94 0.96
Density (g/cc)
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Relative Tie-Chain Probability
30
28
26
24
22
20
C8 C7 C6 C5 C4
Co-monomer Type of LLDPE
31
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Intrinsic Tear Comparison
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Dart Impact Comparison
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Summary: Properties vs. Molecular Weight & Density
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Thank
You
JOY XU
DOW PACKAGING & SPECIALTY PLASTICS
JUNE 2021
General Business
OUTLINE
Plastic circularity
Innovative products accelerating market segment strategy
Design for Mechanical Recycling Product & Feedstock Recycling Renewable
Recyclability Application development Solutions Solutions
Dow is uniquely positioned with resins and Develop options to improve the quality of Evaluate technologies for feedstock Explore and evaluate new technologies like
technologies that enable more plastic recyclate from flexible packaging by recycling via bio-feedstocks
packaging to be recycled • Economics & speed • Pyrolysis
• Enabling partnerships • Gasification
• Regional infrastructure for plastic
recycling
All
PE
Mono-Material
Accelerated Film Design
Time-To-Market
Digital Performance
Modelling
Performance comparison:
Key requirements Blown PE TF-BOPE MDO-PE
Optics
All PE structure (Clarity & Gloss)
Print web: OPE or Thickness variation
blown PE film Toughness
Film
(20~30µm) performance (Tensile, dart & Puncture)
Ink & adhesive Stiffness
Dart impact
Applicable to MD Tensile
VFFS speed
stress
detergent powder,
frozen food, dry
food packaging. Gloss MD Tensile strain
Structure
Puncture energy TD Tensile stress
BOPA (15μm) TF-BOPE (20~25μm)
Ink & adhesive Ink & adhesive
TD Tensile Strain
Oxygen barrier
(cc/m2*day)
1.8 1.7
Moisture barrier
Recyclability
(gm/m2*day)
1.9
Applicable to dry
food, snack food, Gloss 45 (%)
61
54 MD tensile strength (MPa)
29
facial mask 67 26
packaging.
28
765 51
Dart impact (g) TD tensile strength (MPa)
861
Structure 1.1 425
400
1.1 414
BOPA (15μm) TF-BOPE (20-25μm)
Puncture energy (J) MD 2% modulus (MPa)
533
Ink & adhesive Ink & adhesive
TD 2% modulus (MPa)
EVOH-Retain™-PE
PE film (130μm) BOPE(20-25µm)//EVOH-Retain-PE(90µm) BOPA(15µm)//PE(130µm)
Coex film (90μm)
Leveraging a global technology base of 10 Pack Studios for faster local solutions
June 2021
Ref: Euromonitor 2021 Nappies/Diapers/Pants in China
Future Forecast Hygiene Application in APAC
40,756 42,266
6,171 6,599
Steady Growth (CAGR=7%)
21,787
- Population Growth
- Babies in emerging countries
17,124 17,304 - Market penetration rate due to an increase of income
- Consumers’ Convenience
- Occasion to use
26,540
- Pieces to use a day
17,924 18,322
- Hygiene consciousness
- Aging Society (AI)
- 25% of population are elderly in China, Japan, Korea
2019 2020 2025
(Estimate)
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Market Size and Key Brand Owners
RF: Euromonitor March 2021
• USD = Retail Value in 2020 / YoY Growth = 2019 – 2020
• Market Share in APAC = 2020
Argan Oil for Skin Care Diverse Product Types Material Recycling Biobased Material
to meet customers’ needs (under evaluation)
Diapers Washing
Virgin
Gold Foil on Diaper Mosquito Free Cottons
Materials Bio-PE
(Pulps and SAP) Top-Sheet
5
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Dow’ offering to meet trend of disposable hygiene applications
❑ Soft nonwovens ❑ Cloth-like nonwovens ❑ Elastic film ❑ Thin film ❑ Design for Recyclability
❑ Elastic nonwovens ❑ Mechanical Recycling
❑ Bio-PE
6
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7
H&H INNOVATION
Brian Yu
June 2021
General Business
H&H Innovation towards Active Comfort and Healthy
1. Soft-Touch
• End-User’s Experience → Better Softness 3. Healthcare
• Performance Requirement → Softer than PP NW • End-User’s Experience → Safe and lightweight
• Dow’s Solution → ASPUN™ AT2135 for mono PE spunbond • Performance Requirement → low extractables/
leachable
• Dow’s Solution → DOW™ LDPE 91020/91003
HEALTH+™ resins
2. Cloth-Like
• End-User’s Experience → Better Appearance
• Performance Requirement → Less discoloration
• Dow’s Solution → ELITE™ 5220LC
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
1. Dow Next Generation Fiber Grades: ASPUN™ AT FGR
Dow’s new generation ASPUNTM AT FGR expand the sustainability, recyclability and waste reduction
potential of healthcare and hygiene nonwovens.
