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FLEX FILMS

“Manufacturing globally to serve you locally”

Technology Overview

Steven Sargeant, Ph.D.General Manager R&D

Jan 2017

CONFIDENTIAL INFORMATION OF UFLEX & FLEX CORPORATION

Vision, Mission & Values

VISION

“Be a leading company and preferred supplier for

providing flexible packaging solutions to customers

across the world maximizing value for all stakeholders”

MISSION

To meet customers’ dynamic packaging needs by

providing innovative, productive, cost-effective, optimized

and eco-friendly packaging solutions, continually adding

value to their business.

About Uflex

Engaged in providing end-to-end flexible packaging solutions to customers viz. packaging design &

color scheme, packaging structure, packaging products (value added anti-counterfeiting solutions to

prevent look alikes from eroding the brand equity of our clients world over)& filling machines;

Most integrated to have presence in all verticals of flexible packaging value chain

Largest flexible packaging company in India and emerging player in the global market

Promoted and founded in 1985 by Mr. Ashok Chaturvedi, a first generation entrepreneur

A great story of entrepreneurship, perseverance, operational excellence, belief and a proven track record of

success

World class manufacturing facilities of packaging films in India, Dubai, Mexico, Egypt, Poland and USA

(Current Capacity– 337,000 TPA) and of packaging products at multiple locations in India (Current

Capacity- 90,000 TPA) accredited by ISO/BRC/HACCP

Focus on innovation, new product development and faster reach to the customers;

Large array of packaging products in terms of size and types of goods they can pack, touching people’s

lives everyday, everywhere.

Strong Global sales and distribution network with customers in about 140 countries

Strategic Business Units

Flex Films Advantages

Manufacturer NAFTA

Region

Sites

Lead-Time Claims

Resolution

Terms Tech

Service

Lead-time

Product

Portfolio

Field Tech

Service

Lead-time

Local

Technical

Staff

FLEX Films 1-USA

1-MEXICO

Typically 7 -14

Days For

Clear

10 Days For

Metalized

30 Day

Target

Typically

Net 30

Typically 1-

2 Days

Broadest platform

of thin films for

packaging,

printing and

converting

markets

World’s largest

film metalizer

Typically 1-2

Days

Yes

Domestic-

NAFTA

DTF

Toray

Mitsubishi

SKC

Polyplex

Typically 4-12

Weeks for

Clear

Metalized 10-

16 Weeks

Variable Typically

Net 30

Long Focused on IT,

electronics and

related

Typically 2-4

weeks

Yes

Offshore-

BRICs

None 8-12 Weeks ? Prepaid ? Thin Films Not Available No

Offshore-Non

BRICs

None 8 Weeks ? Prepaid ? Thin Films Not Available No

Flex is the most committed supplier to the NAFTA region thin film market

Film Grade Chips : Raw Material for manufacturing Polyester Films

Yarn Grade Chips : Raw Material for manufacturing Polyester Yarn

Bottle Grade Chips : Raw Material for production of PET Bottles

Capacity (TPA) : India – 72,000

Properties : Barrier Properties, High Tensile & Dielectric Strength,Thermal & Chemical Stability & Toughness

Application : Food Packaging, Electric Insulation, Graphic Arts andImaging

Capacity (TPA) : India – 54,000; Dubai – 52,000; Mexico- 60,000;Egypt – 30,000; Poland - 30,000 & USA – 30,000 (2,56,000 TPA)Brand : FLEXPET

BOPET Films

Properties : Strong Moisture Barrier, Highly Cost Effective,Functionally Efficient

Application : Food Products Packaging (confectionery, biscuits,bakery, pasta etc.), Cigarette Cartons Wrapping, Bags forReadymade Garments, Adhesive Tapes & Print Lamination

Capacity (TPA) : India – 30,000; Egypt – 35,000 (65,000 TPA)

Brand : FLEXOPP

BOPP Films

Polyester Chips

Packaging Film Business

CPP Films

Properties : Highly Dynamic & Versatile Films with High Gloss,Greater Transparency, Better Heat Sealability, Good TwistingProperty & Better Tear Strength

Application : Retort Packing, Food Wraps, Anti Wraps, Anti Fog,Garments Bag, Deep Freeze Applications etc.

