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“The Indian Market for
Specialty Packaging Films –
Applications and Opportunities”
-Vijay Shankar (Vice President)
Mamata Extrusion Systems Pvt. Ltd., India.
During
International Conference on MULTILAYER PACKAGING FILMS ‘2014
on
June 24, ‘2014
at
Chicago, Illinois, USA
1www.mamataextrusion.com
1. Introduction
2. Indian Market for Plastics and flexible
packaging films
3. Applications
4. Opportunities
5. A case study of
Edible Oil Packaging Film – Mono to Seven Layer
Contents
2www.mamataextrusion.com
Contents (Contd.)
6. Role of Blown Film Technology -
Mono to Co-extrusion Film
6. Role of Indian Packaging Eco-systems – Case
Studies
“Eno” Effervescence Powder Sachets
6. Something about Mamata Group
7. Conclusion
www.mamataextrusion.com 3
Introduction
4www.mamataextrusion.com
To understand the Indian market for Specialty
Packaging Films, we have look into the current
consumption of Specialty / Flexible packaging/
non packaging films as Indian market is still
driven by COMODITY films
The Current Driving forces in Indian market is
Lower COST of production/ PRICE
The potential of Indian market is it’s own
population of 1.25 B+ @ 18% of world
population of 7 B+
Introduction contd…
5www.mamataextrusion.com
According to the recent studies conducted
,the flexible packaging market in India is worth
USD 8.5 B @4.35% of global market of USD
195 B
This translates into approx. 2.55 MMT of
Flexible Packaging @ 21.6% of Total Plastics
consumed as 11.8 MMT in India
Indian market for plastics & flexible packaging
films
Packaging films :
i. Food Packaging :
Milk Packaging
Edible Oil Packaging
Water Packaging
Bread Bags
Spices – Whole/ grounded
Ready to eat Snacks- Nankeens, Potato Chips
etc.
Chewing Mouth Freshners
Heavy Duty Packing for rice, wheat flour etc.
Snack Food : Oriented PP film
Stand up pouches
www.mamataextrusion.com
6
Film Applications
ii. Non Food Packing :
3 Layer film in flexible lami tube -Huge
market segment growing rapidly
Strech & Cling Film
Shrink Film
Liner Bags
Institution Liner Bags
Bag in Box
Medical packaging
Heavy Duty Sack bags
Plastic Granule Bags
Grocery Sack bags
Agriculture Films
ANTIFOG Films
www.mamataextrusion.com
7
Film Applications
ii. Non Packaging :
Consumer purchased films and articles
Agriculture and Construction films
Diaper and Personal Hygiene films
Mulch, Green House films
Silage bags films
Surface protection films
www.mamataextrusion.com
8
Opportunities –
India as manufacturer base for global market
9
Global market for flexible packaging material is
worth USD 195 billion & growing at a rate of CAGR
3.5% as against 8.5% in India. By this estimate, one
can imagine the growth potential of flexible
packaging in India in coming days which is
tremendous.www.mamataextrusion.com
CAGR %
Plastic Industry Status Report
10www.mamataextrusion.com
Total Polymer Consumption 2012-13
Thermoplastics + Thermosets
POLYMER 2012-2013 2016-2017
(Estimated)
DEMAND 11.80 MMT 17.60 MMT
CARG 10.70%
Polymer Consumption – Application wise 2012-13
11www.mamataextrusion.com
Total Installed Capacity – Film Plants up to
2012-13
12
www.mamataextrusion.com
Up to 2012-13 No of machine
installed
Installed Capacity
(MMT)
Monolayer Film 9370 1.625
Multilayer 1290 1.050
BOPP 33 0.600
PPTQ Film 2950 0.640
Total 13643 3.915
A Case Study of
Edible Oil Packaging Film
- Mono to Nine Layers
13www.mamataextrusion.com
14
3664Ghee
3763Butter
3961Vanaspati
5050Palm
8020Groundnut
8416Soybeans
8812Sunflower
946Mustard /Rapeseed
1090Coconut
Unsaturated fatty acidsSaturated fatty acidsProducts
