Blown Film

Borealis blown film applications deliver effective solutions for advanced packaging based on innovative technologies.

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Technologies

Borstar® Bimodal Technology

Generating value in blown film extrusion, converting and packaging

Our Borstar® technology resins offer flexible extrusion qualities and superior mechanical properties.

Advanced packaging solutions must fulfil ever more sophisticated and varying criteria according to the needs of manufacturers, converters, brand owners and ultimately end consumers. Materials solutions must be sustainable, cost efficient and highly functional in order to accommodate rapidly evolving market requirements.

Based on the bimodal polymer design concept, our Borstar® technology resins offer the flexible extrusion qualities of traditional low density polyethylene (LDPE) combined with the superior mechanical properties of high alpha olefin linear products. This combination facilitates increased production efficiency with value-generating potential in blown film extrusion as well as in converting and packaging.

Our Borstar polyethylene (PE) technology products include:

  • Borstar LLDPE
  • BorShape™ LLDPE
  • BorLite™ LLDPE

Borstar enhances efficiency and performance

All of our grades are ideally suited for extrusion on all blown film lines, including coextrusion and blends as well as coextrusion with high density polyethylene (HDPE) on high neck HD extrusion lines.

Key processing elements Main benefits
Bubble stability Production regularity
Few bubble breaks Full film thickness range
No melt fracture High output
Draw down Recipe standardisation
Lower melt pressure vs. LLDPE Fast transitions
Well suited for coextrusion Production efficiency
Blendability Reduced production cost

The unique combination of stiffness and mechanical properties such as tear, impact and yield strength offers genuine downgauging potential for packaging film. Features traditionally obtained by coextruded structures, combining blends of different PEs in each structure, may be achieved with a single material and in most cases with a thinner film.

Key film properties Main benefits
Very high toughness Improved film strength
High impact vs. stiffness Stiffer films at retained toughness
Extremely low gels Downgauging
High toughness at frozen conditions Improved film quality
Matt surface Printing quality
  Non-blocking
  Easy COF control

When compared to traditional PEs, the controlled comonomer distribution results in low taste and odour levels as well as in improved low-temperature properties. Furthermore, films made of Borstar technology grades have a high seal strength and hot tack force.

Driving innovation in advanced packaging solutions

We have been a leading supplier of superior polyolefin plastics for advanced packaging and fibre solutions for over 50 years. Our unique Borstar® technology supports a broad field of applications in the manufacture of film, fibre, coating and thermoforming products. Thanks to solid partnerships and long-term cooperation with leading machine manufacturers, we can continue to develop revolutionary plastics solutions that inspire the applications of tomorrow while at the same time addressing the challenges of today: from sustainability to cost competitiveness, from film performance to packaging integrity. 

MDO Converter Technology

Setting new standards in MDO performance

When used with MDO converting technology, our BorLite and BorShape solutions offer excellent packaging performance and substantial economic benefits for key value chain partners.

Enhanced packaging performance, improved cost and production efficiencies and increasingly, sustainability are key drivers in the advanced packaging film industry. Thanks to our proprietary technologies and robust cooperation with partners along the value chain we are able to set new standards when it comes to machine direction orientation (MDO) performance.

Added value and more environmentally-friendly packaging thanks to Borstar®

Borealis recently launched the BorLite™ and BorShape™ family of materials based on our unique Borstar® technology. These additions bring step-change innovation to advanced flexible packaging film solutions. When used with MDO converting technology, our BorLite and BorShape solutions offer excellent packaging performance and substantial economic benefits for key value chain partners, from converters to brand owners and ultimately end users:

  • New packaging performance levels at reduced packaging weight, fostering better sustainability and greener packaging
  • Step-change downgauging
  • Value generation across the entire value chain

What is more: our MDO solutions set new standards in MDO film performance, achieving excellent tear resistance in MD as well as a very high toughness. These features, complemented by the recognised performance of the MDO technology, contribute to the films' very high MD tensile strength, high stiffness levels, transparency and gloss.