Performance includes
Performance
• Hand feel
ASPUNTM FGR • Tenacity
• Abrasion resistance
Processability includes
IM HDPE ASPUN™ AT FGR
• Thermal stability
• Drawability
• Fiber denier
• Defect ratio
3
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
ASPUN AT Enabling Softer and Stronger PE Nonwoven
0
• Comparable mechanical performance
Reverse Softness Elongation MD
Melt/bonding temperature
Formulation
(°C)
Drawability Elongation CD
ASPUNTM 6000 FGR 230/122-124
ASPUN™ 6000 FGR ASPUN™ AT 2135 FGR
ASPUN™ AT 2135 FGR 230/122-124
3500
3000
2500
2000
1500
1000
500
0
ASPUN™ 6000 FGR ASPUN™ AT 2135 FGR
ASPUNTM 6000 FGR ASPUN™ AT 2135 FGR
ASPUN™ AT 2135 FGR has improved drawability and thermal stability with ASPUNTM 6000 FGR
5
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
ASPUN AT: Improved Softness and Abrasion Resistance
ASPUN™ AT 2135 FGR has comparable softness and better abrasion resistance with ASPUN TM 6000 FGR
h-PP: homopolymer PP
Cabin pressure (Pa): h-PP:4500; ASPUN™ 6000 FGR:2300; ASPUN™ AT 2135 FGR: 4000
Basis weight of samples: 20gsm
6
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
2. Cloth-Like: ELITE 5220LC for Discoloration
100.0
95.0
ELITE5220G ELITE5220LC
90.0
85.0
80.0
0 1 2 3 4 5 6
ELITE 5220G ELITE 5220LC
2NOx gas fading test: According to AATCC method 23-1994, 60 deg.C, 10 days
1
25 mm twin screw extruder, 250 degC, 50 rpm and 2 k g/h output
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow 7
General Business
3. Dow Offering in blow-fill-seal (BFS) application
Low density polyethylene (LDPE) is widely used for ophthalmic and respiratory medical products
where squeezability, flexibility, and clarity are important for administration.
Benefits of LDPE vs. glass:
• Design versatility/customization
• Aseptic filling
• Shatterproof
• Lightweight
• Fully automated process
• Pre-measured dosages
BFS process Prescription/OTC IV bottles
✓ Comply with USP Class VI, EP 3.1.3 and 3.1.4, USP <661.1>
✓ Manufactured in Europe
9
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Extractable Testing ̶ Pressed Samples
• U.S. FDA hexane extractable and xylene soluble method based on 21 CFR 177.1520 (d)(3)(ii).(1)
• One square inch pressed sample weighing 2.5 grams (± 0.05) was immersed in 1000 mL solvent at 50ºC
for two hours. Removed, dried at 80°C under vacuum for two hours.
• Extractables calculated by percent weight difference.
3.5
DOW ™ 20 HEALTH+™ Ultra-Pure
3
Hexane Xylene
Polyethylene (0.920 density, 1.9 MI)
2.5 has the lowest extractable levels
Extractables (%)
2
DOW ™ LDPE 91020/91003
1.5
HEALTH+™ Resins have lower
1 extractable levels than commercial
0.5 reference
0
DOW 20 HEALTH+ LDPE 91020 Commercial DOW 91003
HEALTH+ Reference HEALTH+
• ELITE™ 5220LC with improved thermal stability for less discoloration cloth
like Backsheet film
11
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
12
HEALTH & HYGIENE
APPLICATION
Brian Yu
June 2021
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Health & Hygiene Overview
VISION
Being an innovation leader & Sustainable Solution Provider in Health and Hygiene Market
Key Segments
Backsheet Film Fiber & Nonwoven Elastics Artificial Turf Medical
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Start with a Diaper (Backsheet, Fiber & nonwoven and
Elastics)
Waistband Ears
Topsheet film/
Topsheet nonwoven
Backsheet film
Backsheet nonwoven
Elastic ears/waist
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Hygiene Barrier Films (Diapers)
Body side
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Dow Resins Offering in Breathable Back Sheet
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Elite™ Enhanced polyethylene resins
5815 0.915 15
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Dow Solutions for Fiber and Nonwoven
Applications
Resin/grade Density (g/cc) I2 (dg/min) Spunbond Meltblown Elastic
Staple fiber Binder fiber
nonwoven nonwoven Nonwoven
FUSABOND™ E204
0.952 12 √
Functional Polymer
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Elastic Components in Hygiene Products
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
INFUSE™ Olefin Block Copolymers (OBC)
for Soft Stretch & Elastic Performance
Film hysteresis for MD ring rolled films
16
4.5 9
14
4 8
12
Stress (Mpa)
3.5 7
10
N/25 mm
3 6
8
2.5 5
%
6
2 4
1.5 3 4
1 2 2
0.5 1 0
0 500 1000 1500 2000 2500
0 0
INFUSE™ 9507 INFUSE™ 9107 PE Random PP Elastomer Strain (%)
OBC OBC Copolymer
Extension @ Series
100% 1 Retraction
Series 2 @ 50%
Series Permanent
3 set PBE INFUSE™ 9107 INFUSE™ 9507
• INFUSE™ 9507 OBC: 0.866 g/cc, 5MI • INFUSE™ offers lower modulus and flatter stress-strain
response for gentle stretching desired in hygiene
• INFUSE™ 9107 OBC: 0.866 g/cc, 1MI applications.