Types of Edible Oil in India and Fatty Acid Composition of Oils
/ Fats
www.mamataextrusion.com
Higher the unsaturation percentage, fast will be the spoilage
Monolayer to 3 Layer Edible Oil Film
Monolayer Structure
No of Layers 01
Polymer
45% LLDPE + 10% HDPE + 10% LDPE +
30% m-LL + 5% MB
% Thickness 100%
Total Thickness 120 Microns ( 4.8 Mil)
Price (USD/kg)* 2.01
www.mamataextrusion.com
15
Monolayer to 3 Layer Edible Oil Film
3 Layer Structure
# of Layers 01 (Outer) 2 3 (Inner)
Polymer
45% LLD + 10%
HD + 10% LD +
30% m-LL + 5%
MB
75% LLD + 10%
HD + 10% LD +
5% MB
60% LLD + 10% LD
+ 30% m-LL
% Thickness 20% 60% 20%
Total Thickness 100 Microns ( 3.93 Mil)
Price(USD/kg) * 1.95
www.mamataextrusion.com
16
Monolayer to 3 Layer Edible Oil Film
Benefits
Distinct skin layers – slip on sealant & non slip on
surface
Low COF on inner layers
Chances of least pin holes
Coloured master batch only in middle and outer
Possibilities of using PP, HDPE & PE in desirable
blends in different layers
3.42 % SAVING ( USD 0.06 PER KG ) IN RECIPE
COST AS COMPARED TO MONO LAYER
www.mamataextrusion.com
17
5 Layer Generic Structure - A
5 Layer Structure
# of Layers 1 (Outer) 2 3 4 5 (Inner)
Polymer
62% LLD
(C4) +
10% LD +
20% m-LL
+ 8% MB
Tie
Poly
Amide
Tie
60%
LLD(C4) +
10% LD +
30% m-LL
% Thickness 38% 6% 12% 6% 38%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg) *
2.44
Benefits
Excellent Gas Barrier Properties in 5 Layer (Shelf Life up to 3-6 months).
www.mamataextrusion.com
18
7 Layer Generic Structure - A
7 Layer Structure
# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner)
Polymer
70% LLD
(C4) +
10% LD +
20% m-LL
82% LLD
(C4) +
10%
LD+8%
MB
Tie
Poly
Amide
Tie
82% LLD
(C4) +
10%
LD+8%
MB
60%
LLD(C4) +
10% LD +
30% m-
LL
%
Thickness
19% 19% 6% 12% 6% 19% 19%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg) *
2.41
Benefits
Lower Sealant Cost & hence lower over all cost of the film
www.mamataextrusion.com
19
5 Layer Generic Structure - B
5 Layer Structure
# of Layers 1 (Outer) 2 3 4 5 (Inner)
Polymer
62% LLD
(C4) +
10% LD +
20% m-LL
+ 8% MB
Tie
Poly
Amide
Tie
60%
LLD(C4) +
10% LD +
30% m-LL
% Thickness 20% 15% 30% 15% 20%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg) *
3.05
Benefits
Excellent Gas Barrier Properties in 5 Layer (Shelf Life up to 6 – 12
months).
www.mamataextrusion.com
20
5 Layer to 7 Layer Generic Structure – B1
7 Layer Structure – Break up PA
Layer# of Layers 1
(Outer)
2 3 4 5 6 7 (Inner)
Polymer
62% LLD
(C4) +
10% LD +
20%
mLL+ 8%
MB
Tie
Poly
Amide
Tie
Poly
Amide
Tie
60%
LLD(C4) +
10% LD +
30% m-LL
% Thickness 25.5% 7% 14% 7% 14% 7% 25.5%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg) *
2.91
Benefits
As 30% Nylon may crack & loose barrier in long run & hence it is
addressed by splitting the Nylon Layer to make structure 7 Layer.
Split Nylon layer to 14% &14% to make ~ 30% single layer of Nylon.
0.14 USD / KG in 7 layer recipe cost as compared to 5 layer Generic
Structure - A
* SEA CIF Prices
www.mamataextrusion.com
21
7 Layer ( Generic Structure – B2)
7 Layer Structure – With EVOH
* SEA CIF Prices
# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner)
Polymer
62% LLD (C4)
+ 10% LD +
20% m-LL+
MB 8%
Tie PA EVOH PA Tie
60% LLD(C4) +
10% LD + 30%
m-LL
% Thickness 41% 3% 4% 4% 4% 3% 41%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg) *
2.55
Benefits
EVoH with almost ~ 5 times barrier than Nylon at ~ 2.5 times price, with
capability to have a sandwich layer with Nylon on both sides without Tie layer
brings over all price down without compromising on Barrier Properties.
