Barcellona

NEW DEVELOPMENT 22-23 November

IN MONO-MATERIAL

Speaker: Mr. Giovanni Stocchetti (GAP Co-Founder)

Our Origins

GAP starts its

Polytype and PRANDI business in the early

ITALIA
begins a new strategic GAP 2000s as a technical
spin- off of
partnership
Polytech.

1998 2004

1960 2001

PRANDI was born in the 60s and soon

becomes worldwide leader in dubble New ownership and
and triple bubble extrusion rebranding transforms
technologies, plus Cast and Extrusion Polytype into Polytech
Coating.

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Our History

GAP strengthens and consolidates

GAP launches Micro-Layers
its financial position while laying
Technology for blown film line, up
the foundations for strong growth
to 27-layers.
in the coming years.

2012 2015

2013 2023

GAP launches the new Multi Launch of Strategic

Bubble Technology: 1st Partnership between Gap
installation of a 9 layers triple and Uteco Group.
bubble line.

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 Our Company
We have a worldwide installed based of extrusion machineries.

45+
Employees
60+
Installed machines
50+
Sold-in countries

Worldwide presence with

specialty solutions
installed

4
Our Product Portfolio
Our machines portfolio satisfies any customer
needs through the most advanced technologies in
the sector.

Extrusion Coating
&
Lamination
A
Casting Single Bubble
(From 3 up to 27 layers using
F B Micro-Layer technology)

Flat Die Blown film

lines EXTRUSION lines
TECHS

E C
Water Quench Double Bubble
D (Bi-Axial orientation)

Multi Bubble
(Bi-Axial orientation)

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New Development in Mono-Material

Topics of our presentation:

1. Monomaterial PE crosslink solution for stand up pouch without

Reduce
lamination

2. Microlayering technology in the PE solution

3. Monomaterial BOPE for reverse printing

4. Monomaterial BOPP barrier film recyclable

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1. Monomaterial PE crosslink solution for Stand-up pouch without lamination

High demand to replace a printable

substrate film BOPA or BOPET on the
duplex or triplex lamination.
The request is to produce a single material
mainly PE based film, fully recyclable.
BOPA or BOPET have both high elastic
modules and high heat resistance.

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Material identity to substitute BOPET and BOPA outer layer

• Transparent

• Heat resistant

• Printable

• Easy to convert

• Fully recyclable

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Table 1: Technology Comparison
Microlayer MDOLike
MDO PE BOPE (*)
Reverse or direct printing ,
/ Reverse printing and Reverse printing and
ready to use for surface printing
lamination Lamination
and lamination
Production System Sensitive and critical sensitive Easy

It depends from temperature It depends from temperature general

Stability During Sealing Stable up to 180°C (**)
sensitive to MD shrink stable for balanced orientation
Surface Heat Resistance
(For high temperature NO NO YES
sealing bar)

Thickness Range 15-40 microns 15-40 microns 20-50 microns

Printability Good it mainly depends from Good

Good
selection

Process Cast or Blown Double bubble Tenter Blown Microlayer

Up to 400 /500 Kg/h

Production Output High rate of production Up to 400-500 Over 1.000 Kg/h Tenter up to 800 Kg/h
scraps rate Kg/h
Two stage or
Orientability Simultaneous simultaneous No orientation
Only MD direction
MD and TD MD and TD
Barrier Version Available and Difficult Available easy available Easy

Product Recyclability Easy Easy Easy

Easy
* Polymers supplied by LyondellBasell ** EB Treated 9
Table 2: Products Comparison

/ / PET MDO PE BOPE DB (*) BOPE TF Microlayer MDOLike

Reverse or direct
Reverse printing and Reverse printing and Reverse printing and Reverse printing and printing, ready to use
Application Unit of Measure
lamination lamination lamination lamination for surface printing and
lamination

Thickness micron 12 25 20 20 25

Tensile modulus N/mm2 4.000 1500/2000 1200/1300 1000/1200 680/910

Tensile strength MPa 163 245 100 140 85

Haze % 3 4 6 5 8

Gloss @ 45° GU 130 80 55 70 66

ELEMENDORF MD 10- TD 15 MD 40 – TD 700 MD 8- TD 10 MD 10- TD 13 MD 50 - TD 1020

Shrink 120°C % MD 1 – TD 0 MD 15 – TD 0 MD 5 – TD 5 MD 5 – TD 5 MD 1 – TD 0

* Polymers supplied by LyondellBasell 10

 Why do not reduce packaging and avoiding lamination?
In the view of reduction of packaging material we have the possibility to combine three
functions: 1st outer layer heat resistance; 2nd barrier; 3rd sealing layer all in one mono-
material fully recyclable film
…..in these last decades we have engineered sophisticated lamination
products also for simple applications.

Today it’s necessary to reduce the “over design” of the packaging………and

may be to accept to have a less “fashion packaging”…. Concentrating on its
functionality.

This packaging should have properties like: heat resistance up to 180 °C,
Oxygen barrier, high mechanical tear and puncture resistance: what else do
you need?

