Q&A on Metallized BOPP Film for Extended Shelf Life and Directional Tear Sealant Retort and Non-retort Films with Kerri Boyens, New Product Development Manager

By Darren Mar in Adhesives on April 01, 2015

Torayfan® PWX5 BOPP film

Torayfan PWX5 BOPP film delivers superior metal adhesion and barrier-durability performance for products requiring an extended shelf life. It is designed for use as a high-performance inner moisture- and oxygen-barrier web in gas-flushed applications.

One side of PWX5 film is vacuum-deposited aluminum on Toray’s proprietary ultra-barrier layer, which produces a packaging film that has superior metal adhesion and a shiny appearance. The other side of the film has a stable coefficient of friction (COF) and is heat-sealable.

Overall, PWX5 offers superior moisture-, aroma-, and flavor-barrier protection. It also offers excellent puncture resistance. In addition, its excellent barrier-durability, including guaranteed oxygen barrier, makes it the preferred choice for applications requiring an extended shelf life. New Torayfan PWX5 is ideally suited for the packaging of salty, flavorful snacks, cookies, crackers, biscuits, confectionery items, and chocolate, as well as health and beauty products.

1.    Is Toray the first maker of this film?

Torayfan® PWX5 BOPP metallized film is a unique, proprietary film manufactured only by Toray Plastics (America).

 

2.    Are there others in the marketplace?

There are other metallized BOPP films in the marketplace, but none are designed with Toray’s resin formula or manufactured by means of Toray’s proprietary extrusion and metallization processes.

 

3.    Is it being used by a customer and if so, who?

PWX5 film is now being used by a major snack food packaging converter for a major snack food manufacturer. Unfortunately, we are unable to name the converter or end user, as that is confidential information.

 

4.    Where is it made?

Torayfan PWX5 film is manufactured in the U.S. at Toray Plastics (America)’s 70-acre campus in Rhode Island. The facility offers integrated services under one roof, including product development, film manufacturing, coating, and metallization.


5.   Is this strictly for food packaging and if so, what geographic markets is it available in?

PWX5 is not strictly for food packaging. It is also suited for health and beauty products that require aroma and oxygen barrier-protection, such as sample sachets.  

Regarding food packaging, it is especially ideal for the CPG who is expanding its global distribution channels and wants a solution for brand applications that require prolonged oxygen- and moisture-barrier protection. Food applications include salty, flavorful snacks, cookies, crackers, biscuits, confectionery items, and chocolate.

 

Torayfan® TreaTear™ OPP directional tear sealant film for retort and non-retort pouches

 

Is Toray the first maker of this film?

 

Toray is actively engaged in developing its next generation of TreaTear™ polypropylene film with enhanced sealant performance characteristics and precise directional tear for retort and non-retort pouch applications. TreaTear will be a unique, proprietary brand manufactured only by Toray Plastics (America). Toray’s directional tear OPP film is slated for use with retort and non-retort pouches and for use as a drop-in film replacement for CPP sealant web applications. TreaTear can be produced at thinner gauges, without sacrificing stiffness or feel, providing source reduction benefits. TreaTear requires only a simple slit, eliminating the need for laser scoring and “V” notching in order to achieve a precise, clean, straight-line tear. TreaTear film will also offer high clarity, for example, for a window to view pouch contents, and high strength.

 

Are there others in the marketplace?

 

There will be no other directional tear OPP sealant film designed with Toray’s resin formulation or manufactured by Toray’s proprietary extrusion and metallization processes. We have found that the common alternative substrate in the U.S. is nylon with directional tear properties.

 

Is it being used by a customer and if so, who?

 

TreaTear is in the development phase. We cannot identify the customer.

 

Where is it made?

 

TreaTear sealant film is manufactured in the U.S. at Toray Plastics (America)’s 70-acre campus in Rhode Island. The facility offers integrated services under one roof, including product development, film manufacturing, coating, and metallization.


5.   Is it strictly for food packaging and, if so, what geographic markets is it available in?

TreaTear will be for food packaging pouch applications including chicken, seafood, prepared entrees, military MREs, cheese, snacks, cookies, confectionery items and nuts. It is also suited for pet food.

It will be available in the U.S. and internationally. Customers will benefit from improved pouch performance, greater production efficiencies, and possible source reduction advantages.

In terms of non-food applications, pouches offer the potential to cross over into other markets. Toray is always open to exploring creative ideas and new innovations with any manufacturer.

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