• PE Random Copolymer: 0.863 g/cc, 5MI • INFUSE™ provides excellent elastic performance closing
• PP Elastomer: 0.865 g/cc, 8 MFR the gap between polyolefinic elastomers and styrenic
block copolymers.
®
Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
General Business
Dow Solution for Artificial Turf Yarn
HDPE
(2.16kg@190oC)
Melt Index
Density(g/cm3)
13
Sustainability landscape
for flexible packaging in
SEA / ANZ
Jason Yew
Market Development Manager
Dow Packaging & Specialty Plastics
June 2021
THE FUTURE OF SUSTAINABLE PACKAGING
SG Green Plan
World
Economic
Forum
Bangkok Post
Ph ilippines
• No national law on SUP but there are local law
Ma l aysia on the ban of some SUP, mainly shopping
• Roadmap Towards Zero-Single Use Plastics 2018 - bags and straws (in some location only)
2030” was launched by Energy, Science, • Bills on EPR started to come under discussion
Technology, Environment and Climate Change but no law approval so far.
Ministry in Oct 2018 • Sustainable plastic bill being discussed in
• Ma laysia Plastic Pact (MPP) will be launched soon
Parliament (Mar 2021)
4
THE FUTURE OF SUSTAINABLE PACKAGING
How2Recycle Labels
North America Recyclable Packaging design principle and standard – testing vs. bench mark film
• All-PE
Compliance
9
OPERATION
CLEAN SWEEP®
▪ Are you following Operation Clean Sweep process to prevent pellet loss in your facilities?
▪ Any similar approach or initiative you are working on if you are not a part of OCS?
▪ If you haven’t implemented any program, do you want to learn more about the best
practice?
2
WHAT IS OPERATION CLEAN SWEEP® (OCS)?
▪ Goal is to:
▪ Help every plastic resin handling
operation implement good housekeeping
and containment practices
▪ Work towards achieving zero pellet, flake,
and powder loss
▪ Improve relations with organizations that
expect the industry to minimize
environmental footprint
3
WHY JOIN OCS?
4
WORKING TOGETHER TO MAKE A DIFFERENCE
5
TAKE THE PLEDGE
https://www.opcleansweep.org/
1. Contain spills
6
ADDITIONAL RESOURCES
7
FOOD AND SPECIALTY
PACKAGING
MARKET & APPLICATION
INTRODUCTION
JOY XU
DOW PACKAGING & SPECIALTY PLASTICS
JUNE 2021
™TRADEMARK OF THE DOW CHEMICAL COMPANY ("DOW ") OR AN AFFILIATED COMPANY OF DOW 1
General Business
OUTLINE
▪ Market sub-segments
▪ Key takeaways
Beverages
4% PE
30%
Asia-Pacific
North
50%
America
18%
CPP
5%
Food
South & 77% BOPA
Central 1%
America BOPET
4% 19%
▪ Recycle-ability
▪ Easy-to-open
▪ Less packaging material per product weight
▪ Differentiated look
▪ Life cycle analysis
▪ Single serve packaging
(energy, water, CO2 emissions)
MAP
(Modified atmosphere VSP
package) (Vacuum Skin
Packaging)
Meat & Pillow Pouch
Snack & Dry Cheese VFFS
Food prolonged shelf life & Lami-tube
(Vertical-Form-Fill-
easy-open & secured packaging Seal)
improved packaging integrity
efficiency
- Oil resistance
300
200
Tie:
- Good bonding to AL foil or metalized film 100
0
ECOT resin: 100% LDPE 20% Nucrel® AE/80% LDPE
▪ Performance benefits
Sealant:
- Excellent sealing performance enable lower sealing temperature and
lower leakage
Structural layer:
- Toughness and stiffness balance enable down-gauging potential
- Good optics
BOPA replacement:
- Cost optimization
▪ Dow solution
- LDPE 722 / Paper / LDPE 722/ Al Foil / NUCREL™ / ELITE™ 5815 + LDPE 722
▪ Performance benefits
➢ Product performance and efficiency:
- Reduced leakage
- Faster filling machine
Extrusion Lamination
- Higher productivity
➢ Sustainability:
- Energy cost saving
- Tie: BYNEL™
™Trademark of The Dow Chemical Company ("Dow") or
General Business 10
an affiliated company of Dow
F&SP STRUCTURE EXAMPLES
-- LAMINATED TUBE
Barrier Layer
Outer film
(printing) Al foil
▪ Flexible Food packaging market is large, Asia accounts half of the global demand with
annum growth rate around 5.6% in 2019.
