When selecting the right technology for barrier film production, film producers have the choice between blown film and cast film technology. Which process is more efficient depends on the final application and the required film properties. Film thickness, height of the gas barrier, film strength and sealability play a role. Cast film lines with higher output are particularly economical for large batch sizes. Especially thicker films with high transparency can be optimally produced as cast films thanks to efficient cooling, for example for deep drawing applications. If different formats and thicknesses are required, e.g. for lid films, the blown film scores with flexibility due to fast format changes. Due to the lower cooling and the resulting higher crystallinity, applications with higher stiffness can also be produced.
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7- and 9-Layer Lines are Standard, 11-Layer is the Next Step into the Future
Cast film lines with 11- and more layers have already been in operation for some time. There is also a trend towards multilayer systems for blown film. "7- and 9-layer blown film lines are now standard in barrier film production. Today, they can be used to produce the entire spectrum of food films," explains Hoppe. The first 11-layer system for barrier applications from W&H has just been sold in Asia. "Long-term flexibility is an important purchasing criterion, especially for barrier films. More and more new recipes are being developed in response to increasing demands for function and economy. With 11 shifts, the customer is certain that he can continue to run high-quality films with the most modern recipes in the future, and that profitably," says Hoppe.
New approaches to the sustainability of barrier films
Sustainability is currently a major driver for new formulations, for example. Barrier films make an important contribution by reducing food losses and enabling hygienic packaging. One challenge that raw material manufacturers and producers are working on is their recyclability. "For example, there are developments in water-soluble and biodegradable barrier materials. Today, these materials are not yet available in large quantities and more expensive than standard materials. This makes it all the more important that the raw materials are used optimally," explains Hoppe.
W&H blown film lines for barrier films: efficiency and quality
W&H blown film lines are used worldwide for the production of high-quality barrier films. "We have over 200 barrier film production lines on the market," says Hoppe. W&H blown film lines are particularly efficient and flexible. The MAXICONE die head with patented conical distribution system enables the implementation of a wide variety of structures, even with extreme layer ratios. The universal W&H HPS barrier screw guarantees flexibility in processing a wide variety of raw materials, such as PE, PP, PA and EVOH. Expensive raw materials can be run very thinly due to very good individual layer tolerances. Short flow paths in combination with small amounts of material in the tool prevent material degradation of sensitive raw materials and enable fast material changes.
Everything from a single source - from extrusion to printing
In addition to the lines optimized for barrier films, W&H's consulting expertise with decades of market expertise is an important success factor. "W&H is the only machine manufacturer to offer air-cooled and water-cooled blown film lines as well as cast film lines in one portfolio. This enables us to provide independent technical consulting. We have the right system in our portfolio for every application," explains Hoppe. W&H also offers both gravure and flexo printing systems for the subsequent printing of the barrier films. "Thanks to our knowledge of the entire process from extrusion to processing, we can provide better advice on, for example, which tolerances in film production ensure optimum further processing in printing. We support our customers in achieving the optimum overall result for their barrier film packaging solution", Hoppe sums up the range of services.
Written By: Leslie Taylor | Article Date: December 23,
Packaging is more than just something that contains your products. It’s more than an eye-catching design that stands out from the shelves. It does more than protect your products in storage and shipping. Custom packaging is all these things and more. Those who are new to packaging often overlook this important aspect until the very last minute
A study shares that up to 80% of consumers do not repurchase from a company if they are not satisfied with the initial experience. As the first thing that customers encounter, custom packaging requires strategic planning even during the start of the product development process.
If you’re interested in custom packaging, then you already know its importance in growing your brand and business. If you are in the initial stages of development, this helpful guide will establish your basic packaging needs and get you started on a packaging strategy. We’ll help you choose what type of custom packaging is right for your product by looking at key factors that impact this important decision.
Which Custom Packaging Is Right for You?
Now that you know the key packaging elements your product requires; you can finally choose what type of packaging to customize. There are dozens to choose from, some more elaborate than others, but you can begin with the essentials to build your packaging strategy.
