Move From Multi-web?
Are advances in film barrier technology to the point that multi-web structures could soon be obsolete? Or is multi-web still preferred to produce today's high-end packaging?
By Chris Bauer
PRODUCERS OF FLEXIBLE packaging materials are constantly on the lookout for products that help bring down costs while speeding up the process. film suppliers now have the ability to add more sophisticated barrier properties to a single layer of film. So does this mean single layers of film for packaging have the potential to replace common multi-web structures?
"We are actually seeing more multiple layer structures being put together at this point," says Rich Eichfeld, national sales manager for Columbus, OH-based Plastic Suppliers. He feels although there is a longing from customers to move to simpler structures, film vendors have not improved products to that point as of yet—but the day should be coming.
"With all the technical advances going on right now, if it were more than five years I would be surprised," predicts Eichfeld. Yet he admits it is difficult to pin-point the future of the ever-changing package printing process. Printers don't seem to be so sure technology will advance to the point that they will be moved to abandon multi-web substrates.
According to a recent Flexible Packaging Association (FPA) survey, multi-web structure usage is on the rise—and is expected to keep growing in the next few years. In five years, 72 percent of converters surveyed expect the majority of their work will involve multi-web structures. And pP's Top Flexible Packaging Converters confirmed that point. Respondents from the largest packaging facilities in North America reported that the majority of their work currently consists of multi-web film constructions—55 percent in 1999.
Marketing changes
"The issue as far as whether one goes with multi-layer comes from a presentation of the package standpoint," explains Malcolm Cohn, marketing manager for UCB Films. "People [need] reverse printed or sandwich printed designs and therefore you have to have a laminated or multi-form type of construction. It's not really that dependent on the barrier, but more about the presentation."
John Coyne, product manager for Van Leer Performance Films, agrees. He says customers still want to use multi-web constructions so that ink can be trapped between the two layers. Surface printed packages are not as popular, film suppliers say. Van Leer offers the Valeron line of products, aimed at chemical, medical, and pharmaceutical applications.
The growth of multi-web packages is the end result of new marketing campaigns and a change to high-end, upscale packaging with detailed graphics used by industries that traditionally went with more modest packaging, says Scott Ross, market segment manager for the flexible packaging group at International Paper. He reports seeing more products in the agricultural market moving to multi-web packaging due to more elaborate package designs.
"Some areas that two, three, or four years ago never considered using a [multi-web] package are very rapidly embracing the technology," Ross says. "Stand-up pouches and the advent of higher-end, value-added packaging in some of the non-traditional market segments will absolutely continue."
Gauging trends in film
Eichfeld, of Plastic Suppliers, says he sees polypropylene beginning to take the place of polyester for many applications. Though he is not willing to sell polyester down the river as of yet, he does say, "price-wise and yield-wise polypropylene does have the advantage." This is leading to another industry trend, vendors say.
"People really want to maximize the yield by minimizing the gauge," Cohn of UCB Films continues. "Everyone wants to bring the gauge down and still maintain the performance. Well, you can downgauge and downgauge to a certain point, but you can't achieve the barriers that are required to extend the shelf life. This is a problem." Cohn feels end-users should look closely at quality and productivity issues and not just at price.
Plastic film vendors are not the only ones affected by trends in the packaging substrate market. Others are rushing to cash in on current industry needs.
"Industry experts consider high-performance barrier levels as the future in food packaging," adds Helmut Frankenberger, general manager of the large area display division at Balzers Process Systems (BPS), a German-based provider of metallizing systems for packaging materials. BPS recently released its TOPNET 4000 product, a coating system designed for use on all types of flexible packaging. It operates by using high throughput evaporation technology for aluminum coatings on plastic films and paper, Frankenberger explains. The TOPNET system was developed in just eight months to meet the growing demand for producing multi-web packages.