Capacity (TPA) : India – 4,000; Egypt – 12,000 (16,000 TPA)

Brand : FLEXCPP

Metallization

Properties : Easy to process because of flexible properties, Getsback to original shape even after folding, Can be used in outer,middle or inner layer because of sealing properties, Easy to slitin narrow widths, High shelf life

Application : Snack food packaging, Biscuits & other Bakeryproducts, Packaging of PET food etc.

Capacity (TPA) : India – 33,600; Dubai – 4,800; Mexico- 15,600;Egypt – 18,000; Poland - 10,800 & USA – 10,800 (93,600 TPA)

Brand : FLEXMET

Packaging Film Business

Overseas Manufacturing Facilities, Capacity &

Commissioning

FME’s state-of-art facility has an installed capacity to produce over 51,600 MT of BOPET film per annum

DUBAI

BOPET Film Line I:

• 6.7 meter wide High Performance BOPET Film line of

22,000 MT p.a. capacity commissioned in Mar 2005

under Phase 1.

• The line produces films for various applications in the

thickness range of 9-50 microns

BOPET Film Line II:


30,000 MT p.a. capacity commissioned in Sep 2007

under Phase 2.



Metalizer:

• 2.5 meter wide state of art metalizer commissioned

under Phase-1

• Produces over 4,800 MT p.a. of high barrier metallized

films

Contd.

FME’s state-of-art facility has an installed capacity to produce over 60,000 MT of BOPET film p.a.

BOPET Film Line I:


30,000 MT p.a. capacity commissioned in April 2009

under Phase 1.



MEXICO

BOPET Film Line II:

• 8.7 meter wide High Performance BOPET film line of

30,000 MT p.a. capacity commissioned in July 2011

under Phase 2.



Metalizer:

• State-of-art metalizers commissioned under Phase 1/2


films

• AlOx Production

Contd.

BOPP Film Line & CPP Film Line:

• 8.7 meter wide High Performance BOPP Film line of

35,000 MT p.a. capacity commissioned in

September,2010 under Phase 1.

• 3.7 meter wide High Performance CPP Film line of

12,000 MT p.a. capacity commissioned in July ,2011

EGYPT

Flex P Films state-of-art facility has an installed capacity to produce over 77,000 MT of BOPET/ PP films p.a.

BOPET Film Line:


30,000 MT p.a. capacity commissioned in December,

2011 under Phase 2. It is the only Polyester film in

Africa.



Metalizer:

• 2.85 meter wide state-of-art metalizers commissioned


films

AlOx Coating:

• Produces 2,400 MT p.a. of high barrier transparent films

Contd.

BOPET Film Line :


30,000 MT p.a. capacity commissioned in July 2012.



POLAND

Flex Films Europa’s state-of-art facility has an installed capacity to produce over 30,000 MT of BOPET film p.a.

Metalizer:

• State-of-art metalizer commissioned


films

Contd.

BOPET Film Line:


30,000 MT p.a. capacity commissioned in Jan 2013.



• One of the world’s largest film line and bigger than any

other film line presently in the USA

USA-KENTUCKY

Flex Films (USA) state-of-art facility has an installed capacity to produce over 30,000 MT of BOPET film p.a.

Metalizer:

