What Makes Polyplex “The Best Polyethylene Film Manufacturer”?

Polyethylene film is a thin plastic film made of polymers that are used in a wide range of applications such as plastic bags, printing, packaging, and insulation as it has high tensile strength, chemical resistance, dimensional stability, and transparency.

We encounter polyethylene (PET) films in almost every day of our lives as they are employed in almost all kind of commercial industries. Though there are numerous companies manufacturing PET films, experts consider Polyplex as one of the best polyethylene film manufacturers in the world and there are specific reasons for them to consider so.

High-Quality PET and PP Films
Polyplex is a master in manufacturing PET and PP films at very high quality. The films manufactured by Poyplex have proven to be more reliable and are known for high performance. The BOPET and BOPP films by Polyplex are the most sought films when it comes to electrical, industrial, and packaging applications.

Wide Range of Products
Though PET and PP films can be easily labelled as a single category of films, Polyplex has managed to alter specific components and the manufacturing process of films and has come out with a wide variety of products to suit different type of applications. The four main products of Polyplex are Sarafil, Saracote, Saralam, and Saraprint. However, there are many sub-categories under these products that are designed for specific purposes.

Innovative Approach
Polyplex employs an innovation center that operates with an objective of introducing new value-added products to their customers. The company constantly improvises its manufacturing technique and reviews its products so that their customers will be benefitted in terms of both quality and remuneration. Polyplex also manufactures customized films for their clients.

Initiatives to Protect the Environment
This is the key factor that makes Polyplex the best polyethylene film manufacturer in the world. Apart from satisfying its customers with high-quality products, the company also has an eye for preserving the natural resources and protecting our environment from becoming polluted. The company has ensured waste management through recycling, effluent and emission control, optimum usage of energy and natural resources, and development of Green Pet film.

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Introduction to Polyester and Metallized Polyester Film (BoPET)

Discovered in 1930, Polyester has been known for its many desirable qualities ever since. Because of its higher tenacity and durability, Polyester can withstand strong and repetitive movements. As we go along further, we would explore one of the most amazing fiber things - Polyester. Now you must be wondering how Polyester can be used. Well, it is quite popular in the clothing industry as well as other industries. It is often used in garments like pants, shirts, suits, and bed sheets. Apart from these, Polyester has industrial uses as well, such as carpets, filters, synthetic artery replacements, ropes, and films.

Explore More about Polyester Films
BoPET is generally known as Polyester Film which is polymer resin of the polyester family. It is an excellent multipurpose film which is commonly used across various industries owing to their innate properties and advantages. It is majorly used in the electronics industry and the packaging industry such as fabrics, finishes on high-quality word products, beverages and food products wrapping, and insulation for cushions and pillows. BoPET can be divided into two types- BOPET - Thin (Metallized Polyester Film) and BOPET - Thick Industrial. Before purchasing any polyester or plastic film, consult your requirement with Metallized Polyester Film manufacturers, so that can guide you in a better way.

Made from petroleum substances, Polyester films are known for its high mechanical strength, durability, heat tolerance, chemical resistance, and dimensional stability. Benefits:

•     Attractive appearance
•     Strong oxygen barrier
•     Brilliant printing and sealing capabilities
•     Dimensional Stability
•     Good tensile strength
•     Tear Resistance

Metallized Polyester Films
Metallizing of PET film is done under high vacuum conditions to achieve special desired optical properties like metallic finish, which makes it defiant of gases and less diffusive to the aroma as well as flavors.  There are various metallized polyester film manufacturers around the globe from which you can buy at market leading prices.

Because of the promising quality and performance, Metallized Polyester Films has gained a lot of popularity in different industries. Environmental friendly and very high barrier performance, it has significantly replaced other substances. It ensures high lamination bond strength and is easily process-able which makes it one of the most desirable products in various industries.

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Know About Extrusion Coating

Extrusion coating is defined as a process which is used to coat the thermoplastic material onto a substrate like paperboard aluminum foil, woven fabric, paper, PET, BOPP film etc. Most commonly used resins in this process are various polyolefin such as ethylene vinyl acetate copolymers, polyethylene, ionomers, and polypropylene. For instance, extrusion coated film manufacturer use this process is for improving the features of paper by coating it with polyethylene, making it a better water resistant.

