Packaging: Downgauged air column bags for logistics; full PE thermoformed packaging for recyclability

Chinese film convertor Zhejiang Jujie New Material Co wanted to reduce material use by downgauging the co-extruded polyethylene (PE) films used for its air column bags. Air column bags are widely used as protective packaging during e-commerce logistics and transportation.

Thus, it collaborated with US materials supplier ExxonMobil to utilise its Exceed XP and Exceed S 9243 performance PE that can enable downgauged PE films for use of less material.

The typical structure of an air column bag is PE/ tie-layer/PA/tie-layer/PE co-extrusion. ExxonMobil provided Jujie with one of its new downgauged starting formulations that uses Exceed S 9243 and Exceed XP 6056 performance PE in the PE layer of the air column bags.

Starting from the ExxonMobil-provided formulation, Jujie made custom modifications to arrive at a solution that works in its five, seven, nine-layer blown lines, and Jujie then seals and tubes the film into bags with its bag making line.

Data from trials conducted by Jujie demonstrated that a 45-micron film, downgauged by 10% compared to a market reference film, offered excellent burst resistance, comparable film stiffness and needle puncture performance, as well as strong cost and material savings potential, says the firm.

The success of the trial led to the commercialisation of 45-micron air column bag by Jujie, which helps to establish its technology advantage compared to other market players with the 50-60 micron products.

Meanwhile in another case study, ExxonMobil collaborated on a full PE thermoformed packaging with 95 weight % PE content. It consists of a formed PE/ EVOH bottom web and PE/EVOH lid film - with both high oxygen barrier and package integrity through optimised corner thickness and puncture.

The bottom web was produced with ExxonMobil resins like Exceed XP, Exceed and Enable performance PE and a special EVAL EVOH resin for thermoforming. The films were made on a Reifenhäuser Aqua Cool nine-layer barrier line.

ExxonMobil resins Exceed XP 7052ML and Enable 4009MC provide puncture performance and formability, while the EVAL EVOH resin LT172B designed for thermoforming, combines low thickness with high barrier properties.

The top film consists of a PE/EVOH coex film produced on a Reifenhäuser Aqua Cool nine-layer barrier line with Exceed XP 7052ML, Exceed 2012MA and EVAL EVOH high barrier resin L171B.

The suppliers say that the combination of Reifenhäuser’s Aqua Cool technology and ExxonMobil’s performance resins can result in excellent optics, exceptional puncture performance and formability.

The package was then formed and filled on a Multivac R126 machine according to industry standard process conditions. Under optimised thermoforming trial conditions on the R245 Multivac line, maximum line speed (>12 cycles/ minute) was achieved.

(PRA)

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