• State-of-art metalizer commissioned


films

Film Making Process Front-End

Film Making Process-Backend

Film Making Process-Slitting and

Packaging

Metalizing and METSLIT

PET Film Process

• PET Chip

• Co-Ex Process

• MDO Process

• Inline Coating

• TDO Process

• Metalizing

Film Design Control Points

• Overall population growth continues

• Need for increased barrier products

• Cost effective options allow new forms of flexible packaging

• Convenience and ease of use are critical

• Environmental consciousness expands

• Recyclable options

• Other “Green” Options

• SolventAqueous, UV/EB or Solventless

• Light-weighting options

• Brand awareness creates differentiation

• Clear Barrier-customer can see product

• Printing quality critical

• Digital for short-run customization

• Packaging design for shelf-appeal

• Package security essential

Global Megatrends & Flexible Films

PCR Film

Technology

Flexible Film Surface

Enhancements

Plain FilmPlain Film

Corona Treated

Plain Film

Corona Treated

Acrylic Coated

Plain Film

Corona Treated

Acrylic Coated

Co-ex

Copolyester Coating

1970s 1980s 1990s 2000s

Plain Film Release Coating

Corona Treated Barrier Coating

Acrylic Coated Co-ex Barrier

Co-ex Heat-seal Co-ex Slip

Copolyester Coating Variable Corona

Hybrid Coatings Custom Materials

Super Matte

TODAY

• Twistable Antistatic

• Low Antimony PET film

• Direct Extrusion Coatable

• Special Effect film

• AlOx Coated PET Film

• Universal PET Film

• Easy Stackable Film

• Heat Sealable Film

• Modified Heat Sealable Film

• White Opaque / White Opaque Metalized Film

• Isotropic PET film

• Down Gauged PET film

• Easy Peel

• High Shrink Film

• Matte Film/Super Matte Film

• 9um micron Balloon Film

• UV Block

• Bio Degradable BOPET Film

• PCR based PET films

• Film for digital printing

• Etc.

Available PET Film Offerings

Many available grades expand potential market uses

Flexible Films & Properties

Polymer PET LDPE HDPE PP PS PVC PETG BON

Density 1.35 0.85 0.93 0.90 1.05 1.35 1.28 1.20

Clarity Clear Sl. Haze Sl. Haze Sl. Haze Clear Hazy Clear Clear

Moisture

Barrier

Fair Good Good Excellent Fair Fair Fair Fair

Oxygen Barrier Good Poor Poor Poor Good Poor Good Good

Grease & Oil

Resistance

Excellent Fair Fair Good Fair Good Good Good

Glass

Transition

75C -125C -80C 0C 100C 81C 78C 53C

Stiffness High Low Moderate High Moderate Low High High

Impact Good Excellent Excellent Fair Fair Fair Good Excellent

Heat

Resistance

Excellent Poor Fair Good Fair Fair Good Good

Low

Temperature

Poor Good Excellent Good Poor Poor Fair Fair

Film

Elongation

100-200% 200-400% 200-300% 100% 20-50% 10-200% 100-

300%

100-

200%

Films are chosen for inherent properties and cost

Plastic material with the following attributes

• Very strong (high tensile properties per

thickness)

• Good barrier to water, oxygen, CO2 etc.

• Great thermal resistance

• Clear or hazy depending on formulation

• Easy to print/cut/process

• Highly water and solvent resistant

• Easy to make very thin and very thick

films

Polyethylene Terephthalate

Copolymers to Modify Properties

Diol Diacid Material Use Goal

EG PTA PET Fibers, Films, Bottle Standard

EG iPET ThermoformingLower

Crystallinity

PTA PBT Fiber, FilmLower

Crystallinity

PTA PETG ThermoformingLower

Crystallinity

EG PEN Fiber, FilmHigher

Crystallinity

BOPET Films-Capabilities

Capability Range

Film Thickness 6um to 75um

(24Gauge to 300 Gauge)

Length >120,000’

Widths Up to 129”

OD-Max 42”

Core 3”, 6” or 10”

Treatments Plain, Corona, Various coatings

Metalizing OD 0.22 to 3.2

General Purpose Packaging & Printing Films

Grade

Code

Type of Film Typical

Haze

Typical

Thickness

Typical

COF

Dyne Value Typical Applications

F-PAP Plain Film 4.0%-7.0% 7-75um 0.50us

0.54ud

42

52-Corona

Reverse Printing

F-AU Acrylic Coated 4.0%-6.0% 8-50um 0.50us

0.45ud

42 Solvent Printing and Laminations

F-CH Copolyester Coated 4.0%-6.0% 8-50um 0.50us

0.45ud

60 Aqueous Printing and Laminations

F-UPF Polyurethane

Coated

4.0%-6.0% 8-50um 0.50us

0.45ud

48 Retort Laminations and High Bonds

F-AT Modified Acrylic 4.0%-6.0% 8-50um 0.50us

0.45ud

52 Higher dyne value than F-AU

F-DSC 2-Side Coated Film 2.0%-3.5% 12-50um 0.35us

0.30ud

42/42 Double Laminations

F-EXC Direct Extrusion

Coatable

4.0%-6.0% 12um 0.45us

0.40ud

48 Direct Extrusion Coatable High PE Bond

F-ESB Very High Slip <1.5% 12um >1.0us 42/52-coated

side

High COF Outer Webs (Multiwall Bags)

F-ESC Medium Slip <1.5% 12um 0.6us-

0.8us

42 dyne-

coated side

Medium Slip Outer Webs (Multiwall Bags)