▪ In order to meet performance and process requirements, film designer need to make the
most use of functionality of different material leading to multi-layer structures.
▪ Dow has broad product portfolio including resins and adhesives to serve the market.
SUSTAINABILITY INNOVATIONS
DANIELLE LEE
DOW PACKAGING & SPECIALTY PLASTICS
JUNE 2021
General Business
FILL IT. MOVE IT. REDUCE IT.
– Enhancing films for HDSS with Dow Solution –
INNATE™ ST50
0.75
Ultimate Tensile Strength
DDI (Method B)
(TD)
0.5
0.25
700 42
41
600
40.9
569 40
500
Mpa
473.4 39
Dart (g)
400
38.5
38
300
37.5
37 37.3
200
36
100
35
Reference (125 um) Dow film structure (110 um)
0
Reference (125 um) Dow film structure (110 um) Ult tensile strength (MD) Ult tensile strength (TD)
30
50
25
40
20
30
15
20
10
10
5
0 0
100°C 110°C 120°C 130°C 140°C 150°C 80°C 90°C 100°C 110°C 120°C 130°C 140°C 150°C
Sealing bar temperature
Seal bar temperature
XUS 60921.01
APPLICATIONS
DANIELLE LEE
DOW PACKAGING & SPECIALTY PLASTICS
JUNE 2021
General Business
Dow’s offerings for I&CP in APAC
• Sustainability
Using fewer resources
Using “greener” materials
• Downgauging
Material and converting efficiencies
Productivity
• Durability
Abuse and weather resistance
Equivalent performance with
thinner films
Hooding around of
Film gathering around horns
corners & edges of pallet
Pallet Stability
Follow Polymer
Regulation & Technology
Work Process
Packaging Extrusion
Technology Technology
Load Security
✓ Dow has the widest portfolio in the industry for stretch films!
Dow Restricted General Business 17
SCF Requirements
Value Propositions :
Thickness: 12u
Processing condition: > 400 mpm, > 1 mt/hr
A B
Tilting Angle: 19 degrees
---------------------------------------------
A: Dow formulation
B: Conventional LLDPE
A B
Just Started
A
320g 685g
of Film of Film
After 16 hours
After 7 days
Dow Restricted General Business 25
DOW PACKAGING SOLUTIONS:
LIQUID CONTAINER LINER
Key Drivers:
Package • Limited shelf space
Shelf Integrity &
Appeal Durability
• Consumer convenience
• Growth in e-commerce
• Challenging supply-chain &
logistics demand in Asia
Machinability
Sustainability or • Ever increasing consumer pull
Processability on sustainability
• Technology advancement
Melt Index
Resin Grades Density (g/cc)
(g/10min)
DOWLEXTM NG 5045P 0.8 0.917
DOWLEXTM 2038.68G 1.0 0.935
DOW™ LDPE 150E 0.25 0.921
XUS 60921.01 0.25 0.935
Product offerings
MI
Density
Grade g/10min, Value
g/cc
2.16Kg
ELITETM 5815
15 0.910 Low HSIT, toughness
EPE
DOW LDPE 722 8 0.918 Easy processing, low gauge variation
AGILITY™ 7030 2.5 0.919 Low neck-in for medium line speed
AGILITY™ 7000 3.9 0.919 High speed line, downgauging
TRAVIS HUANG
June,2021
DOW RESTRICTED
DOW PACKAGING ADHESIVE OVERVIEW
Springboard
A Market • Specialty • Operational
Towards Growth
Focused Chemicals Excellence
• Application • Global reach
Business One Stop Solution To
Technology • Technology
Customers’ needs
Innovation
Built from
Core
Technologies
High Innovation
ance Upgrade Performance)
Recyclability
3
DOW RESTRICTED General Business
Food Regulations and Dow’s Commitment
General Business
PACK ACADEMY DAY 3:
PACKAGING ADHESIVES –
Trouble Shooting
Meilin Li
24 June 2021
DOW CONFIDENTIALGeneral
- Do not share without permission
Business
TROUBLE SHOOTING
General Business
Tacky Issue
PROBLEMS
▪ Poor bond strength
▪ Tacky to the touch
General Business
Low Bond Strength
POSSIBLE CAUSES SOLUTIONS
▪ Low adhesive coating weight ▪ Apply optimum adhesive coat weight
▪ Inaccurate mixing ratio ▪ Ensure accurate adhesive mixing
ratio and no other sources of OH
▪ Low surface energy of the film
▪ Low nip roll temperature and/or ▪ Corona retreat the films online
pressure ▪ Increase nip temp and/or pressure
▪ Inadequate drying of the adhesive ▪ Ensure sufficient drying (temp and
▪ Insufficient curing of the finished roll ventilation) of the drying tunnel
▪ Check curing conditions and ensure
▪ Poor anchorage of metal coating on
laminate is cured fully
film (metal transfer)
▪ Poor ink adhesion (ink transfer) ▪ Change to high-quality metallized film
(chemically coated)
▪ Check lamination grade ink is used
▪ Ensure adequate drying and curing
during printing process
4
General Business
Wetting Failure
PROBLEMS
▪ White spots (mainly in white/yellow printed areas)