0.36 USD Per kg in recipe cost w.r.t 5 Layer Generic Structure-A
www.mamataextrusion.com
22
9 Layer ( Generic Structure – B2)
9 Layer Structure – With EVOH
* SEA CIF Prices
# of
Layers
1 (Outer) 2 3 4 5 6 7 (Inner)
Polymer
67% LLD
(C4) + 10%
LD + 20%
m-LL+ MB
3%
90% LLD
(C4) + 10%
LD
Tie PA EVOH PA Tie
90% LLD
(C4) + 10%
LD
57% LLD(C4)
+ 10% LD +
30% m-LL
% Thickness 20% 21% 3% 4% 4% 4% 3% 21% 20%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg)
*
2.51
Benefits
The sealant layer costs reduced
www.mamataextrusion.com
23
24www.mamataextrusion.com
Role of Blown Film
Mono to Co-extrusion
Why Co-extrusion Blown Film
As there are still many MONO Layer
Blown film lines in market, there is a
need to either upgrade / replace them
to/ with at least a 3 Layer line.
25www.mamataextrusion.com
Film Properties : Multilayer Vs. Monolayer
26
Film property, Unit Monolayer
film LDPE
(50 micron)
Multilayer
3-layer film
LL/LD/LL
(30 micron)
Benefit (%)
Yield Tensile strength MD, MPa 9.5 12.3 + 29.5
Yield Tensile strength TD, MPa 9.0 13.0 + 44.0
Ultimate Tensile stress MD, MPa 26 28.2 + 8.0
Ultimate Tensile stress TD, Mpa 21 27.4 + 30.0
Ultimate Elongation MD, % 245 415 + 69.0
Ultimate Elongation TD, % 650 745 + 14.6
Specular Gloss, % 60 65 + 8.3
Tear Resistance MD, g/mil 38 50 + 31.5
Seal ability property Moderate Excellent improved
Note:
• All the above figures are merely indicative and for academic intent. They are not a commitment for any
offered model of Film Plant and must be discussed in advance. Types of materials and material blends can
reduce / enhance the characteristics mentioned above.
www.mamataextrusion.com
The output rates of individual layers in a multilayer
die are very much lower than for equivalent size of
single layer die. The results in reduced shear rate and
longer resistance time in the die spirals, leading to
better homogeneity and additional relaxation of
melt. Hence, the inherent benefits of Co-extrusion is
improvement of film quality.
27
Why Co-extrusion Blown Film
www.mamataextrusion.com
FILM QUALITY
Ultimately there will be no need of any MONO Layer
as 3 Layer will be able to offer a BETTER & CHEAPER
solutions as it can now produce films using all PEs
(LDPE/LLDPE/mLLDPE/HDPE etc.) & PPs (Homo as
well Co- Polymer) through an ENGEENIRED
STRUCTURE in a 3 Layer Blown Film Line.
28
Why Co-extrusion Blown Film
www.mamataextrusion.com
Present Future
This trend will need a joint co-operation with
Machine manufacturers, Resin manufacturers & film
producers to ADD VALUE to the whole process in
phased manner.
29
www.mamataextrusion.com
Future Trends in Co-Extrusion
The SLIM packaging ahead will force the Industry to control
the RESOURCE by producing thinner & thinner films without
compromising the core properties. A film today of say 1 mil
(25 micron) will have to be down gauged to ultimately be of
12- 15 microns. To achieve this, we will have to develop very
high line speed based Post Extrusion Equipment.
30
www.mamataextrusion.com
Low Speed PEEs
High Speed PEEs
1 mil (25 microns)
0.5 mil (12-15 microns)
Film Thickness Blown Film Line
Post Extrusion Equipment (PEEs)
Looking into the future concerns globally
to be kept this EARTH as GREEN as
possible, we need to produce 100%
recyclable flexible packaging laminates.
This means we will have to produce blown
films to replace existing non- recyclable
substrates like PET, BOPP etc. Hence, there
is a need to produce the blown film which
could be having HIGH CLARITY & HIGH
STIFNESS using say Homo Polymer PP
blend in core & LL/mLL/LD blends in skins
as usual to get a Double FROST line based
film.
31
www.mamataextrusion.com
Future Trends in Co-Extrusion
Future Trends of Co-Extrusion
This film needs to be further processed for
Double Bubble/ Triple Bubble operations for
highest possible across the width strength due to
higher BUR. The film has to pass further through
MDO (Machine Direction Orientation) process for
enhance machine direction strength to enable
film be running at very high line speed during
printing with negligible STRTCHING. All the above
processes has been achieved by Industry very
successfully on individual operation base. Now
the need of the hour is to marry them all together
which is a challenging mile stone ahead. The
reverse printed Blown film will then be laminated
with another Blown film as sealant layer to offer
recyclable LAMINATES.