F-ALP Low COF 4% 12um 0.27us

0.25ud

38 Low COF Outer Webs

F-PDP Digital Print 4% 12-23um 0.40us

0.38ud

42 HP Indigo Certified

Printing Techniques Need Different Substrates

Ink TypesF-PAP

(Untreated)

F-PAP

(Corona)

F-CHE

(Sulphocop)

F-AUU

(Acrylic)

F-ATU

(Mod

Acrylic)

F-UPF

(Polyurethane)

F-CSP

(Co-ex)F-PDP

F-PGX

(AlOx)

Nitrocellulose P P E E E E E - E

Urethane E E E E E E E - E

Vinyl E E E E E E E - E

Alcohol E E E E E E E - E

Water Based P F E F E P P - P

UV Flexo P P F G G E P - E

EB Cure P P P F P E P - E

Acrylic Shrink

InksP P P P P P P - P

Polyamide

BasedE E E E E E E - E

Polyamide-

Toluene FreeE E E E E E E - E

HP Indigo - - - - - - -RIT

Certified

UV Offset P P P G E p P - P

E=Excellent results G=Good results F=Fair results P=Poor results

Film Surface Printability

Enhancements

• Inline coated PET film

• Enhanced bond strength to metal and many inks,

coatings and adhesives

• Good metal bond-adhesion even after boiling

• Suitable for Retort application up to 130°C

• Excellent adhesion to other substrates

• Smooth surface that enables applicators to avoid ink

defects such as orange peel

• Has good resistance to many solvents, plasticizers and

chemicals

• USFDA & EC Regulation compliance (For indirect food

contact)

Adhesion of Different Inks with F-UPF

INK BASE RESULT

NC PASS

PU PASS

VINYL PASS

ALCOHOL PASS

For UV Inks Needs Primer

Electron Beam Base Ink curing

PASS

F-UPF-Universal coated PET film

BOPET

Hybrid surface coating

PET- usual thickness 12 µ- usually reverse printedAdhesiveMet-PET thickness ≈12 µ. For desirable barrier propertiesAdhesive

LDPE- 20-100 µ- Sealant layer

How is PET Film Used in Flexible Packaging?

Recent Innovations in film

Eco grades• Bio PET

Recently produced in our Mexico facility. This PET film will break down morereadily in typical landfill conditions due to natural biological processes.

• PCR r-PETThis is another range of “Green Films” . This class of film may contain up to

90% post consumer reclaimed. The resin is obtained through a partnership

with container recycling firms under strict FDA guidelines.

• Antimony FreeFilm produced with environmentally safe ingredients, heavy metal free filmwith similar heat resistance as compared to conventional PET film.

• PCR based film options available

• 30-90% PCR content

• Exploring higher content

• Coated grades

• High COF Grades

• Custom or exclusive product options

“Green Film Options”-Using PCR

Grade Name PCR Content Purpose Thickness Non-PCR

Offset

F-ESR 30% High COF

outer web

12um F-ESB

F-CHR 50% Print Web 12um F-CHE

F-CHR 50% Bag

Strength

23um F-CHE

C-CHR/M 50% Barrier

Web

12um F-CHE/M

F-SLC 90% Liner 23um, 36um F-SLC

Traditional Film

Oil Feed Monomer/Polymer Film

Process/Collect

Oil Feed Monomer/Polymer Bottles

RepelletizeFilm

PCR Film

BioPET

• New additive chemistry allow BOPET film to degrade through natural process• More cost effective than PLA films• Converts like standard PET film

Material BioPET Oxo Degradable PLA

Breakdown

Process

Biodegradation Fragmentation Industrial

Composting

Landfill

Biodegradable

Yes No Slow

Heat Stability High Moderate Moderate

Moisture

Resistance

High High Moderate

Recyclable Yes No Yes

Remnants Soil and Gases Plastic particle Soil and Gases

ENSO PLASTICS, LLC4710 E Falcon Drive, Suite 220Mesa, Arizona 85215 USA

US Toll Free: (866) 936-3676

www.ensoplastics.com

ENSO Plastics was created with a vision of making the world a cleaner place through plastic solutions that are better for the environment.

Our goal is to end plastic pollution by developing innovative plastic solutions that integrate effectively into current waste management practices and infrastructure.

We believe that a true environmental approach requires working together to find solutions based on science and data that lead us to achieving the right environmental long-term goals.

