Types of flexible packaging and films

Flexible packaging protects what is sold and sells what is protected. The first thing food and beverage manufacturers need to consider when producing a new product is how they will package it. Protecting the product from physical damage and preserving the product during transportation is very important. These factors determine the choice of rigid and hard packaging or flexible packaging.

Taknam Keyhan Polymer products

Many flexible packaging options are cheaper and more convenient for manufacturers, transporters, and customers compared to their rigid counterparts. The question is, how much do you really know about flexible packaging?

This article aims to provide you with an overview by examining the details of various types of flexible packaging and films and their applications.

What is flexible packaging?

Flexible packaging is inherently soft and pliable. This packaging is made from plastic polymers or a combination of materials such as coated cardboard, foil, and paper. Shrink films, stretch films, coatings, and flexible laminates all fall into this category.
This type of packaging earns its name “flexible” due to its elastic properties. Good examples of flexible packages include vacuum bags and bags like trash liners.

Generally, flexible packages take the shape of their contents. The qualitative design somewhat determines its shape. All types of flexible packaging are made from “films.”

Types of flexible packaging films

Each type of film has different properties. Its use depends on the nature of the product that needs to be packaged. The packaging industry loves abbreviations because they are much simpler than trying to pronounce long names. We have listed them below more or less in order of popularity.

LLDPE
LLDPE, or linear low-density polyethylene, is the most flexible film among plastic layers. Other valuable properties of this sheet include its durability and higher strength. It is a hybrid form of LDPE and has the ability to absorb impacts without puncturing or tearing. It has greater thermal resistance but is more opaque. Approximately 80% of LLDPE production worldwide is used in food and non-food packaging and for making shrink and stretch films. Its increasing application as a food packaging film is due to high-performance structures that reduce its permeability. Practically, this means enhanced flavor retention of the packaged contents and extended shelf life.

LLDPE is also used in extrusion coating applications as an additional protective layer in paper and cardboard packaging for liquid containers.

LDPE

Low-density polyethylene (LDPE) was first introduced as a packaging film in 1933. It is the most common type of plastic wrap but lacks the tensile strength and density of LLDPE. However, it is useful in a wide range of applications where those characteristics are not a priority.

LDPE is often used in food packaging for making coffee lids and other cans. Bread bags, protective wrap for multi-packs of certain beverages, and produce bags found in grocery stores are often made from LDPE as well.

LDPE has been a boon for the food processing industry since it complies with food safety standards. It has standard approval for food contact and is recyclable. Common applications of low-density polyethylene film can be categorized into various industries:

• Agriculture
• Meat and seafood
• Janitorial
• Outdoor/construction
• Vegetable and fruit bags
• Freezer bags
• Trash/hygiene bags
• Tarps/sheets
• Anti-static bags
• Cooking bags
• Mattress covers
• Freight packages
• Fish processing bags
• Furniture bags
• Wood coverings

BOPE

Biaxially oriented polyethylene (BOPE) is one of the polymer films that some foreign companies often use in producing flexible packaging. Products that require a high degree of rigidity and tensile strength use BOPE films. They not only show good resistance to puncturing and thermal sealing strength but also provide good moisture barrier properties. They also have the added advantage of high gloss and clarity.

The cost of producing these films is relatively low. BOPE is often used for items such as shopping bags, perishable fruits, and vegetables. They are also used for packaging medicines as well as liquids and spices. Pesticides, industrial goods, laundry detergents, and some cosmetics also utilize BOPE packaging.

BOPET
Food manufacturers accept biaxially oriented polyethylene terephthalate (BOPET) for various reasons such as its properties: strength, chemical inertness, high tensile strength, and heat resistance. It also acts as an oxygen barrier, protecting products like coffee and convenience foods from loss of aroma and oxidation. Additionally, it is widely used as a surface film in laminates. BOPET is often used for the lids of yogurt containers and ready-to-eat foods, whether fresh or frozen. Biaxially oriented polyethylene terephthalate is usually white or transparent.

PET Film:
This film is based on polyethylene terephthalate and comes in various types in terms of appearance, application, and packaging. In terms of appearance, it includes transparent, metallized, matte, and milky varieties. Due to its inability to be heat-sealed, it is generally used only as a printing film in the printing industry. Structurally, it includes types that are double-sided, chemical, and regular, and due to the specific type of polymer, both sides of the film have corona treatment. The double-sided type is used only for printed orders on one side and single-layer applications, and it deforms significantly under heat. The other two types of polyester films have very high heat resistance and are used as printing films in multi-layer orders. The chemical film is sometimes used as an intermediate layer in multi-layer films. This film has a very dry nature and exhibits high resistance to tensile stress, elongation, and tearing.