32www.mamataextrusion.com
Role of Indian Packaging Eco-friendly
system –
i. ENO Sachets
33www.mamataextrusion.com
Eno Pouches – Eco Friendly System
34
Earlier Present
www.mamataextrusion.com
Something about Mamata Group
35www.mamataextrusion.com
Mamata Group
36
The Flagship company of the GroupThe Flagship company of the Group
A Fully owned subsidiary of MamataA Fully owned subsidiary of Mamata to make
Multi layer Blown Film Line Systems and elements
A Green Field ProjectA Green Field Project to propogate Usage of Solar
Thermal Energy for Purpose of Cooling & Heating
applications.
Engineering & Marketing Arm of MamataEngineering & Marketing Arm of Mamata
MachineryMachinery in USA at ILLINOIS & FLORIDA
How we started:
In 1989, MAMATA MACHINERY introduced a unique
concept in Bag Making Machines. Mamata was one of
the very few companies in the world to have offered
Microprocessor controlled Machines at that time.
Mamata has been exporting it’s product historically,
Infact, Mamata exported it’s 1st
machine in 1990 itself.
Mamata has developed Machines which are specifically
targeted for the markets of Europe and United states of
America.
Mamata introduced Vega series Machines in Europe in
1998 and introduced Machines in USA in 2003.
www.mamataextrusion.com
Bag making machines
37
Where we are today:
Today, Mamata has significant presence in USA. Mamata USA
Inc. was formed and became operational in 2003 to service
USA, Canada and Central South American Markets.
With over 3000 Machines in more than 75 countries, Mamata
Machinery Pvt. Ltd. Has emerged as one of the Leading
companies in this field Globally.
www.mamataextrusion.com 38
Fastest System in world for Zip inserted Wicket Bags.
www.mamataextrusion.com
Bag making machines
39
Fastest system in world for making Flower Sleeve / Bags
www.mamataextrusion.com
Bag making machines
40
Fastest system in the world for making slider zipper
pouches
www.mamataextrusion.com
Bag making machines
41
More than
110 machines supplied to USA in 100 months.
300 machines running in Europe.
200 machines supplied to South Afirca.
800 machines supplied to rest of African Countries.
Undisputed leadership in Indian market with more than
1000 machines
www.mamataextrusion.com
Bag making machines
42
Manufactured based on design from
Klockner, Germany.
Basic design was based on clutch and
brake technology for indexing. Sealing
jaw movement was cam driven.
We changed film indexing and sealing
jaw movement in line with our design
philosophy with servo technology.
First machine became ready for
commercial sale in ‘2000.
Since then we have sold 13 machines for
applications to pack powders / liquids.
43
Packaging machines
www.mamataextrusion.com
44
M-200 HFFS Pouch Machine
Setting New Standards in Pouch Making
www.mamataextrusion.com
45
MAMATA ENTERPRISES INC.
MONTGOMERY, ILLINOISwww.mamataextrusion.com
Facilities / Locations…
Head Office & Manufacturing facility at:
Ahmedabad, Gujarat, INDIA
Pre-sales & After sales service centre &
showroom:
Montgomery, IL-60538 USA.
Agent Network in:
Over 15 countries in…
Europe
Middle East
Far East
Africa
www.mamataextrusion.com 46
Blown film lines
47www.mamataextrusion.com
MES has dedicated facility of
140,000 Sqr. Feet. For Assy. and
testing of Blown Film Line
With Canadian technology platform,
we manufacture -
Blown Film Lines of 1000 mm to
3000 mm width, output range from
120 kg/hr to 1000 kg/hr.
Basic 3 Layer Lines & State-of-the
art, Fully Automated Lines with
Internal Bubble Cooling Systems for
higher output and critical
applications.
Conclusion
48www.mamataextrusion.com
PE-PE laminate for bulk packaging application
PE-PE laminate for environment /recyclability- major thrust
by MNC globally
As can be seen, monolayer is not a market but a phase in
many part of the world as ultimately any monolayer has to
upgrade itself into co-ex with 2 0r 3 layer to go away from
the problems of Pin Holes, Strength Properties / Process
ability /down gauging and finally cost per square meter of
Film. With recent advance in Die Design and Air Ring
designs, Co-Extrusion Blown Films have far more benefits
in terms of cost savings with optimum film properties by
varying layer ratios in range of 1:2:1 and can go up to
1:5:1 and even up to 1:8:1.