Important California Notice: California law prohibits the sale of plastic packaging and plastic products that are labeled with the terms ‘biodegradable’, ‘degradable’ or ‘decomposable’, or any form of those terms, or imply in any way that the plastic will break down, biodegrade or decompose in a landfill or other environment. These restrictions apply to all sales in or into the state of California, including such sales over the internet.

Label and Tape Grade Films

Grade Type of Film Thickness Haze Shrinkage COF Pretreatments Typical Applications

F-SLR* Silicone

Release Liner

12um-

50um

3.0% 3.0%MD

1.0%TD

0.22us

0.19ud

Silicone

Release

· Release liners for PSA

emulsions

F-MAT Matte Film 12um-

50um

45%-

80%

<3.0%MD

<1.0%TD

0.50us

0.45ud

Corona

Optional

· Durable label stock

· Tape base

F-XLR Very Clear

Film

12um-

36um

1.1% <3.0%MD

<1.0%TD

0.50us

0.45ud

Acrylic Coating · Over lamination film

· Durable label stock

F-CLR Clear Film 12um-

50um

1.5% <3.0%MD

<1.0%TD

0.35us

0.30ud

Corona

Treatment

Acrylic Coating

· PSA labels

· Decorative laminations

F-DSC Two Side

Coated

12um-

50um

2.0%-

3.5%

<3.0%MD

<1.0%%TD

0.35us

0.30ud

Acrylic Coating · Label stock

· Tape base

F-ELE Electrical

Grade Film

12um-

50um

4.5% <3.0%MD

<1.0%TD

0.50us

0.45ud

Corona

Optional

· Tape base

F-SLC Film for

Silicone

Coating

19um-

50um

6.0% 3.0%MD

0%TD

0.35us

0.30ud

Corona

Optional

· Base film for off-line silicone

coating

F-EMB Embossable

Film

13um 3.0% <3.0%MD

<1.0%TD

0.70us

0.50ud

Embossable

Surface

· Base film for holographic

embossing

· Film for brushed applications

Specialized PET Films

Grade Type Applications Site Manufactured

F-IST Isotropic Film for lidding etc.MEX, USA, DUBAI, INDIA,

POLAND

F-XLR Very low haze film USA, DUBAI

F-MAT Matte surface finished film MEX, DUBAI

F-CLR/M Ultra glossy metalized USA

F-PAB Thin gauge high barrier films USA

F-TSTEasy twisting film to replace

cellophaneMEX, DUBAI, INDIA

F-WAPWhite film for lidding and

packagingMEX, DUBAI, INDIA

F-PDPDigitally printed labels and

packagingINDIA

F-PCR PCR Based Film USA

Optical Grade Comparisons

Grade 12um F-MAT 12um F-MSH 23um F-MAT 23um F-MSH

Haze (%) 40 70 45 85

Gloss (45) ~45 28 ~40 25

Tensile

Strength at

Break (MD)

24.2 KPSI 21.4 KPSI 22.7 KPSI 19.9 KPSI

Tensile

Strength at

Break (TD)