One of the areas in which our BorLite and BorShape solutions meet and even exceed current market standards is in shipping sacks, where we offer advantages such as:

  • Step-change downgauging, from 130 μm to 80 μm, i.e. 38% thickness reduction
  • Same or higher performance at the key parameters
  • High load security during transport and storage
  • Reduction of per unit bag cost
  • Highly positive environmental impact: 130 tonnes of CO2 emission reduction per kilotonne of packed goods

Other areas of application include twist wraps, magazine wraps, lamination films, compression packaging, labels and more.

Driving innovation in advanced packaging solutions

We have been a leading supplier of superior polyolefin plastics for advanced packaging and fibre solutions for over 50 years. Our unique Borstar® technology supports a broad field of applications in the manufacture of film, fibre, coating and thermoforming products. Thanks to solid partnerships and long-term cooperation with leading machine manufacturers, we can continue to develop revolutionary plastics solutions that inspire the applications of tomorrow while at the same time addressing the challenges of today: from sustainability to cost competitiveness, from film performance to packaging integrity.

Products

BorShape™

Outstanding processability and performance

BorShape offers high packaging rigidity for enhanced end-user feeling and improved packaging integrity – all without compromising operational performance.

The film packaging industry is currently driven by three important trends: cost competitiveness, enhanced packaging performance, and sustainability. BorShape™ is a revolutionary new generation of materials created to deliver on all three objectives, and is especially suited to meet the fundamental challenges in sustainability: downgauging and lightweighting.

Tackling multiple packaging challenges with one comprehensive solution

Based on our proprietary bimodal Borstar® technology, BorShape offers high packaging rigidity for enhanced end-user feeling and improved packaging integrity – all without compromising operational performance. What is more, BorShape delivers outstanding processability at the converter, allowing for an output 20% higher than other linear low density polyethylene (LLDPE) and/or metallocene linear low density (mLLDPE) materials.

To meet the challenges of the flexible packaging industry, the BorShape product family has been designed to become the benchmark in the polyolefin film market when it comes to unparalleled performance in the most demanding film properties:

  • Excellent stiffness-toughness balance offers a significant downgauging potential of more than 30%
  • High stiffness for high packaging rigidity and efficient film converting operations allows for superior stand-up ability and enhanced end-user feeling
  • High toughness and superior seal strength results in excellent packaging integrity and fewer default packages
  • Good hot tack performance in combination with mLLDPE/plastomer skin solution for high packaging speed improves operational performance

BorShape supports sustainability within the film packaging industry in a significant way, enabling more environmentally friendly developments and, as a consequence, less packaging waste. When combined with BorShape's optimum processing behaviour, this yields the complementary advantages of lower energy usage during processing and transportation as well as environment-related benefits.

Driving innovation in advanced packaging solutions

We have been a leading supplier of superior polyolefin plastics for advanced packaging and fibre solutions for over 50 years. Our unique Borstar® technology supports a broad field of applications in the manufacture of film, fibre, coating and thermoforming products. Thanks to solid partnerships and long-term cooperation with leading machine manufacturers, we can continue to develop revolutionary plastics solutions that inspire the applications of tomorrow while at the same time addressing the challenges of today. The performance features and unique property profile of our BorShape family translate into benefits along the whole value chain: from film converters to packers, from brand owners to end users.

Polypropylene Blown Film

Better performance across a variety of applications

Our film industry customers and partners know they can rely on our PP grades thanks to their excellent performance and superior properties.

Recent polypropylene (PP) developments in regard to polymer structure (co-polymers) and special nucleation systems have made it possible to use PP in a much more economical way on blown film lines with air cooling. The latest breakthroughs in coextrusion technology now support the exploitation of the full potential of PP.