Thank You…
49

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Indian market for specialty packaging films

  • 1. “The Indian Market for Specialty Packaging Films – Applications and Opportunities” -Vijay Shankar (Vice President) Mamata Extrusion Systems Pvt. Ltd., India. During International Conference on MULTILAYER PACKAGING FILMS ‘2014 on June 24, ‘2014 at Chicago, Illinois, USA 1www.mamataextrusion.com
  • 2. 1. Introduction 2. Indian Market for Plastics and flexible packaging films 3. Applications 4. Opportunities 5. A case study of Edible Oil Packaging Film – Mono to Seven Layer Contents 2www.mamataextrusion.com
  • 3. Contents (Contd.) 6. Role of Blown Film Technology - Mono to Co-extrusion Film 6. Role of Indian Packaging Eco-systems – Case Studies “Eno” Effervescence Powder Sachets 6. Something about Mamata Group 7. Conclusion www.mamataextrusion.com 3
  • 4. Introduction 4www.mamataextrusion.com To understand the Indian market for Specialty Packaging Films, we have look into the current consumption of Specialty / Flexible packaging/ non packaging films as Indian market is still driven by COMODITY films The Current Driving forces in Indian market is Lower COST of production/ PRICE The potential of Indian market is it’s own population of 1.25 B+ @ 18% of world population of 7 B+
  • 5. Introduction contd… 5www.mamataextrusion.com According to the recent studies conducted ,the flexible packaging market in India is worth USD 8.5 B @4.35% of global market of USD 195 B This translates into approx. 2.55 MMT of Flexible Packaging @ 21.6% of Total Plastics consumed as 11.8 MMT in India
  • 6. Indian market for plastics & flexible packaging films Packaging films : i. Food Packaging : Milk Packaging Edible Oil Packaging Water Packaging Bread Bags Spices – Whole/ grounded Ready to eat Snacks- Nankeens, Potato Chips etc. Chewing Mouth Freshners Heavy Duty Packing for rice, wheat flour etc. Snack Food : Oriented PP film Stand up pouches www.mamataextrusion.com 6
  • 7. Film Applications ii. Non Food Packing : 3 Layer film in flexible lami tube -Huge market segment growing rapidly Strech & Cling Film Shrink Film Liner Bags Institution Liner Bags Bag in Box Medical packaging Heavy Duty Sack bags Plastic Granule Bags Grocery Sack bags Agriculture Films ANTIFOG Films www.mamataextrusion.com 7
  • 8. Film Applications ii. Non Packaging : Consumer purchased films and articles Agriculture and Construction films Diaper and Personal Hygiene films Mulch, Green House films Silage bags films Surface protection films www.mamataextrusion.com 8
  • 9. Opportunities – India as manufacturer base for global market 9 Global market for flexible packaging material is worth USD 195 billion & growing at a rate of CAGR 3.5% as against 8.5% in India. By this estimate, one can imagine the growth potential of flexible packaging in India in coming days which is tremendous.www.mamataextrusion.com CAGR %
  • 10. Plastic Industry Status Report 10www.mamataextrusion.com Total Polymer Consumption 2012-13 Thermoplastics + Thermosets POLYMER 2012-2013 2016-2017 (Estimated) DEMAND 11.80 MMT 17.60 MMT CARG 10.70%
  • 11. Polymer Consumption – Application wise 2012-13 11www.mamataextrusion.com
  • 12. Total Installed Capacity – Film Plants up to 2012-13 12 www.mamataextrusion.com Up to 2012-13 No of machine installed Installed Capacity (MMT) Monolayer Film 9370 1.625 Multilayer 1290 1.050 BOPP 33 0.600 PPTQ Film 2950 0.640 Total 13643 3.915
  • 13. A Case Study of Edible Oil Packaging Film - Mono to Nine Layers 13www.mamataextrusion.com
  • 14. 14 3664Ghee 3763Butter 3961Vanaspati 5050Palm 8020Groundnut 8416Soybeans 8812Sunflower 946Mustard /Rapeseed 1090Coconut Unsaturated fatty acidsSaturated fatty acidsProducts Types of Edible Oil in India and Fatty Acid Composition of Oils / Fats www.mamataextrusion.com Higher the unsaturation percentage, fast will be the spoilage
  • 15. Monolayer to 3 Layer Edible Oil Film Monolayer Structure No of Layers 01 Polymer 45% LLDPE + 10% HDPE + 10% LDPE + 30% m-LL + 5% MB % Thickness 100% Total Thickness 120 Microns ( 4.8 Mil) Price (USD/kg)* 2.01 www.mamataextrusion.com 15