Process of Extrusion Coating
It includes coating of a substrate with precisely metered film of molten plastic. The thin extruded molten film is pulled down onto a substrate and then into the nip which is amidst the pressure rolls and chill roll, below the die. A specific amount of pressure is there in between these two rolls which forces the plastic onto the surface. This surface moves at a speed which is faster as compared to the extruded film and the drawing of film onto the desired thickness. This entire process includes- Extruder, Die, Chrome Plated Chilled Roll, Back Up Roll, and Winders / Unwinders.


Advantages of Extrusion Coating
As a process-

• •    Double sided coating to achieve desired properties
• •    Solvent / adhesive free
• •    Thickness of the coating varies depending on the end use
• •    Higher line speeds

As an end product-

• •    Provides moisture barrier
• •    Avoid direct contact of content to the substrate
• •    Provide heat seal-able characteristics
• •    Reduces loss of content

Factors Influencing Coating Performance
In the extrusion coating process, various resins is used by the extrusion coated film manufacturers and the entire processing is dependent on various factors that are as follows:

• •    Melt Temperature
• •    Die Gap
• •    Air Gap
• •    Chilled Roll Temperature

The resins must have some special characteristics like higher melt index (to ensure better adhesion), free from additives, and ideal amount of antioxidants for extrusion coating. In addition to these, some other characteristics should also be present in the resins; these are reduced neck-in properties and good adhesion to substrate at higher line speeds.

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Metallized Polyester Film Manufacturers Produce Metallized Films

 

Metallized films are top quality films of polymers layered with the aluminium skinny layer. These films provide a shiny metallic appearance similar to foils of the aluminium at decreased prices and lower weight. The Metallized films are mainly used for decoration purposes, packing of food and for important applications like insulation and electronics. 

What is the important use of metallized films?

The important uses of metallized films are given below:
1.    The metallized films are used for lamination and tensile holograms.
2.    These are also used for the production of twist wraps for candies and the toffees.
3.    These films are manufactured through the procedure of micro slitting to ensure consistent weight and the uniform coating.
4.    Metallized films are water and chemical resistant. Metallized polyester film manufacturers make top-quality metallized films.

How high-barrier metallized films are manufactured?
The high-barrier metallized films are manufactured by various metallized polyester film manufacturers by deploying deposition of physical vapor procedure. For the deposition, aluminium is a very important metal, but some other metals such as nickel and chromium are used also in the deposition process.

In this procedure, the first metal is heated and below the vacuum, the metal is dissolved. This focus on cold films of the polymer near to the source of vapor of the metal. With the passage of time, this coating will not fade.

These films are necessarily impassable by moisture and the oxygen. When packs are manufactured by using these foils then they are forced to repeated manipulation and handling which is repeated with shelf stocking, consumer handling, manufacturing and cartooning in a retail territory, and they develop permeable and pinholes. 

What benefits metallized films offered as compared to aluminium foils?
The surface of the metallized films is glossy silvery similar to foils of aluminium. They offer the following main benefits as compared to metallized films.
•    Low density at the reduced cost
•    Heat preserving capacity
•    Extreme toughness

Therefore, metallized films are more beneficial as compared to aluminium foils.

Some leading companies produce top quality metallized films. They have a matte and gloss finish. These films offer numerous applications like they are used in yarns, spangles, sequins, making of paper plates and fancy boxes, used on board and paper for decoration purposes. The metallized films are available at competitive prices in the market.

Summary: For the manufacturing of metallic yarns multitude, metallized films are the key input. For the purpose of decoration, these are used extensively. In the packaging industry, they also have many applications. 

Author Bio: 
 The author of this article has excellent knowledge regarding how metallized films are manufactured by Metallized polyester film manufacturers.

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Why to choose metallized polyester film?

