Responding to waste reduction drive

As a result of a national strategy based on producing zero waste, recycling rates in Japan are amongst the highest in the world. Due to the cost of recycling, the strategy has also resulted in a drive towards consuming less material by using stronger, thinner packaging films. Since the introduction of the Containers and Packaging Law in 1995, there have been very high growth rates of plastics recovery and re-use in Japan.

As the volume of packaging materials has risen so has the cost of collection and recycling. The primary aim of the plastics sector is to reduce the amount of material used, through thinner, or light-weight packaging. As a result, the need for innovative materials, that allow downgauging while maintaining packaging performance and keeping costs under control, from a company with a pedigree in technology leadership, has never been higher.

Thinner, stronger metallocene polyethylene films

The introduction of high performance plastic films is a welcome one in Japan, as well as in other regions around the world. For instance, ExxonMobil Chemical’s Enable? mPE and Exceed? metallocene polyethylene (mPE) resins and Vistamaxx? propylene-based elastomer (PBE) have allowed converters to develop downgauged flexible films with excellent mechanical properties and sealing strength which then enhances package integrity. These materials are ideal for a broadrange of film applications in consumer and retail packaging, industrial packaging and agricultural films.

Enable mPE resins offer an outstanding combination of film processing and higher alpha olefin (HAO) performance benefits in a single resin. In this case, converters can benefit from more stable operations, improved film line output, film downgauging and simpler resin sourcing when replacing multi-resin blends. When replacing LLDPE-rich blends output can increase by up to 20 percent with no additional capital cost and, because Enable mPE resins can be extruded at lower melt temperatures, they may result in energy savings during the manufacturing process.

Often surpassing the mechanical performance requirements of LLDPE-rich structures, Enable mPE resins cansignificantly improve film toughness allowing downgauging by more than 20 percent. These downgauging opportunities can result in lower material use and reduced film consumption. This, when combined with more consistent film quality, can lead to less waste and improved film performance, including lower rates of package failure, less product spillage and longer packaging shelf life.

Exceed mPE resins allow the manufacture of films for highly demanding end-use applications, creating value not only for film converters but also their customers. Film properties include an outstanding balance of film toughness and strength, excellent film impact resistance, dazzling optical properties and exceptional sealing performance. The toughness and strength can potentially deliver film downgauging opportunities which may result in lower packaging weight. The toughness and strength may also reduce end-of-line packaging shut-downs caused by film breakage.

The optical properties provided by Exceed mPE resins can improve print quality, enhance product appeal, increase consumer brand recognition, and make bar code reading easier versus conventional LLDPE resins. The sealing performance increases end-of-line packaging speed at potentially no additional cost and can delay packaging line investment. It may enhance packaging integrity, improve performance of sealed packages such as pouches and laminated bags for longer shelf-life, and reduce form, fill and seal packaging line shut-downs.

Vistamaxx PBE creates new possibilities for a range of flexible film, extrusion coating and lamination applications. At the core of many of these new solutions is the ability of Vistamaxx PBE to tailor, enhance and balance a combination of properties, includAir Maxs