  • 16. Monolayer to 3 Layer Edible Oil Film 3 Layer Structure # of Layers 01 (Outer) 2 3 (Inner) Polymer 45% LLD + 10% HD + 10% LD + 30% m-LL + 5% MB 75% LLD + 10% HD + 10% LD + 5% MB 60% LLD + 10% LD + 30% m-LL % Thickness 20% 60% 20% Total Thickness 100 Microns ( 3.93 Mil) Price(USD/kg) * 1.95 www.mamataextrusion.com 16
  • 17. Monolayer to 3 Layer Edible Oil Film Benefits Distinct skin layers – slip on sealant & non slip on surface Low COF on inner layers Chances of least pin holes Coloured master batch only in middle and outer Possibilities of using PP, HDPE & PE in desirable blends in different layers 3.42 % SAVING ( USD 0.06 PER KG ) IN RECIPE COST AS COMPARED TO MONO LAYER www.mamataextrusion.com 17
  • 18. 5 Layer Generic Structure - A 5 Layer Structure # of Layers 1 (Outer) 2 3 4 5 (Inner) Polymer 62% LLD (C4) + 10% LD + 20% m-LL + 8% MB Tie Poly Amide Tie 60% LLD(C4) + 10% LD + 30% m-LL % Thickness 38% 6% 12% 6% 38% Total Thickness 100 Microns ( 3.93 Mil) Price (USD/kg) * 2.44 Benefits Excellent Gas Barrier Properties in 5 Layer (Shelf Life up to 3-6 months). www.mamataextrusion.com 18
  • 19. 7 Layer Generic Structure - A 7 Layer Structure # of Layers 1 (Outer) 2 3 4 5 6 7 (Inner) Polymer 70% LLD (C4) + 10% LD + 20% m-LL 82% LLD (C4) + 10% LD+8% MB Tie Poly Amide Tie 82% LLD (C4) + 10% LD+8% MB 60% LLD(C4) + 10% LD + 30% m- LL % Thickness 19% 19% 6% 12% 6% 19% 19% Total Thickness 100 Microns ( 3.93 Mil) Price (USD/kg) * 2.41 Benefits Lower Sealant Cost & hence lower over all cost of the film www.mamataextrusion.com 19
  • 20. 5 Layer Generic Structure - B 5 Layer Structure # of Layers 1 (Outer) 2 3 4 5 (Inner) Polymer 62% LLD (C4) + 10% LD + 20% m-LL + 8% MB Tie Poly Amide Tie 60% LLD(C4) + 10% LD + 30% m-LL % Thickness 20% 15% 30% 15% 20% Total Thickness 100 Microns ( 3.93 Mil) Price (USD/kg) * 3.05 Benefits Excellent Gas Barrier Properties in 5 Layer (Shelf Life up to 6 – 12 months). www.mamataextrusion.com 20
  • 21. 5 Layer to 7 Layer Generic Structure – B1 7 Layer Structure – Break up PA Layer# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner) Polymer 62% LLD (C4) + 10% LD + 20% mLL+ 8% MB Tie Poly Amide Tie Poly Amide Tie 60% LLD(C4) + 10% LD + 30% m-LL % Thickness 25.5% 7% 14% 7% 14% 7% 25.5% Total Thickness 100 Microns ( 3.93 Mil) Price (USD/kg) * 2.91 Benefits As 30% Nylon may crack & loose barrier in long run & hence it is addressed by splitting the Nylon Layer to make structure 7 Layer. Split Nylon layer to 14% &14% to make ~ 30% single layer of Nylon. 0.14 USD / KG in 7 layer recipe cost as compared to 5 layer Generic Structure - A * SEA CIF Prices www.mamataextrusion.com 21
  • 22. 7 Layer ( Generic Structure – B2) 7 Layer Structure – With EVOH * SEA CIF Prices # of Layers 1 (Outer) 2 3 4 5 6 7 (Inner) Polymer 62% LLD (C4) + 10% LD + 20% m-LL+ MB 8% Tie PA EVOH PA Tie 60% LLD(C4) + 10% LD + 30% m-LL % Thickness 41% 3% 4% 4% 4% 3% 41% Total Thickness 100 Microns ( 3.93 Mil) Price (USD/kg) * 2.55 Benefits EVoH with almost ~ 5 times barrier than Nylon at ~ 2.5 times price, with capability to have a sandwich layer with Nylon on both sides without Tie layer brings over all price down without compromising on Barrier Properties. 0.36 USD Per kg in recipe cost w.r.t 5 Layer Generic Structure-A www.mamataextrusion.com 22
  • 23. 9 Layer ( Generic Structure – B2) 9 Layer Structure – With EVOH * SEA CIF Prices # of Layers 1 (Outer) 2 3 4 5 6 7 (Inner) Polymer 67% LLD (C4) + 10% LD + 20% m-LL+ MB 3% 90% LLD (C4) + 10% LD Tie PA EVOH PA Tie 90% LLD (C4) + 10% LD 57% LLD(C4) + 10% LD + 30% m-LL % Thickness 20% 21% 3% 4% 4% 4% 3% 21% 20% Total Thickness 100 Microns ( 3.93 Mil) Price (USD/kg) * 2.51 Benefits The sealant layer costs reduced www.mamataextrusion.com 23
  • 24. 24www.mamataextrusion.com Role of Blown Film Mono to Co-extrusion
  • 25. Why Co-extrusion Blown Film As there are still many MONO Layer Blown film lines in market, there is a need to either upgrade / replace them to/ with at least a 3 Layer line. 25www.mamataextrusion.com