▪ Water-based adhesive shrinkage
▪ Streak appearance using water-based
SOLUTIONS
POSSIBLE CAUSES ▪ Optimize adhesive coat weight
▪ Low adhesive coat weight ▪ Ensure sufficient surface treatment
▪ Insufficient surface tension of films ▪ Lower running solid% to ensure good flow-ability
▪ Too high solid content (SB) ▪ Proper temperature setting at MMD and
▪ Low adhesive temperature (SL) application station
▪ Lack of/wrong setting of smooth bar ▪ Ensure sufficient pressure, correct rotating
direction and speed of smooth bar
▪ Incompatible ink system with WB
▪ Pre-check of ink compatibility and select the
▪ Soft nip rubber roll
correct adhesive
▪ Low nip temperature and pressure ▪ Rubber roller 85-95 Shore A, footprint < 0.5 inch
▪ Low rewind tension
▪ Adjust nip condition, rewind setting and curing
▪ Insufficient curing of the finished roll condition
▪ Too high line speed ▪ Optimize running speed
5
General Business
Regular Optic Faults
PROBLEMS
▪ Appearance defect along machine ▪ Distance between the spots is the same
direction. as the circumference of the damaged
roller.
POSSIBLE CAUSES SOLUTIONS
▪ Damage of application or nip rollers ▪ Close inspect roller condition and
▪ Improper cleaning of rollers replace with new ones when needed
▪ Stale adhesive mixture ▪ Stick with thorough cleaning routine
of the rollers
▪ Monitor pot life of adhesive and
discard old adhesive
6
General Business
Orange Peel
PROBLEMS
▪ Poor appearance
General Business
Haze in Lamination
Hazy Clear
General Business
Oxidation of Metalized Film (Water-Based Adhesive)
PROBLEMS
▪ Compromised barrier property
▪ Diminished glossy appearance
General Business
Wrinkles/Tunneling
PROBLEMS
▪ Poor appearance
10
General Business
Telescoping
11
General Business
Poor Heat and Chemical Resistance
PROBLEMS
▪ Delamination at sealing area
▪ Adhesion failure after heat
treatment or product aging
12
General Business
Misting (Solvent-less Adhesive)
PROBLEMS
▪ Health hazard
▪ Source of contamination
▪ Challenge of machine cleaning
13
General Business
Cylinder Clogging (Water-Based Adhesive)
PROBLEMS
▪ Challenge to cleaning
▪ Reduced adhesive loading
▪ Shorten cylinder shelf life
14
General Business
Disclaimer
The Dow Chemical Company and its subsidiaries (“Dow”) has a fundamental concern for all
who make, distribute, and use its products, and for the environment in which we live. This
concern is the basis for our Product Stewardship philosophy by which we assess the
safety, health, and environmental information on our products and then take appropriate
steps to protect employee and public health and our environment. The success of our
Product Stewardship program rests with each and every individual involved with Dow
products ─ from the initial concept and research, to manufacture, use, sale, disposal, and
recycle of each product.
NOTICE: No freedom from infringement of any patent owned by Dow or others is to be
inferred. Because use conditions and applicable laws may differ from one location to
another and may change with time, the Customer is responsible for determining whether
products and the information in this document are appropriate for the Customer’s use and
for ensuring that the Customer’s workplace and disposal practices are in compliance with
applicable laws and other governmental enactments. Dow assumes no obligation or liability
for the information in this document.
NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
15
General Business
Thank
You
Meilin Li
24 June 2021
DOW CONFIDENTIALGeneral
- Do not share without permission
Business
Contents
1. Brief Introduction to Flexible Packaging Applications &
Dow’s Full Range of Portfolios
2. Product Selection Guide
3. Successful Stories
General Business
Typical Packaging Applications & Structures
High Performance
−Retort packs, Ready meals, sterilized dairy products,
Highly aggressive products and Chemicals…
− PET//Al//CPP, PET//Al//PA//CPP, PA//CPP, PET//CPP
Medium Performance
− Fruit juices & Concentrates, Sauces, Spices, Pickles,
Condiments, Medicines, Detergents, Salt, Fairness
creams, Milk…
− PET//Al//PE, PET//VMPET//PE, PET//PE,
BOPP//VMPET//PE, PA//PE
General Performance
− Dry food products, Snacks, Cereals, Rice, Wheat
power, Biscuits, Chocolates, Candies, Wafers….