It may not be the first thing that comes to mind when you think about custom packaging, but these little custom labels are considered primary packaging. Labels come in immediate contact with the product. From beer bottles to scented candles, medicine containers to shipping tags, labels are everywhere.
Custom labels can be used for:
This is the most popular type of custom packaging. The versatility, design capabilities, and durability of custom boxes make them suitable for almost any type of merchandise. The most common box categories are product boxes, mailer boxes, and shipping boxes.
Product boxes can be used to store items and boost shelf impact and presentation. From baked goods, clothes, or liquor, these boxes can be customized to the exact measurements you need. You can also print your brand story or share other information on the product box.
If you’re delivering directly to customers, branded mailer boxes and shipping boxes are a more durable option.
Custom boxes are widely used for:
If you need something adaptable and secure for liquids or perishable items, custom pouches are a great option. They’re affordable and made of high-quality materials to keep products fresh. These often come in two (2) types: flat, suitable for single-use items, and stand-up, which expands to accommodate the volume.
Custom pouches are perfect for:
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Based on your preferred packaging, you can begin customizing in various materials and coatings that suit your product’s design, storage, and shipping requirements. Here are the most popular packaging materials:
This is a flexible material that’s perfect for custom product boxes and in-store displays. Cardstock often comes in a variety of thickness options, from lightweight 14 pt. cardstock that’s ideal for smaller items up to thick 24 pt. cardstock you can use for multiple or heavier products.
Cardstock offers these distinct benefits:
This is the thickest material for custom shipping boxes and mailer boxes. It’s made for heavier items to withstand shipping and handling. Corrugated board thickness is classified in flutes from A to F and varies depending on what your packaging supplier offers. In general, the thicker the flute, the more durable the packaging (F-flute being the thinnest and B/C flute the thickest).
Here are more pros to corrugated material:
This material is widely used for custom pouches. High barrier films are made with a combination of flexible plastics, aluminum, paper, and coating that makes these pouches one of the most versatile packaging solutions for any product.
Here are the key characteristics of custom pouch high barrier material:
High-barrier films in custom pouches are perfect for these products:
Before you print custom labels, bear in mind that different materials are more suited for certain applications. How your product will be used will help you choose the right material for the job. Below are the most popular types of label materials:
White premium sticker paper is the most popular paper label for indoor applications. Made of smooth, semi-gloss, pressure-sensitive adhesive. You can add lamination for extra protection.
Biaxially-oriented polypropylene or (BOPP) is perfect for products exposed to oil, moisture, and refrigeration. It comes in clear, solid white, and metallic material options.
White vinyl is the thickest and most durable sticker material available. Waterproof and made with UV-resistant gloss laminate. Printing companies highly recommend white vinyl for products that require outdoor exposure.
After choosing your basic packaging essentials, you can add special touches for more seamless branding. Packaging slips and materials are an easy and affordable way to elevate your entire product presentation.
Print custom hang tags to add a decorative touch to bottled items, clothes, and other merchandise. They make great gift tags for holiday packaging or product information tags. Add custom tissue paper inside product boxes or mailer boxes for a luxurious, gift-like unboxing experience.
Printing custom boxes are not the only way you can stand out during shipping. Try branded water-activated tape that keeps boxes and envelopes sealed during transit. Bag toppers or header cards are also a quick solution to products stored in poly bags, while packaging sleeves can be wrapped around any product for instant branding.
Now that we covered the basics of custom packaging, you can now start with packaging design and customization. There’s a wide selection of packaging styles to choose from, but it’s important to choose what works for your product, process, and budget.
Want more packaging tips? Our top packaging do’s and don’ts can help you save money in the long run.
Get started on custom packaging for your business. You can even design your custom box online, along with other packaging materials.
At NextDayFlyers, we’re committed to helping you bring your packaging ideas to life. With our customization options, high-quality materials, and decades of online printing experience, we can print custom packaging your products deserve.
Want more information on High Barrier Films? Feel free to contact us.