Presentation on the Bopp line for the...
- 1. Presented by: Muhammad Junaid (Executive Process Engineer- Film line) Submitted to: Sir Farhad (Line Manager, Film Line) Sir Abu Bakar (Production Manager, Film Line) International Packaging Films Limited April 2025 BOPP Film Line
- 2. Contents • Introduction to BOPP • Polymer and it’s Origin • Types of Films & their Applications • Silo’s Section & Raw Materials • Extrusion Section • Die & Casting Unit • Machine Direction Orienter (MDO) • Transverse Direction Orienter (TDO) • Pull and Winder Section
- 3. Biaxially Oriented Polypropylene • BOPP (Biaxially Oriented Polypropylene) film is a type of plastic film known for its exceptional strength, clarity, and versatility. • Used in various industries, particularly in packaging and labelling. Applications of BOPP Film: Packaging: • Packaging (snacks, confectionery, frozen foods, Consumer goods) • Labeling, • Lamination Properties: • High clarity • Strength • Moisture resistance
- 4. Polymer Polymers are large molecules composed of many repeating smaller units called monomers. Applications of Polymers: • Plastics: Polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), and others are used for packaging, containers, toys, and many other items. • Fibers: Nylon, polyester, acrylic, and other synthetic fibers are used in clothing, carpets, and textiles. • Rubber: Natural and synthetic rubbers are used in tires, gaskets, and other flexible products. • Paints and Coatings: Polymers like acrylics and epoxies are used as binders in paints. • Adhesives: Many adhesives, such as epoxy and superglue, are based on polymers. • Biomedical Applications: Polymers are used in medical implants, drug delivery systems, and artificial organs.
- 5. Types of Polymers Synthetic Polymers These are man-made polymers, often created to have specific properties: • Thermoplastics: These can be melted and reshaped multiple times, such as polyethylene and polystyrene. • Elastomers: Show significant elastic behaviour, like rubber. • Fibers: Used in textiles, like nylon and polyester. These are polymers found in nature, such as: • Proteins: Found in living organisms, responsible for various functions like muscle contraction and enzyme catalysis. • Carbohydrates: Include cellulose (found in plant cell walls) and starch (used as an energy source). • Rubber: Obtained from the rubber trees. Natural Polymers
- 6. Origin of Polymer Drilling Distillation Steam Cracking Polymerization Refining of crude oil Crude Oil Extraction Naphtha Propylene is converted into Polypropylene
- 7. Types of Films Types Sub – Type Local Name Export Name Thickness Density (g/cm3) Application Plain Non-Sealable TNB-PL-10 TNO-20 TN01-20 TN01-30 10, 20, 30 0.91 Reverse Printing, lamination of book covers, labels, album overlays and multipurpose bags. Transparent Sealable THO TH21- 15, 18, 20, 25, 30, 35, 40 0.91 Printing, lamination, overlapping, label, soap wrapper and cigarette cover wraps White Pearl PRL OC-216 20, 25, 30, 38, 40, 50, 65, 70 0.72 Printing, lamination, soap wrapping, low density lamination and printing WSO WSO OW/OLW 219 20, 40 0.95 Lamination and printing purposes due to excellent adhesion of inks. Metallized THOM-18, 20 MB21S-18, 20 15, 18, 20 0.91 Lamination and
- 8. Material Code Melt Temp. (o C) Homopolymer Qurain - HF029 162 Borouge - HC402BF 161 Tasnee - H3030T 163 Copolymers (With additives) ADSYL 5C37F 125 SFI 841 130 Copolymers (Bare footed/without additives) ADSYL 5C30F 132 SFI 841 A 162 ADSYL 7572 XCP 126 Additives Anti-block ABVT 22 NSC ABVT 22 SC Anti-static PT 21 HD COEXAS 2 Masterbatches White WT 60 125 Pearl CB53 Reclaim White 162 Transparent 162
- 9. • Skin (Co-polymer & Anti-Blocks) - Printing, Metallization. • Core (Homo-polymers & Master batches) • Tie (Homo-polymers & Anti-Static) Homo-polymer in all layers for plain film Layers of Film & Process Flow Chart Diagram: Flowchart with arrows showing: Extrusion → Die & Casting → MDO → TDO → Pull Roll → Winder
- 10. Silo & Dosing Section • It is the area where raw materials come together according to the recipe. • Their feed is controlled by the pneumatically operated diverter valves which are connected on the top of silos. • There are total 04 silos, three of them (Silo 1, 2, 3) have same capacity of (160 tons) while the last one (Silo 4) has less capacity of (80 tons). Components of Silo & Dosing Section: Blowers • 1- V010 (twin) lobe blower is used for pushing the material from big bag to silos at flowrate of 15ton/hr. • 2- V101 (twin) lobe blower is used for pushing the material from silo to the main extruder at flowrate of 6ton/hr. Diverter Valve • These valves are operated pneumatically. Diverter valves are used to send material flow from one feeding point to two or more receiving points. Heat Exchangers • Heat exchangers cools down the compressed air from blowers to avoid the formation of angel hairs.