− BOPP//VMCPP, PET//PE, BOPP//PE,
BOPP//CPP, PET//VMCPP, PET//CPP, Paper//Al
General Business
Overview for Product Line
Ready-to-eat food
Sterilization
Pouches/lidding
Boil in bag
Softener/Detergents
Stand up Pouches
Hot fill/Pasteurization
food pack
Juice/Ketchup
Stand up Pouches
Snack/Biscuits
Label/Wrappers
Noodles
General Business
Contents
1. Brief Introduction of Flexible Packaging Applications &
Dow’s Full Range of Portfolios
2. Product Selection Guide
3. Successful Stories
General Business
Dry Food and Snack Packaging
Good wetting
Solvent-Based Good bond strength
ADCOTE™ 710/F
Solution Easy handling
Green solution
Water-Based Ready to use
ROBOND ™ L-80D Fast slitting and delivery
Solution
No metal transfer
General Business
Food Liquid Sachet
Mature technology
Solvent-Based Good chemical & heat resistance
ADCOTE™ 545-75EA/F
Solution Easy handling
General Business
Non-Food Liquid Sachet
General Business
Vacuum/Frozen/Pasteurized Packaging
General Business
Powder Packaging
10
General Business
Flavored Food Pouch
11
General Business
Food Stand-Up Pouch
12
General Business
Non-Food Stand-Up Pouch
13
General Business
Retort Packaging
14
General Business
Contents
1. Brief Introduction of Flexible Packaging Applications &
Dow’s Full Range of Portfolios
2. Product Selection Guide
3. Successful Stories
Case 1: MOR-FREE™ 899A/C99 Solventless Adhesive for GP-LMP Applications
Case 2: PACACEL™ 968/C-108 Solventless Adhesive for Cooking Oil SUP
Case 3: ADCOTETM 700A/E700C2 Solvent-based Adhesive for Cooking Oil SUP
Case 4: ROBONDTM L-91D Water-based Adhesive for GP Application
15
General Business
Case 1: MOR-FREE™ 899A/C99 Solventless Adhesive
Project Background:
Customer was looking for a SL grade to cover GP-LMP jobs, requirements including:
- Great bonding
- Minimal impact on COF value
- Good appearance without bubble
- No delamination or tunneling after 3 month aging @ 60oC
16
General Business
Case 1: MOR-FREE™ 899A/C99 Solventless Adhesive
Key Converting Parameters:
NCO tank: 40-45ºC Structure Coating Weight Line Speed
(gsm) (mpm)
OH tank: 35-40ºC
PET//PE 2.0-2.2 200-250
Hose Pipe: 40ºC
PET//CPP 2.0-2.2 250-300
Metering roller: 40-45ºC
OPP//VMPET 1.8-2.0 250-300
Application roller: 45-50ºC VMPET//PE 1.8-2.2 200-300
Nip roller: 45-55ºC VMPET//CPP 1.8-2.2 300-350
Performance Results:
Bond Strength COF
(MD, N/15mm)
17
General Business
Case 1: MOR-FREE™ 899A/C99 Solventless Adhesive
Value Proposition:
✓ Great bond strength on both metalized and clear films
✓ COF neutral performance
✓ Excellent chemical resistance for powder and liquid content
✓ Good wetting at high line speed
✓ Long pot life for production convenience
✓ Fast PAA decay for food safety
MOR-FREETM 899A/C99
Reference SL grade
18
General Business
Contents
1. Brief Introduction of Flexible Packaging Applications &
Dow’s Full Range of Portfolios
2. Product Selection Guide
3. Successful Stories
Case 1: MOR-FREE™ 899A/C99 Solventless Adhesive for GP-LMP Applications
Case 2: PACACEL™ 968/C-108 Solventless Adhesive for Cooking Oil SUP
Case 3: ADCOTETM 700A/E700C2 Solvent-based Adhesive for Cooking Oil SUP
Case 4: ROBONDTM L-91D Water-based Adhesive for GP Application
19
General Business
Case 2: PACACEL™ 968/C-108 Solventless Adhesive
Project Background:
• PA//PE structure for cooking oil SUP
• Require high bond strength and heat seal strength
• To replace SB adhesive
Key Deliverables:
20
General Business
Case 2: PACACEL™ 968/C-108 Solventless Adhesive
Physical Properties: Production Details:
Structure PA//PE
Parameter PACACEL™ 968 PACACEL™ C-108 Mixing ratio 100:45
NCO tank temp 35oC
Viscosity OH tank temp 40oC
@ 25°C 3500 2200 Hose pipe temp 40oC
(cps) Metering rollers temp 40oC
Density Application roller temp 40oC
1.21 1.12 Nip roller temp 42oC
(g/cc)
Metering roller gap 80 micron
Mix ratio Coating Weight 1.8-2.0 gsm
100 45
(pbw) Line Speed 150-250 mpm
Performance Comparison:
PA//PE PACACELTM 968/C-108 SB grade
Coating Weight (gsm) 1.8-2.0 3.5-4.0
21
General Business
Contents
1. Brief Introduction of Flexible Packaging Applications &
Dow’s Full Range of Portfolios
2. Product Selection Guide
3. Successful Stories
Case 1: MOR-FREETM 899A/C99 Solventless Adhesive for GP-LMP Applications
Case 2: PACACELTM 968/C-108 Solventless Adhesive for Cooking Oil SUP
Case 3: ADCOTETM 700A/E700C2 Solvent-based Adhesive for Cooking Oil SUP