PET MET is a Polyester film metallized with aluminum powder. PET is already known for its high strength and surface hardness and especially with regard to the diffusion density; the favorable properties can be improved through the use of aluminum powder. Metallized polyester film developed for packaging applications demanding very high barrier performance and good metal adhesion. The product is protected throughout its targeted shelf time with the high barrier, whereas the high metal adhesion ensures high lamination bond strength.

Some countries have already replaced traditional aluminum-laminated packaging by metallized flexible plastic packaging. Substitution is more concentrated in some product categories such as tomato based products, powdered milk and coffee. And this migration trend from aluminum laminate to metallized films continues globally. In fact, it follows a quite strong trend: the substitution of rigid packages for flexible packaging, especially for pouches.

Process-
Metallized polyester film manufacturers produce these films using physical vapor deposition process. Aluminum is the main metal for deposition; however other metals like chromium or nickel are also used. The metals which are heated are then dissolved under vacuum which concentrates on cold polymer films and these unwind next to metal vapor source. Such coatings do not fade over time.

Advantages-
From a simplified production process to logistics optimization the benefits include-

•     reduction of packaging weight
•     possibility of better filling the space during transport and storage
•     Flexibility of formats and opening / reclosing systems, etc.
•     flexible packaging and its production process is totally safe to the product
•     Metallized polyester films provide excellent barrier to moisture and oxygen

For consumers-
Flexible packaging tends to be more economical than rigid, with the same, and sometimes even better, barrier properties. This is an attribute that is being watched with great interest by several market sectors, especially by the pharmaceutical and food industries.

For Environment-

•     These pouches have a smaller carbon footprint
•     The CO2 emission is lower during the production process of a pouch than other packaging materials.

Application-

•     These are used as a barrier layer in two and three layer flexible packaging
•     Suitable for hot fill applications like liquid juices, jellies, tomato ketchup etc.
•     These are widely used for laminates for coffee, milk powder, juice powder, tea, cereals, malt based food powder, dry nuts, cosmetics and personal care products.
•     Replacement of aluminum foil in flexible packaging where dead fold is not required.

So, you can now see the different uses of metallized polyester films manufactured by Metallized polyester film manufacturers and the various advantages of these films.

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Uses and Characteristics of BOPP films

BOPP film stands for- Biaxially Oriented Polypropylene films. It is a widely used thermoplastic polymer. It has many uses and due to its characteristics it has become one of the most popular and highly demanded films across the globe.

Polyplex is one of the leading BOPP film manufacturers that add value to BOPP films by vacuum metalizing, coating and laminating the substrate for variety of uses.

Unique attributes of BOPP films are-

•     With density nearer to 0.90/gm it renders high yield at the same cost as compared to other films.
•     It has excellent gloss and high transparency that gives excellent look and fine finish.
•     BOPP films acts as good moisture resistant and have tendency to resist pollution and harmful chemicals.
•     It has excellent clarity
•     It has best dimensional stability and flatness
•     It has low electro static charge
•     It also resists water vapor
•     It provides good puncture and flex crack resistance
•     It also acts as a resistance to oil and grease.
•     They are also recyclable

Some of the benefits of BOPP films-

•     They are environment friendly
•     They are light in weight
•     They can reduce the damage of any product due to transport, weather etc.
•     They also keep the product dry
•     No de-lamination is required
•     Along with good clarity they are also resistant to ultra violet rays

The BOPP film manufacturers know that the right luxury packaging is necessary to capture the attention of potential customers. This builds a brand identity that is associated with premium quality, craftsmanship, and attention to detail. These films are also suitable for food packaging.

The most common uses for these products are:

•     Luxury bags
•     Fragrance packaging
•     Premium beverage boxes
•     Books and other print media.

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Plastic Film: Properties and Unique Uses

Packaging industry is heavily dependent upon plastic films for the purpose of protecting and layering the products which need to be transported from one place to another and often miles away and overseas. The plastic film manufacturers produce the film with quality that is compatible with different weathers and different external conditions which ensure that the product is protected throughout thick and thin.