28.5 KPSI 27.0 KPSI 28.5 KPSI 27.0 KPSI

Grade 12um F-PAP 12um F-XLR 12um F-CLR 12um F-ESB

Haze (%) 3.5% 1.2% 1.6% 0.5%

A/A COF ~0.33uS ~0.50uS ~0.35uS >0.8uS

A/B COF ~0.33uS ~0.50uS ~0.35uS ~0.45uS

Ma

tte

Film

sC

lea

r F

ilms

Metalized Packaging & Printing Films

Opaque(shiny) Metalized Film

Vacuum metalized PET films are

an effective replacement to

aluminum foils

Continuous development of

improvement to adhesion and

barrier extends the fitness for use

applications

Bag in box

Medical products

Extended shelf-life

applications

Decorative or high-gloss

applications

Thickness (um) 6 7 8 9 10 11 12

Al Foil Yield 43,556 37,333 32,667 29,037 26,133 23,758 21,778

Al Foil$/MSI

$1.75/# 0.040 0.047 0.054 0.060 0.067 0.074 0.080

$/MSI $2.00/# 0.046 0.054 0.061 0.069 0.077 0.084 0.092

$/MSI $2.25/# 0.052 0.060 0.069 0.077 0.086 0.095 0.103

$/MSI $2.50/# 0.057 0.067 0.077 0.086 0.096 0.105 0.115

PET Film Yield 84,000 72,000 63,000 56,000 50,400 45,818 42,000

PET Film$/MSI

$1.30/# -- -- -- -- 0.026 0.028 0.031

$/MSI $1.40/# -- -- 0.022 0.025 0.028 0.031 0.033

$/MSI $1.50/# -- -- 0.024 0.027 0.030 0.033 0.036

$/MSI $1.60/# -- -- 0.025 0.029 0.032 0.035 0.038

$/MSI $1.75/# -- -- 0.028 0.031 0.035 0.038 0.042

METPET films are cost effective replacements to Al foil

Special Effect Films-Extending

Applications

Decorative embossing requires• Thermoplastic film with “soft” surface for

texturizing

• Diffraction shim

• Metalization to enhance contrast

Applications

• Lamination with different substrates

• Lamination with polyester to make pouches or boxes to

eliminate piracy or counterfeiting.

• Balloons

• Security Holograms to avoid duplicity

• Labels

• Holograms ( 2D/3D, Available in sheets ) Used for

Brand protection/ document protection/ and aesthetic look.

• General patterns increases the aesthetic value of product

helps in increasing the market value of a brand on shelf.

Film for Lidding Application F-IST

• Especially designed for the Isotropic

properties by working together with the

customer & project team

• Critical properties of Isotropic ratio is

achieved for a wide roll width

Shrinkage, tensile and

elongation taken every 1M & at

4 orientations

Haze, thickness etc taken L/C/R

and at 2 orientations (MD/TD)

Mill Roll Width

Developmental Areas

• Heat-sealable Films• PET films with properties like Nylon

• F-ETF; Easier to tear PET film• F-TFP; Thermoforming and puncture• F-ISB: CFF formable

• Barrier Films

• Clear

• AlOx coated + inline topcoat

• Opaque

• F-LBP/M for Bag-in box

• Super High Barrier Metalized (SHB)

• Shrink films

• Customer specific developments

Heat-sealable PET Films-

Expanding Market Areas

0

5000

10000

15000

20000

25000

2000 2005 2010 2015

NAFTA Market For Heat-seal PET Films

MT

Ye

ar

Year

Large Growth-Why?

• Convenience applications are

growing dramatically

• Safety utility of Heat-seal PET

film growing for tray use

• Overall material costs reduced

• Suitable for mono-web film use

due to OK O2TR

• Dual-ovenable use

• Stand-up pouch use growth is

accelerating

• The functional side Sealable with APET, CPET and other

polar materials to give lock seal over a wide range of sealing

temperature.

• Opposite Side UT/CT or coated

• Development options exist

Heat Sealable Films

0

200

400

600

800

1000

1200

80 100 120 140 160 180 200

F-HSP Typical Seal Curves 30um

23um

12um

Sealant

Corona, Plain or Coating

Core Layers

Product Structures

gf/

inch

Temp (C)

Heat Sealable Films

Grade Code Type of

Film

Type of

Seal

Substrates to Seal With Typical Seal

Strengths

Thickness

Offered

Typical End-uses Can be Back-

side Treated?

F-HSP Co-extruded

PET

WELD -Self Sealing

-Sealable to CPET, PVC,

Glass

450gram/force 12-30um -Laminations

-Dust Covers

-Cap/Liners

-Microwave structures

Yes

F-CSP Co-extruded

PET

WELD -Self Sealing


APET

250-

300gram/force

10-15um -Laminations

-Tack seal for gussets


Yes

F-HLS Co-extruded

PET

WELD -Self Sealing


Glass

550gram/force 12um -Laminations

-High seal structures


Yes

F-HSP_U1 Co-extruded

PET

Backside

primed

WELD -Self Sealing


Glass

450gram/force 12-30um -Laminations requiring

higher ink or adhesive

bond

-Monoweb structures

No

*F-HSP_U1/M Metalized

Heat Seal

Film

Weld -Self Sealing


Glass

450gram/force 12-30um -Metalized film for

complex structures

-thicker films for

monoweb use

No

*F-HSP/AlOx AlOx & Heat-

seal

WELD -Self seals

-Clear barrier webs

-Unique structures possible

450gram/force 12um -Clear heat-seal barrier

use

NO

*=Developmental item not commercially available yet

Transparent High Barrier Vacuum Coated PET

Transparent PET barrier webs allow

the consumer to see the product. This

increases brand awareness and shelf

appeal. Dry foods, retort, even liquids

are being packaged.