- 11. Extrusion Process Description: • Conversion of polymer into melt • The raw material pellets are fed to one end of the screw from a feed-hopper • The polymer feed is then forced through the rotating screw, and as it moves forward, it is melted, partly by heat conducted through the walls from the external heater bands. • When the molten and compacted polymer reaches the end of the screw it is forced through a die, to form the finished product by using Melt Pump. • Main Extruder: Company: Krauss Maffei, RPM: 264, Type: Twin Lobe, Capacity: 5750 kg/hr
- 12. Main Extruder (Krauss Maffei) Components Working Specifications Characteristics Mechanism Manufacturer Gear box Helical gear type Reduction ratio of 1:5.6 11 kw motor (SIEMENS) FLENDER DRIVE Heat Exchanger Shell and tube type Maintained oil Temperature Counter Flow Melt pump Used to pressurize the melt Max RPM: 64 MAAG Filter Vertical configuration T set 250C Candles: 48 Supporting Rod: 30 Mesh size: 80 microns Vacuum Heating unit Vacuum heating is used for its cleaning Tmax = 400C • It removes air/oxygen to avoid combustion. • Choked material melts and drains out. FOURNE
- 13. Co-Extruders Components Working Specifications Characteristics Mechanism Manufacturer Process Parameters Co-Hoppers F610 F620 F630 F640 Dossing Volumetric feeding Vacuum operated PIOVAN 300 kg/h Co-Extruder 1 Single screw motorized (132kW) 120 rpm Tmax = 300C Single screw mechanism 6 heating zones (3kW heater) BB Engineering Co-Extruder 2 Single screw motorized (200kW) 120 rpm Tmax = 300C Co-Extruder 3 Single screw motorized (132kW) 120 rpm Tmax = 300C Co-Extruder 4 Single screw motorized (200kW) 120 rpm Tmax = 300C Screens/Filters Dual filter screens Pressure range 70 bar Material flow into mesh HUILONG Screen pressure
- 15. Die & Cast • Melted raw material from main extruder as well as from co-extruders is introduced at die section where our 05 layer BOPP sheet is formed and proceeded for further processing. • 03 Die Adaptor → 1 for Main & Tie Layers while 2 for Skin Layers. • Air Knife: Make contact of material from die to chill roll. Main die • Max. 280 - 300 C ᵒ • Set point 250 C (depends upon the film ᵒ grade) • Die width: 1225 mm • Die Lip - Centre: 2.5 mm & Edges: 2.8 mm • Die type: Coat hanger. • Company: SIMDLAS • Melt is shaped into film at die section. Prior to this section, all layers come separately and joins according to their respective layer arrangement of position. Die Section Chill Roll (Craft Company) • Melt is quenched on a chilled casting roll, and semi-crystallization occurs • Dia: 2800 mm, Width: 1400 mm & working: 1200, Speed: 5-130 m/min, Water Removal Pressure: 200 mbar
- 16. Machine Direction Orienter (MDO) • The machine direction orienter is used to stretch the film in the longitudinal direction MDO is the section next to die and cast where our film stretches in machine direction. • 08 Chrome Rolls - (Pre-Heating Zone), 12 Teflon rolls, 06 Chrome rolls - (Stretching Zone), 02 Annealing rolls 08 Chrome Rolls – Pre-Heating Zone • Temperature Range: 1-150 ºC • Set Range: 45-90 ºC Purpose & Features: • Used at the start of pre-heating due to relatively low initial temperature. • Heated by thermal oil. • Low temperature maintained to prevent stickiness between the sheet and rolls. 12 Teflon Rolls – Heating Zone • Temperature Range: 1–150 ºC • Set Range: ≈ 125–130 ºC Purpose & Features: • Positioned after chrome rolls in the pre-heating zone. • Teflon surface has higher Coefficient of Friction (C.O.F). • Reduces stickiness as temperature is higher than earlier chrome rolls.