Properties of Good Quality Polyester Film

Polyester film manufacturers ensure the film should match the following quality standards before subjecting it in the market:

•     Light in Weight: It should be light in weight so that the product remains comfortable to be transported from one place to another destination.
•     Smooth: The skin of polyester film should be smooth and seamless which is the sign of good quality of material.
•     Scratch Resistant: It should be scratch resistant so that packaging is not destroyed while goods are on their way to be transported.
•     Weather Resistant: Packaging should not get ruined if weather is extreme hot or cold, and rainy- it should have the capacity to bear all the moods of weather. 
•     Chemical Resistant: The plastic film should be immune to chemical reactions so that the product doesn’t get damaged.

A reliable plastic film can be used for multiple purposes; here we have best 2 of them: 
 

•     Covering Rooms while Renovation: Plastic film can be used as protection against dust to cover home materials while the renovation is going on.
•     Sun Shade on Windows: You can use the polyester film as shade against the sun rays in your rooms.

There are different unique uses of a plastic film that one can make, however, it is widely used for the purpose of product packaging. The products can be of different kinds such as food material, clothes, décor items and other type of things.

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Qualities of best metalized polyester film

Packaging industry has grown with leaps and bounds in the past century or before with the onset of industrialization and commercialization. Different variations and creative dimensions have been added to the packaging style and method which has widened the growth of packaging industry. There are different types of materials which are used in packaging and to the basic level – plastic films and metalized polyester film is used to a great extent.
 
Metalized polyester film manufacturers ensure the film is supported with rich quality that enables it to be used for different purposes and to cater different industrial uses.

Some of the important properties that polyester film should possess include:

• Durable: The metalized polyester film should be strong enough to ensure strong protective layer to the material packaging. It should last for long and should not get damaged easily with external forces.
• Moisture Proof: The metal polyester film should have the moisture resistant property so that packaging doesn’t get affected in humid-moist weather or when it comes in the contact of water.
• Chemical Tolerant: The film should possess chemical tolerance so that it doesn’t lead to any chemical reaction which can affect the quality of packaged product. It is more likely to happen in the case of food product packaging where if any chemical reaction takes place, it can degrade the quality of food.
• Smooth Finishing: There should be uniform thickness and smooth finishing of the metal polyester film which will given even look to the packaged product.
• Weather Resistant: The packaging of the product or the film used for different industrial purpose should remain neutral in all weathers and should not get affected due to climatic changes. 
• Scratch –Free: Scratches are the sign of bad quality of film so the metal film should not take the scratches and should remain strong.

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A Sustainable and Future Oriented Packaging Material

What is Polypropylene and what are its uses?
 

Polypropylene (PP) is a thermoplastic “addition polymer” which is made from the combination of propylene monomers.  Polypropylene films are one of the most proponent barrier films, versatile and economic. It is used in a variety of applications including packaging for consumer products, textiles, plastic parts for various automotive industries, films for lamination etc.

Characteristics of polypropylene

• Chemical resistant
• Fatigue resistant
• High resistance to electricity
• Elasticity and toughness

Polypropylene film manufacturers have found many qualities with PP films which made it a versatile film for a wide range of application. It is a unique material which can be steam-sterilized without damage and resists environmental stress cracking. It also offers high heat resistance and is therefore more suitable for retort packaging or hot filling.

When produced with cast polypropylene, the PP films offers magnificent transparency and extra glossy qualities. Some of the features of polypropylene films are-

• Excellent moisture barrier
• Clarity
• Glossy
• Durability
• The ability to print
• Emboss ability
• Aroma strength
• Great Dimensional stability
• Easy processabilty

A step towards sustainable environment
The three “R”s are the virtue and only path to attain a sustainable environment. PP films are recyclable and highly sustainable. There is a leading manufacturer of polyethylene and polypropylene films, who strongly believe in sustainable growth they reduce waste generation through the re-use of process trims. PP films have a positive environmental profile as it is a remarkably energy-efficient material, with an environmental impact.

The polypropylene film manufacturers ensures optimum utilization of energy and other resources, waste management through recovery, recycle and re-use of material, reduction in emissions and effluents, enhancement of awareness amongst the employees through effective communication and training. They continually improve their environmental performance to ensure sustainable growth.

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