Case 4: ROBONDTM L-91D Water-based Adhesive for GP Application
22
General Business
Case 3: ADCOTETM 700A/E700C2 Solvent-based Adhesive
Project Background:
• PET//PE structure for cooking oil SUP
• Require good wetting performance at high line speed
• Require great bond and heat seal strength
Physical Properties:
Functionality NCO OH
Solid content 65% 75%
Viscosity @ 25oC 550 3500
23
General Business
Case 3: ADCOTETM 700A/E700C2 Solvent-based Adhesive
Production Details:
Structure PET//PE120-150
Mix ratio 100:20
Cylinder 120-150 LPI
Running solid 32-35%
Viscosity (Zahn cup #4) 7 - 8 sec
Dying tunnel temp 85oC to 90oC
Nip temperature 70oC
Nip pressure 5 bar
Line speed 280 - 320 mpm
Coating weight 2.8 - 3.0 gsm
24
General Business
Contents
1. Brief Introduction of Flexible Packaging Applications &
Dow’s Full Range of Portfolios
2. Product Selection Guide
3. Successful Stories
Case 1: MOR-FREETM 899A/C99 Solventless Adhesive for GP-LMP Applications
Case 2: PACACELTM 968/C-108 Solventless Adhesive for Cooking Oil SUP
Case 3: ADCOTETM 700A/E700C2 Solvent-based Adhesive for Cooking Oil SUP
Case 4: ROBONDTM L-91D Water-based Adhesive for GP Application
25
General Business
Case 4: ROBONDTM L-91D Water-based Adhesive
ROBOND™ L-91D is a one component ready to use WB adhesive balancing high line speed
with good wetting and high initial bond on 2-layer metalized structures:
Customer Case:
❑ Structure: BOPP//MCPP, BOPP//MOPP
❑ Lamination speed: ≥250 mpm
❑ Results: bubble free appearance & bond strength > 1.0 N/15mm without metal transfer
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Disclaimer
The Dow Chemical Company and its subsidiaries (“Dow”) has a fundamental concern for all
who make, distribute, and use its products, and for the environment in which we live. This
concern is the basis for our Product Stewardship philosophy by which we assess the
safety, health, and environmental information on our products and then take appropriate
steps to protect employee and public health and our environment. The success of our
Product Stewardship program rests with each and every individual involved with Dow
products ─ from the initial concept and research, to manufacture, use, sale, disposal, and
recycle of each product.
NOTICE: No freedom from infringement of any patent owned by Dow or others is to be
inferred. Because use conditions and applicable laws may differ from one location to
another and may change with time, the Customer is responsible for determining whether
products and the information in this document are appropriate for the Customer’s use and
for ensuring that the Customer’s workplace and disposal practices are in compliance with
applicable laws and other governmental enactments. Dow assumes no obligation or liability
for the information in this document.
NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
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Thank
You
Julia Roselee
24 June 2021
General Business
Dow: Pioneering in Laminating Adhesives
Broad Product Portfolio World Class R&D Centers Long History and Many
and Market Participation and Manufacture Invention “First”
General Business
Dow’s Capabilities in Asia
15 Manufacturing Sites
enables manufacturing efficiency &
on-time delivery
Pack Studios
empowers our capabilities in testing,
Nagoya
simulation & prototype design
BERHC
Experienced Local Team
SERHC
Shanghai provides on-site support and fast
Sanshui Minhsiung
response, enabling alignment to
market needs
Taloja LasPinas
MTP-1,2 Vietnam
Chennai
Singapore
Packaging Adhesives
Shanghai Development Center
Manufacturing
R&D & Application Center Cilegon
Technical Center
Geelong Auckland
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Packaging Laboratory Capabilities at Shanghai Dow Center (SDC)
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Packaging Laboratory Capabilities at Dow Singapore Development
Center (DSDC)
NanoSEM 630
General Business
Dow Innovation History
General Business
Technologies and Brand Names
General Business
Water-Based Adhesive Handling and
Laminating Process
General Business
Dry Lamination – Water-based Adhesive
Appearance
Like milk – translucent to opaque white
Particle Size
Usual range is 50~1000nm(0.05~1.0microns)
Molecular Weight
500,000 – 1,000,000 is typical.