This packaging should not have any adhesive, should be ready for de-
inking, if necessary, and should be recyclable.
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Off-line crosslinked solutions
GAP provides unwinder + EB system + rewinder
Possibility of producing recyclable barrier film PE / EVOH / PE in line (max 5% EVOH) which guarantees an optimal
WTR and OTR for various types of barrier packaging (examples of barrier films that could be produced and printed
on the outer layer).

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 Off-line crosslinked solutions

Example with 100 micron film, crosslinked,

surface printed, no lamination
The PE-X-GAP allows you to be flexible; the process is divided into two
phases: the first it’s a Microlayer blown film line to produce multifunction
layers by microlayer technology.

After blown film process, we have an off line crosslink equipment that,
combined with dedicate film structures, the film achieves a heat resistance and
no re-shrink at 180°C during sealing.

MD and TD film characteristics are also balanced and makes a single material,
for example 100 micron crosslinked film,printed outside and so you avoid the
lamination.

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2. Microlayers – multifunction a new proved way

GAP proves already in all the technologies the value of the process evolution and you have a
challenge to translate process developments into prospective film applications , there are
new business opportunities and have to be identified into:

Production advantages: we are offering an important evolution in terms of better quality extrusion
performance and extreme flexibility of our system. It’s new and totally different from an old extrusion concept
systems and distribution, its really a new era with a new concept.
Film technical performances: our objective with 27 layers is to create alternating layers of different PEs in
order to couple the best impact strength polymer with the best tear strength polymer. Therefore, alternating
layers of very strong mLLDPE’s will produce the best film toughness using polymers that would not yield the
same properties if blended in one thick layer.

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 Main production advantages for Microlayer

 The die can work with a 9 layer standard configuration or 27 layers that means you have a lot of possibilities to
change film structure from non barrier to barrier type.
 Constant material flow rate and layer % : each layer is 3,7% of the total.
If you have to change layer %, there is no need to change throughput of each layer, but simply to increase the
numbers of layers, those combining more layers together.
Conventional die concepts requires to change polymer flow inside the die to increase layer %.
 Easy alternation of PCR and virgin material
 Easy way to change over EVOH: we are able in 20 minutes to entry with a EVOH layer and the same time to take
out EVOH and move back to PE. Possibility to extrude EVOH layer of minimum of 2%
 Flexibility to use a specific layer structure as the number of formulations and film structures are unlimited.
 Easy bubble TD blown since each layer is thinner and its easier to blown in comparison with thick layers
 Faster and better film tolerances.
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 Technical film characteristics advantages with multifunction layers

 Improved mechanical characteristics of the film and reduction of film thickness by 30%, at least
• Formulations and film structures are unlimited as the materials pass through a feed block
 Possibility to strengthen the film structure with material like HDPE , PP etc. in dedicated layers
 Reduced additives and tie layers consumption
 Possibility to extrude EVOH layer with a minimum of 2%
 Possibility to increase elastic modules with specific formulation to reach MDO characteristics
 Best flex crack resistance by dividing the EVOH nucleus into 4 thin layers, very important for BIB (Bag-In-Box)
 New potentails in film reflection and possibility to include a “color-not-color” in the film.
 Possibility to include nano additive to improve barrier
 Higher transparency due to microlayer
 Possibility to strengthen the film structure alternating PA and EVOH inside the film structure.
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Microlayering technology up to 27 layers in the PE solution, where we are using
microlayers.
Alternating layers, the mechanical
characteristics are improving by at
least 30%

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7 Extruders x 21 layers and 9 Extruder x 27 layers: What next ?

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PCR study with Microlayers

RECIPE WITHOUT PCR RECIPE WITH PCR

MECHANICAL PROPERTIES MD TD MECHANICAL PROPERTIES MD TD
Tensile (Mpa) 32 30 Tensile (Mpa) 27 29
Elongation (%) 500 745 Elongation (%) 450 720
Elastic Modulus (MPa) 440 455 Elastic Modulus (MPa) 400 420
Tear Resistence (N) 9,6 10,6 Tear Resistence (N) 9,2 10,5

OPTICAL PROPERTIES VALUE SD OPTICAL PROPERTIES VALUE SD

Haze (%) 6,04 0,2 Haze (%) 8,02 0,49
Trasmittance (%) 92,7 0,14 Trasmittance (%) 91,4 0,23

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GAP MicroLayer Vs. Commercial Blown Film

400 TENSILE AT BREAK &MODULUS

360
350 Commercial film produced on 3 layers blow film line 340
325
Die diameter 300mm 310 305
300 Die lip 1,25/2,25 mm 290
film width 1600mm
Blow-up ratio 3,4
250 Draw-down ratio 7,35

GAP film produced on 27 layer GAP blow film line

200
Die diameter 400mm
Die lip 2 mm
150 film width 1600 mm
Blow-up ratio 2,55
Draw-down ratio : 35um 22,4 - 55um 14,3
100
Polymer extruded, same or equivalent