High Barrier Transparent PET Films

• Alternative to PVDC Coated films

• Sterilizable and retortable (121C/30 minutes)

• Microwaveable

• High Barrier PET film through transparent AlOx Coating

• Products Available

AlOx Protect™ F-PLO

AlOx Protect™ F-PLX

AlOx Protect™ F-PGX

• AlOx available only on PET Film and not on BOPP/CPP.

F-PLO F-PLX F-PGX

O2TR

CC/M^2/Day

8.0 2.0 0.5-1.0

MVTR

Gram/M^2/Day

8.0 2.0 0.5

Retortable (No) (No) Yes

Topcoated No Yes Yes

Date :- 12-03-2014

S.NO.Trial

StagesProperties Unit Method F-PLX (R-105)

1 Micron Standard 12.5

coated side 48

Plain side 46

NC Pass

PU Pass

Vinyl Pass

Alcohol Pass

1.54

1.71

Super combi-2000Mitsui retort Adhesive (polyurathane

based)-Takelac-pp-6260 (8 kg)

Hardner-I-3000 (1kg)

Pet film(12mic)/adhesive/BON

(15mic)/ADHESIVE/70 mic CPP(Retort)

70 mtr/min

IST

Pass gm/15mm 280-300 (Tear)

IIND

Pass gm/15mm 800 (Tear)

200 x 150 mm

VINEGAR + SALAD OIL + TOMATO

KETCHUP

1+1+1

150 gm

Pet film(12mic)/adhesive/BON

(15mic)/ADHESIVE/70 mic CPP(Retort)

PASS

IST

Pass gm/15mm 250

IIND

Pass gm/15mm 750 (Tear)

1.53

1.89

7

4

RESULT

LAMINATE SAMPLES HAVE TAKEN OUT FROM HOT ROOM AFTER 15 DAY CURING

LAMINATE STRUCTURE

POUCH SIZE

INGREDIENT FILL IN POUCH

TOTAL QUANTITY FILL IN POUCH

PET/BON/CPP

Machine

(Autoclave/121°C/30min)

Lamination

Run

O.T.R at 230C 0% R.H (cc/m2/day)

Barrier

Results

(After

Retort)

Thermal

Shock Test

Ref: Retort lamination trial on Aloxpet F-PLX..

Barrier

Results

W.V.T.R at 380C & 90% R.H (gm/m

2/day)

O.T.R at 230C 0% R.H (cc/m2/day)

3Ink Adhesion

(coated side ) Use all FCL Inks

2

5

ASTM-D-2578

Thickness (By wt)

Treatment

Laminate Structure

Dyne/cm

M/C speed

Adhesive Type

Q.A Deptt.

LAMINATION PROCESS DETAILS

PET/BON/CPP

INGREDIENT MIXING

W.V.T.R at 380C & 90% R.H

(gm/m2/day)

Laminate bond strength (Before

Retort)6

Laminate bond strength (After

Retort)8

9

0123456789

10 O2TR (CC M^2/Day)

MVTR (G M^2/Day)

AlOx Film Properties

F-PGX Barrier

Stability

Opaque Metalized PET Films-

Extended Applications

Sample Reference Laminate Structure Test

Result(2)

UFLEX

(Developmental

sample F-UPF-M)

PET/Ink/Adh/MPE

T-Coated/Adh/PE

OK

UFLEX F-CHE-M PET/Ink/Adh/MPE

T-Coated/Adh/PE

Delaminate

Temp=74C, Time=4 hrs

Material Metal

Adhesion(1)

Metal

Durability

Comment Recommended for

Bag in Box?

F-LBP/M >600g/inch Excellent Highest

Adhesion

Yes-Aseptic

Applications

Yes-Dry Foods

Yes-Bulk Liquids

F-UPF/M >600g/inch Excellent-

Good

Excellent Wet

Bond

Yes-Dry Foods

Yes-Bulk Liquids

F-MTG_PZ >300g/inch Good Snack Food

Grade Film

No

[1] Measured by AIMCAL method[2] Internal test method

New Coated/Metalized

grades are suitable for;

(1) Hot-Fill

(2) Bag in box

(3) High adhesion and

robust packaging

BOPET

Hybrid surface

coating Al Metal

Super High Barrier Opaque

Seed-coat

Al metal

Topcoat

PET film

Seed-coat

Al metal

PET film

Goals•<0.25 CC Day O2TR•<0.25g Day MVTR•Significantly improved robustness•Ability to supply monoweb materials•Proprietary Technology

