The customer was perfectly happy with the existing co-ex UN approved film we were supplying but they had feedback from their customers in the Asia Pacific region asking for a more rigid pack to help in their manual handling activities.
We therefore had to adapt the existing FFS (form fill and seal) film to;
- Propose a stiffer more rigid film for easier single-pack handling
- Take cost out of the packing and logistics chain
- Have an easy-seal recipe for dusty filling environments
- Run through the FFS packer at high speed
We looked at this from a technical development perspective rather than the usual route of “thicker is better”. We decided to formulate a 3 layer co-ex film using premium resins that would give us these performance criteria.
The film required would need to be tubular FFS so we had a problem with lower BUR (blow up ratio) performance from the extruder compared to flat film technology. This is where recipe knowledge and experience in the laboratory and real-life applications is essential.
We proposed a 140mu co-ex film that we had developed > this film increased the yield strength of the film (that which most people know as stiffness or rigidity) by between 40-50% compared to the existing film that had performed well and to expectation.
In addition the puncture and tear resistance also increased by between 15-20% which brought further additional enhancements and benefits to the pack.