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24,5 22,6 26 27 24,5 23

0
MD TD MD TD
STRENGTH AT BREAK (MPa) MODULUS (MPa)
GAP 35 μm GAP 55 μm (600kg/H) EXISTING FILM IN THE MARKET 90 μm

* Polymers supplied by LyondellBasell 20

GAP MicroLayer Vs. Commercial Blown Film

TEAR AND PUNCTURE RESISTANCE

25

22,6
21,5

20

15,7
15
15

11,2

10
8,6
8
6,86 6,64 6,95 7

5,2 5 5
5
3,61 3,67

0
MD TD UP DOWN
TEAR RESISTANCE (N) PUNCTURE RESISTANCE (N)
GAP 35 μm GAP 55 μm (600kg/H) GAP 90 μm EXISTING FILM IN THE MARKET 90 μm

* Polymers supplied by LyondellBasell 21

3. BOPE produced by Simultaneous Orientation is a great alternative to
MDO film up to 500 Kg/h
PROPERTIES UNIT TEST BOPE 20
ASTM
THICKNESS µm 20
D2103
100% BOPE and BARRIER BOPE
DENSITY g/cm3 - 0,953
YIELD g/m2 - 16
PHYSICAL PROPERTIES*:
TENSILE STRENGTH (L/T)
80 / 75
ELONGATION (L/T)
ELASTIC MODULUS (L/T) MPa ASTM 150 / 160
% D882 1500 / 1500
*TEST DONE WITHIN 24 H FROM THE
MPa
PRODUCTION, AT T = 22 °C AND HR
60%
ASTM
SHRINKAGE - 120 °C IN HOT AIR % 5/7
D2732
ASTM
HAZE % 8
D1003

ASTM
GLOSS % 92
D1003

* Polymers supplied by LyondellBasell 22

 1st step: primary tube production

Multilayer tube production without any orientation 1:1 , we

have different concepts for tube quenching:
- External Vacuum quench system
- Dry calibrator quench system
- Wet calibrator quench system
- New contactless calibrator system

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 2nd step: tube pre heating and orientation

The primary tube is then

re-heated up to a
suitable temperature
and blown to form the
main bubble of thin film.
Orientation is made
simultaneously in
machine direction and
transversal direction no-
contact simultaneox
orientation is achieved
thanks to the air inflated
during the start up
phase.

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Simultaneox orientation BOPE film

Contactless orientation no need of

Uniformity and balance any clips which damages the
mechanical and shrink material and requires large
characteristics in MD and TD trimming.

Trim-less process , huge saving

Flexibility in the film thickness cost in the productivity, costly
barrier film can not be recycled

Application range of material is Band-less with 360° continuous

wider ( heat set – shrink – partial winder rotation especially in
shrink) important thickness

Simultaneox orientation easy to Increased planarity of the film

get a very transparent barrier film

Film heating one time only no

need to re heat for second Final product flexibility in terms of
orientation avoiding defect in type of products and retraction.
crystallization. 25
4. BOPP Barrier produced by simultaneus orientation at up to 1.000 Kg/h

BARRIER OPP

Properties Unit Test Value Value

Thickness um D2103 30 40
Yield gr/m2 - 27,5 36,6
cc/24hr/m2/atm
O2 permeability D3985 20 20
(85%RH), 23° C
Physical properties°:
tensile strength (MD/TD)
230/210 MD / TD
elongation (MD/TD) MPa D882
80/120 MD/TD
elastic modulus (MD/TD) %
3000/2600 MD/TD

Water vapour transmission gr/24hr/m2/atm F1249 5 4

7 MD
Retraction % 120°C X 60 sec
1 TD
Haze % D1003 2.0-2.5
Gloss GU D2457 87
Sealing range 2 sec 0,10 NM/m2 GAP 110-130°C

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 Why BOPP barrier film?

 High oxygen barrier, even at high %RH  Global food contact compliance
 Gas barrier – MAP, N2, CO2  High clarity and low haze
 MOSH / MOAH mineral oil barrier  Printable
 Aroma barrier  Suitable for lamination
 Chlorine and plasticiser free, alternative to PVDC  Heat sealable on both sides
coating  Designed for Recycling

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Today flexible packaging producers need to reduce packaging weight

- Reducing the thickness , weight of the packaging

- Avoiding further converting steps if possible
- Recyclability
- Keeping same performance of the film in terms of barrier, mechanical
properties, etc.
- Reduce, recycle and increase performance for barrier and monomaterial

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We have solutions to reduce material consumption and film down gauging,
increase performances and recyclability of films, such as:

No-contact simultaneous orientation double

and multi bubble lines up to 4.000 mm
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Or:

Annular micro-layer die

technology x layers MIRA LAYER to be
used in all annular processes
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 Or a Combination of Both

We have experimented it: we have achieved great

results from 30% up to 50% thickness reduction
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 We prove already in all the technologies the value of the
process evolution and you have a challenge to translate
W W W. G A P I TA LY. CO M

process developments into prospective film applications:

there are new business opportunities that have to be
identified.

Giovanni Stocchetti
[email protected]

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