Trial MVTR O2TR Abrasion Note

Control 1.2 1.4 Poor

Trail #1 0.08 0.15 Excellent

Trial #2 0.19 0.32 Good Became F-

EBP

Trial #3 0.05 0.06 Excellent On hold

Data is Meter^2/Day

New Opaque Barrier Grade F-EBP

New barrier technology; relies on several

technology stacking concepts

• Base Film design

• Metalizing material and alloy

• Metalizing process control

Potential for Foil Replacement

Structure O2TR

M^2/Day

Target

O2TR M^2/Day

Measured

Lowest

Value

Note

Incumbent <0.2CC ~0.18CC N/A 4-Ply Foil

F-EBP <0.3CC 0.16CC 0.09CC Flat sheet data

F-EBP/Laminate <0.3CC 0.19CC 0.13CC 3-Ply laminate

Real-world Data

0

0.2

0.4

0.6

0.8

1

1.2

-5 0 5 10 15 20 25 30

O2TRdataasafunctionofsmoothness

O2

TRC

C/M

^2/D

ay

MetalizedFilmSurfaceSmoothness(Sra nm)

F-MTG

F-EBP

FlexData

TypicalHigh

BarrierMPET

F-EBPCustomerData

• New process for making biax PET to give nylon like character for;

• Improved puncture & impact

• Improved formability

• Asymmetrical tear properties

• Maintains similar converting properties to PET

• Cost effective to BON

• Patent Pending “Metaphasic PET” Process Technology

“Nylon Like” PET Films F-TFP, F-ETF & F-ISB

Grade Name Purpose Thickness Where

Produced

Drug Master File

F-ETF Create structures with unique tear 12um

19um

KY No

F-TFP Forming web and generic Nylon

replacement

12um

19um

23um

KY

India

Dubai

Egypt

No

F-ISB Cold forming web 23um

36um

India Yes

When compared to Nylon;

F-TFP Test Results

Test Type Material Puncture Dart ImpactBiaxially Oriented

Nylon Film

23um Biaxially Oriented

Nylon Film

9.14 N/mm 710 gf/cm^2

New F-TFP* 23um Metaphasic Biaxially

Oriented PET Film

9.38 N/mm 700 gf/cm^2

Standard PET

Film

23um Biaxially Oriented

PET Film

8.23 N/MM 609 gf/cm^2

*Similar puncture and impact resistance.

When compared to PETG;

Test Type Material Total Film

Elongation

Cavity Well

Volume

FormationPETG Amorphous Copolyester Film 240% >180CC

New F-TFP* 23um Metaphasic Biaxially

Oriented PET Film

260% >170CC

Standard PET

Film

23um Biaxially Oriented PET

Film

115% Film Got Broken In

Test

*Similar elongation and formed volume.

Date :- 20-02-2015

S. No. Unit MethodF-TFP-12 (KY

sample)

F-TFP-19 (KY

sample)

F-TFP-23 (Egypt

sample)

MD 2015-2125 1902-1933 1900-2000

TD 2947-3019 2575-2910 2611-2761

MD 204-214 231-233 232-237

TD 115-124 101-119 120-138

MD 7.2 6.9 5.0

TD 3.0 2.8 1.7

% ASTM-D-1204

Tensile strength Kg/cm² ASTM-D-882

Elongation % ASTM-D-882

UFLEX LIMITED

A-1 SECTOR -60, NOIDA

FILM DIVISION QA

3

Properties

Ref:- F-TFP BOPET film sample test report.

1

2

Shrinkage

(At 150˚c 30 Minutes).

Cold

Fo

rmin

g F

-IS

B

Te

ar

Pro

pert

ies F

-ET

F

Hig

h E

longa

tion

F-T

FP

TEST DATA

• Tear initiation reduces as a function of PET film thickness• These data are un-notched tear (ASTM D1004)

• Examples of customer specific developments

• Low COF film for denesting in stand-up pouch

• High gloss metalized films for decorative laminations

• Cold Forming film for medical packaging

• F-ETF

• Unique shrink/haze combinations

• Triplex laminatable film for bag in box use

• Etc

• >50% of R&D resource globally dedicated to custom

development

Customer Specific Developments

Thank You!

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