Designing Sustainable Ultra-Thin Hygiene Packaging Films for Superior Performance
Challenge
To create a hygiene compression package incorporating recycled content without compromising the film processability or the overall performance of the package In response to consumer preferences and brand owner commitments, many converters are facing the challenge of developing hygiene compression packaging films with sustainability benefits such as downgauging, incorporation of recycled content, and design for recyclability. Examples of these benefits can be demonstrated with monomaterial polyethylene (PE) solutions that can be recycled* and that require a reduced amount of virgin PE material because of a reduction in film thickness and/or the incorporation of recycled content. The challenge lies in achieving these goals while maintaining the film machinability and package performance.
The films were then converted on Hudson-Sharp’s Apollo wicket machine. The wicketer is ideally suited for monomaterial PE films, which may or may not incorporate recycled content, even at very thin gauges. Thanks to the excellent sealability and easy side cutting/punching provided by ExxonMobil’s two PE film formulations, high machine output can be achieved. Customers can continue to benefit from fast changeovers, while achieving high output speeds.
Solution
Design of two recyclable solutions with reduced film thickness and/or the incorporation of up to 35% recycled content A thorough collaboration throughout the full value chain has led to the development of two monomaterial PE film solutions, using Exceed Tough+ m 0518 metallocene polyethylene. In ExxonMobil’s formulation, the use of Exceed Tough+ m 0518 helps enhance the production of films with remarkable toughness and puncture resistance. When combined with ExxonMobil HD 6107FL polymers, it results in high stiffness and excellent creep resistance, ensuring that the package maintains its dimensional stability throughout and after the packaging process. Minor additions of ExxonMobil LD 07523 polymers can be employed to adjust processability and optical features. By leveraging just three PE grades, it is possible to reduce the film thickness and/or incorporate up to 35% recycled content while still meeting performance and processability requirements. The films were made on lines located in an ExxonMobil facility.
The package was subsequently formed and sealed using Optima’s machinery, which is specifically calibrated to handle these materials while ensuring optimal performance and quality. The two PE films produced by ExxonMobil demonstrated easy machinability on Optima’s equipment, exhibiting sufficient stiffness to prevent film elongation during handling and a good coefficient of friction for the grippers. These attributes are essential for maintaining the shape and functionality of the package, helping the products to be securely contained.
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