- 17. Machine Direction Orienter (MDO) 06 Stretching Rolls: • Temperature Range: 1 - 150 o C Purpose & Features: • Use Chrome’s rolls, having a smaller diameter are used for better stretching and to avoid stickiness issues. 04 Annealing Rolls: • Temperature Range: 1–150 ºC • Set Range: ≈ 125–140 ºC Purpose & Features: • Chrome rolls are used at the annealing zone, where temperatures are as high as in pre-heating or stretching zones. • High RPMs of these rolls avoid the sticking of the sheet with chrome rolls as the contact time of the sheet decreases with the rolls.
- 19. Transverse Direction Orienter (TDO)) • Stretches the film in the transverse direction (sideways). • Film is held by clips on both edges and guided via a rail and chain system. • Film enters an oven and is heated by hot air. Pre-heating: • Centrifugal blowers are used for hot air circulation. • Ducts are available on the top and bottom sides of the film. • Oil flows into heat exchanger, blowers suck this hot air and throws them into ducts which have pores to heat film. Effects on film: Imperfect stretching cause breaks if low pre-heating temperatures. Stretching: • Same process as Preheating. • It has two blowers per section because of increased duct size (increased width). • Stretched up to 9 times in the transverse direction. Effects on film: Uneven stretching can result in a Profile Variation, Increased edge width, and Variation in edge profile. Annealing: • Same as above in stretching and pre-heating zones. • Higher temperatures are used in annealing to maintain the disturbance (change in width) caused by stretching. Effects on film: Low annealing temperatures can lead to Increased haze and Low stiffness.
- 20. Transverse Direction Orienter (TDO)) Neutral: • Insulated with the help of a shutter and cotton cloth to avoid the heat transfer from the annealing to the cooling zone. Effects on film: Film may carry condensate particles (oil), which can affect the visuals of the film. Cooling: • Sucks air from atmosphere and maintain temperature of sheet with atmospheric temperature. Effects on film: Improper cooling causes thermal shrinkage.
- 22. Pull Roll & Winder • Pull Roll Stand: Pulls the film from the TDO and transfers it to the winder. Pre-Winding Steps: • Thickness Measurement: By thickness gauge. • Edge Trimming: Razor blades cut unstretched edges. • Edge Recycling: Edges conveyed via venturi duct to grinder, then to main extruder. Surface Treatment: • Corona or Flame Treatment used to increase surface energy. • Improves printability and adhesion properties. Automatic Thickness Control: • Film thickness is continuously monitored. • Adjustments made via bolt heating system on the die.
- 24. Results Property Definition Controlling Factors Thickness NDC Scanner, Die lip opening bolts, Chill roll rpm Grammage Grammage is the mass per square meter. Master Batches Density Mass per unit volume Raw Materials Tensile Strength Tensile strength is the maximum stress that a material can withstand while being stretched or pulled before breaking MDO Stiffness The extent to which an object resists deformation in response to an applied force MDO Elongation The action or process of lengthening MDR Opacity The degree to which content behind film is hidden Chill Roll temperature, Master baches. Gloss A smooth, shiny appearance on the surface of something Master batches, Pre heating temperatures of MDO and TDO Coefficient of Friction The coefficient of friction (fr) is a number that is the ratio of the resistive force of friction (Fr) divided by the normal or perpendicular force (N) pushing the objects Anti-blocks , slip agents. Shrinkage Contraction of sheet Annealing temp. should be high, Pre heat temp. must be high if shrinkage is not controlled with annealing temp. Heat Seal Strength It is the maximum force required to separate the two layers of a seal under particular conditions Co-polymers
- 25. THANK YOU Address: IPAK Raiwand Road Lahore. Name: Muhammad Junaid