BOPP
This biaxially oriented polypropylene polymer is an excellent retail packaging solution with great strength and clarity. It serves as an effective barrier against moisture. Often, BOPP is coated with foil to enhance its performance. This film is made from polypropylene and comes in various types in terms of appearance and sealability. In terms of sealing, it is divided into heat seal and cold seal types, and in terms of appearance, it includes clear, metallized, pearlescent, matte, metallized pearlescent varieties, etc. This film is semi-dry structurally and is used in the production process as both printing film and laminate film as well as intermediate film. It has good resistance to tensile stress, elongation, and tearing.

Transparent wraps and a wide range of snack food packages use BOPP films. Bags made from BOPP layers are significantly utilized in the packaging of dairy products and confectionery. Biaxially oriented polypropylene is also used for pesticide products in agriculture and personal care and hygiene products. The softening point of polypropylene is around 140 degrees celsius.

CPP
This film is based on polypropylene and comes in various types in terms of appearance and packaging. In terms of appearance, it includes clear, metallized, and rarely milky varieties. Due to good sealability and suitable resistance to water and oil penetration as well as good resistance to tearing, it is used as laminate film. Another type of metallized CPP film with twisting properties exists that is used as a single layer for printed orders with double-sided capabilities. Structurally, this film is relatively soft and has low resistance to tensile stress and tearing; it can stretch more than ten times its original length.

BOPA
BOPA or biaxially oriented polyamide is very tough and resistant to puncturing due to its high clarity. It serves as a good barrier against oxygen, certain chemicals, and aromas. It is often used in the packaging of perishable food items, distilled goods, and foods prone to oxidation.

Polyethylene (PE) film:

This film is based on polyethylene and comes in various types in terms of thickness and appearance with very good sealability. In terms of appearance, it includes clear and milky varieties. Due to its good sealability and suitable resistance to water and oil penetration as well as good resistance to tearing, it is used as laminate film and rarely serves as an intermediate layer in three-layer orders.

This film is produced in various thicknesses ranging from 30 microns to 200 microns and above. High-thickness films (usually 100 microns and more) can be used as single-layer films and for surface printing as well.

This film is structurally a relatively soft film with low resistance to stretching and tearing, and it can stretch more than 10 times its original length.

PVC
This film is made from polyvinyl chloride and comes in various thicknesses and appearances, offering very good sealing properties. It is rarely used in the food industry and, due to its inability to be laminated with adhesive, is only applicable in surface printing with dual wrapping capabilities. This film is laminated only with heat and is mainly used in decorative prints.

Aluminum foil (Al):
This is a very thin film made of aluminum metal and is the most resistant film against sunlight penetration. This type of film cannot be sealed with heat and is always used as an intermediate layer in multi-layer orders. In very rare cases, such as packaging for pasteurized butter, it is used as a printing film. Depending on the application, this type of film is produced in very thin thicknesses like 5 and 7 microns up to high thicknesses like 200 microns, and due to its metallic structure, it has corona treatment on both sides of the film. Aluminum foil and other metallic substrates provide excellent barriers against gases, light, and moisture. Aluminum reflects radiant heat very well.

Plastic polymers are not the only type of flexible packaging. Polymer films are not the only types of flexible packaging; Kraft paper is a type of tear-resistant paper due to its tensile strength and high stretchability. Kraft paper is effective in single-wall paper bags and sacks for products like cement, chemicals, food, flour, and sugar. It is also used for packaging in the food industry and for food bags.

Laminates
Many forms of flexible packaging consist of a multi-layer structure where one of the polymer or paper layers is supported by aluminum or metallic films. Such laminates prevent odors or fragrances. Flavored drinks, food items like sauces, single-serving sachets, canned foods, and powders are often found in such multi-layer packaging. The pharmaceutical industry also relies on laminate packaging.

Single and multi-layer materials
Depending on the product being packaged, either single-layer or multi-layer materials are used. Each layer serves a protective function and provides a barrier that prevents contamination or enhances freshness. Laminates and multi-layer structures also provide greater resistance to bursting, puncturing, or tearing. Sealability and tensile strength are two factors that should be considered when deciding on suitable flexible packaging for your product.

Sustainability
Biodegradable plastics are on the rise in an effort to make the flexible packaging industry more sustainable and go beyond the recycling capabilities of LDPE, polyethylene, and polypropylene polymers.

Versatility
Teknam Kayan Polymer offers a range of flexible packaging solutions by providing solvent-based and non-solvent-based laminating adhesives under the Namitac brand used in the lamination process for wraps and packaging films. One of our strengths is 20 years of combined experience across various industries. Our success lies in our efforts to utilize the latest technologies. Our continuous technological advancements enable us to offer innovative products.