  • 26. Film Properties : Multilayer Vs. Monolayer 26 Film property, Unit Monolayer film LDPE (50 micron) Multilayer 3-layer film LL/LD/LL (30 micron) Benefit (%) Yield Tensile strength MD, MPa 9.5 12.3 + 29.5 Yield Tensile strength TD, MPa 9.0 13.0 + 44.0 Ultimate Tensile stress MD, MPa 26 28.2 + 8.0 Ultimate Tensile stress TD, Mpa 21 27.4 + 30.0 Ultimate Elongation MD, % 245 415 + 69.0 Ultimate Elongation TD, % 650 745 + 14.6 Specular Gloss, % 60 65 + 8.3 Tear Resistance MD, g/mil 38 50 + 31.5 Seal ability property Moderate Excellent improved Note: • All the above figures are merely indicative and for academic intent. They are not a commitment for any offered model of Film Plant and must be discussed in advance. Types of materials and material blends can reduce / enhance the characteristics mentioned above. www.mamataextrusion.com
  • 27. The output rates of individual layers in a multilayer die are very much lower than for equivalent size of single layer die. The results in reduced shear rate and longer resistance time in the die spirals, leading to better homogeneity and additional relaxation of melt. Hence, the inherent benefits of Co-extrusion is improvement of film quality. 27 Why Co-extrusion Blown Film www.mamataextrusion.com FILM QUALITY
  • 28. Ultimately there will be no need of any MONO Layer as 3 Layer will be able to offer a BETTER & CHEAPER solutions as it can now produce films using all PEs (LDPE/LLDPE/mLLDPE/HDPE etc.) & PPs (Homo as well Co- Polymer) through an ENGEENIRED STRUCTURE in a 3 Layer Blown Film Line. 28 Why Co-extrusion Blown Film www.mamataextrusion.com Present Future
  • 29. This trend will need a joint co-operation with Machine manufacturers, Resin manufacturers & film producers to ADD VALUE to the whole process in phased manner. 29 www.mamataextrusion.com
  • 30. Future Trends in Co-Extrusion The SLIM packaging ahead will force the Industry to control the RESOURCE by producing thinner & thinner films without compromising the core properties. A film today of say 1 mil (25 micron) will have to be down gauged to ultimately be of 12- 15 microns. To achieve this, we will have to develop very high line speed based Post Extrusion Equipment. 30 www.mamataextrusion.com Low Speed PEEs High Speed PEEs 1 mil (25 microns) 0.5 mil (12-15 microns) Film Thickness Blown Film Line Post Extrusion Equipment (PEEs)
  • 31. Looking into the future concerns globally to be kept this EARTH as GREEN as possible, we need to produce 100% recyclable flexible packaging laminates. This means we will have to produce blown films to replace existing non- recyclable substrates like PET, BOPP etc. Hence, there is a need to produce the blown film which could be having HIGH CLARITY & HIGH STIFNESS using say Homo Polymer PP blend in core & LL/mLL/LD blends in skins as usual to get a Double FROST line based film. 31 www.mamataextrusion.com Future Trends in Co-Extrusion
  • 32. Future Trends of Co-Extrusion This film needs to be further processed for Double Bubble/ Triple Bubble operations for highest possible across the width strength due to higher BUR. The film has to pass further through MDO (Machine Direction Orientation) process for enhance machine direction strength to enable film be running at very high line speed during printing with negligible STRTCHING. All the above processes has been achieved by Industry very successfully on individual operation base. Now the need of the hour is to marry them all together which is a challenging mile stone ahead. The reverse printed Blown film will then be laminated with another Blown film as sealant layer to offer recyclable LAMINATES. 32www.mamataextrusion.com
  • 33. Role of Indian Packaging Eco-friendly system – i. ENO Sachets 33www.mamataextrusion.com
  • 34. Eno Pouches – Eco Friendly System 34 Earlier Present www.mamataextrusion.com
  • 35. Something about Mamata Group 35www.mamataextrusion.com