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General Business
Water-based Lamination Machine
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Machine & Coating Conditions
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Tips For WB Lamination Process
Lamination Process: Drying Tunnel: Nip Roller:
− Recirculation feeding system − Drying tunnel length ⩾ 8m − hardness 85 -90°
− Gravure cylinder − Air flux: around 40-50m3/min − Temperature⩾60℃
− Smooth bar − Temperature: 70-100℃ − High pressure
− Sufficient drying improve initial BS
− Nip roller
Recirculation Feeding:
− Full circulation of adhesives
− Use low shearing pump
− Choose shortest route for
adhesive circulation
− Ensure sufficient adhesive in
container
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After 30 Seconds Cylinder Stoppage
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Key Points to Note for Good Lamination
15
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ROBOND™ Water-Based Adhesives Overview
WATER-BASED
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Solvent-Based Adhesive Handling and
Laminating Process
17
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Types of SB Adhesives
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Types of SB Adhesives
19
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The Laminating Process of Solvent-Based Adhesive
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Temperature Setting
Drying tunnel
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Machine and Coating Conditions
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ADCOTE™ Solvent-Based Adhesives Overview
Solvent- based
General Medium High
Performance Performance Performance
ADCOTETM 545S/F ADCOTETM 811A/F
ADCOTETM 545-75EA/F
ADCOTETM 700A/E700C
ADCOTETM 516A/B
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Solventless Adhesive Handling and
Laminating Process
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General Business
Basic Chemistry For Solventless Adhesive
Polyol + Di-isocyanate
HO(•••)OH OCN()NCO
Polyether OR Aromatic OR
Polyester Aliphatic
Polyurethane
(NH-CO-O) n •••
polymerization
OH terminated - NCO terminated
Polyester base OR polyether base
Aromatic OR aliphatic
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General Business
Solventless Lamination Process
R2
X s4 Rewind
Unwind 2
R1 X
TR s3
OH NCO
s1 s2 Unwind 1
MMD Application
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Meter, Mix and Dispense (MMD)
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Application Roller
1. Temperature
Check the actual temperature in the “Dam”. Do not rely on the temperature settings
Adhesive too thin - hard to achieve Adhesive too thick - poor flow &
coating weight, shorter pot life appearance at correct coating weight
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General Business
IMPORTANT For Checking Coating Weight (CW)
CW is affected by :
1. Dosing roll gap (uniform across length)
2. Speed of transfer roller.
3. Viscosity of adhesive.
It MUST be measured at the beginning of each job with the fresh adhesive, correct
temperature and at the production running speed.
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Important Processing Parameter to Note with
Solventless Adhesives
Good web tension is needed The roll hardness, impression Suspend horizontally for at
due to low initial bonds and pressure, cleanliness and least 24 hours in the aging
shear strengths of the shape of the nip roller affects room before slitting.
adhesive. the laminate appearance
Best to cure at 45-55 deg C
Uniform pressure across the Hot nip gives good optical
width is needed to prevent appearance but may lead to Heat seal and pouching done
telescoping tension control problems or after 4 – 5 days.
laminate curl.
Chemical resistance after 7 –
Nip temperatures are usually 10 days
Poor tension control can lead
to curling, folds, creases and set between 40 – 60oC
tunneling. depending on the substrates.
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General Business
Solvent-less Adhesives Overview
Solvent-less
MOR-FREETM 706A/C99
MOR-FREETM 899A/C99
MOR-FREETM 706A/C79
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New Innovation Technologies on The Horizon
HP SL Adhesive for
PET/Foil
GP SL
MP WB adhesive for
Adhesive better
wetting/metal
Innovation adhesion
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General Business
Differences in Parameters
Solvent-based Water-based Solventless
Chemistry Polyurethane Poly-acrylate Polyurethane
Machine Dry Laminator Solventless Laminator
Mixing
Standard Mechanical Mixer Metering Mixing Device
Method
Running
25% to 50% 42% to 45% 100%
Solid
Coating
Method
5 roller solventless
Rotogravure adhesive coating system
Coating
2.0gsm to 5.0 gsm 1.8gsm to 2.5gsm 1.5gsm to 2.5gsm
Weight
Drying
60℃ to 80℃ 70℃ to 90℃ N.A.
Condition
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Comparison Among Adhesive Technologies
Solvent-based Water-based Solventless
• Needs capital
investment
• Potential solvent • Lower initial bond strength • Very low initial bond
exposure might pose (compared to solvent- strength
health concerns based adhesives)
Considerations • Requires higher
• Improper handling • Applicable to general and operational skills
might lead to low-medium performance
explosions market segments • Requires Metering
Mixing Device (MMD)
pump
* Potential health hazards such as irritations to eyes, skin and may cause drowsiness. For additional information, please refer to the respective
product’s material safety data sheet (MSDS).
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