  • 36. Mamata Group 36 The Flagship company of the GroupThe Flagship company of the Group A Fully owned subsidiary of MamataA Fully owned subsidiary of Mamata to make Multi layer Blown Film Line Systems and elements A Green Field ProjectA Green Field Project to propogate Usage of Solar Thermal Energy for Purpose of Cooling & Heating applications. Engineering & Marketing Arm of MamataEngineering & Marketing Arm of Mamata MachineryMachinery in USA at ILLINOIS & FLORIDA
  • 37. How we started: In 1989, MAMATA MACHINERY introduced a unique concept in Bag Making Machines. Mamata was one of the very few companies in the world to have offered Microprocessor controlled Machines at that time. Mamata has been exporting it’s product historically, Infact, Mamata exported it’s 1st machine in 1990 itself. Mamata has developed Machines which are specifically targeted for the markets of Europe and United states of America. Mamata introduced Vega series Machines in Europe in 1998 and introduced Machines in USA in 2003. www.mamataextrusion.com Bag making machines 37
  • 38. Where we are today: Today, Mamata has significant presence in USA. Mamata USA Inc. was formed and became operational in 2003 to service USA, Canada and Central South American Markets. With over 3000 Machines in more than 75 countries, Mamata Machinery Pvt. Ltd. Has emerged as one of the Leading companies in this field Globally. www.mamataextrusion.com 38
  • 39. Fastest System in world for Zip inserted Wicket Bags. www.mamataextrusion.com Bag making machines 39
  • 40. Fastest system in world for making Flower Sleeve / Bags www.mamataextrusion.com Bag making machines 40
  • 41. Fastest system in the world for making slider zipper pouches www.mamataextrusion.com Bag making machines 41
  • 42. More than 110 machines supplied to USA in 100 months. 300 machines running in Europe. 200 machines supplied to South Afirca. 800 machines supplied to rest of African Countries. Undisputed leadership in Indian market with more than 1000 machines www.mamataextrusion.com Bag making machines 42
  • 43. Manufactured based on design from Klockner, Germany. Basic design was based on clutch and brake technology for indexing. Sealing jaw movement was cam driven. We changed film indexing and sealing jaw movement in line with our design philosophy with servo technology. First machine became ready for commercial sale in ‘2000. Since then we have sold 13 machines for applications to pack powders / liquids. 43 Packaging machines www.mamataextrusion.com
  • 44. 44 M-200 HFFS Pouch Machine Setting New Standards in Pouch Making www.mamataextrusion.com
  • 45. 45 MAMATA ENTERPRISES INC. MONTGOMERY, ILLINOISwww.mamataextrusion.com
  • 46. Facilities / Locations… Head Office & Manufacturing facility at: Ahmedabad, Gujarat, INDIA Pre-sales & After sales service centre & showroom: Montgomery, IL-60538 USA. Agent Network in: Over 15 countries in… Europe Middle East Far East Africa www.mamataextrusion.com 46
  • 47. Blown film lines 47www.mamataextrusion.com MES has dedicated facility of 140,000 Sqr. Feet. For Assy. and testing of Blown Film Line With Canadian technology platform, we manufacture - Blown Film Lines of 1000 mm to 3000 mm width, output range from 120 kg/hr to 1000 kg/hr. Basic 3 Layer Lines & State-of-the art, Fully Automated Lines with Internal Bubble Cooling Systems for higher output and critical applications.
  • 48. Conclusion 48www.mamataextrusion.com PE-PE laminate for bulk packaging application PE-PE laminate for environment /recyclability- major thrust by MNC globally As can be seen, monolayer is not a market but a phase in many part of the world as ultimately any monolayer has to upgrade itself into co-ex with 2 0r 3 layer to go away from the problems of Pin Holes, Strength Properties / Process ability /down gauging and finally cost per square meter of Film. With recent advance in Die Design and Air Ring designs, Co-Extrusion Blown Films have far more benefits in terms of cost savings with optimum film properties by varying layer ratios in range of 1:2:1 and can go up to 1:5:1 and even up to 1:8:1.