 

We have a grade to cover your application needs

Our film industry customers and partners know they can rely on our PP grades thanks to their excellent performance and superior properties.

High stiffness in blends or as coextrusion layer offers:

  • Downgauging potential
  • Very good conversion on packaging equipment
  • Good film flatness / punching quality

High heat deflection temperature enables:

  • Sterilisation up to 145°C, depending on individual PP grade and conditions
  • Hot fill applications

Good optical properties, including:

  • Surface gloss
  • High transparency

Converters enjoy a wide variety of applications

Grade Market need / property Applications
Heterophasic copolymer BA110CF Balanced stiffness / toughness ratio, sterilisable Laminated film for food packaging, monoaxial oriented film, hygienic   film, siliconisable film
Enhanced heterophasic copolymer BC918CF High stiffness / toughness balance, good optics after sterilisation Stand-up pouch, label film
Random copolymer RB707CF High stiffness and very good optics Label film, laminated film, food packaging
Random copolymer RB709CF Excellent clarity and sealing Label film, laminated film, food packaging
Random / heterophasic copolymer SA233CF Low temperature resistance, high softness and toughness Hygienic film, industrial packaging, stand-up pouch

Driving innovation in advanced packaging solutions

We have been a leading supplier of superior polyolefin plastics for advanced packaging and fibre solutions for over 50 years. Our unique Borstar® technology supports a broad field of applications in the manufacture of film, fibre, coating and thermoforming products. Thanks to solid partnerships and long-term cooperation with leading machine manufacturers, we can continue to develop revolutionary plastics solutions that inspire the applications of tomorrow while at the same time addressing the challenges of today: from sustainability to cost competitiveness, from film performance to packaging integrity.

Queo™

Bridging the gap between plastics and elastomers

Our unique plastomers brand Queo delivers a range of unique performance attributes including superior sealing, flexibility, compatibility and processability.

Queo plastomers are a range of low-density ethylene copolymers made possible by combining metallocene catalyst technology with the Borceed™ solution polymerisation process. The comonomer used by Borealis plastomers is octene. As the name implies, plastomers bridge the gap between plastics and elastomers. They exhibit many of the physical properties of a rubber and combine this with the processing advantages of a thermoplastic.


Image: Comparison of select properties of polyolefin elastomers and plastomers. © Borealis.

What do Queo plastomers deliver?

Our metallocene catalyst technology affords a highly efficient and consistent incorporation of octene comonomer into a polyethylene backbone. This results in low density and ensures precisely defined polymers with a range of unique performance attributes:

  • Lower peak melting points and narrower melting ranges, providing controlled sealing performance and superior sealing against contaminations
  • Flexural modulus similar to elastomers and thermoplastic behaviour without plasticisers or polar comonomers
  • Exceptional compatibility with other polymers and elastomers to provide tailored attribute-blending opportunities
  • Outstanding clarity
  • Very low extractables
  • Exceptional toughness

Queo plastomers add value in a wide range of film applications, many of which have been demonstrated to exceed the requirements of the plastomer attributes. As a result, Queo plastomers are extensively used as a blend partner, offering the opportunity to tailor performance to the cost balance of finished articles.

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Applications

Unique technologies delivering tailored solutions for flexible packaging

Borealis strives to answer to the key trends in the flexible packaging film industry: food safety and freshness, convenience and sustainability. 

An overview of key trends driving the flexible packaging film industry might begin with the issue of food safety and freshness. The amount of available arable land is finite, yet global demand for food is growing. The agriculture industry must seek out the most efficient methods of getting more food to the table – faster and fresher than ever before. Polyolefins will maintain their principal role as the backbone of most packaging solutions because they can best safeguard the quality and shelf life of food, and can fulfil increasingly stringent regulatory and legislative requirements. What is more, polyolefins can help make enhanced functionalities possible, such as peelability, breathability, and sterilisability; they also boast high barrier and light blocking properties, and are microwavable.

As convenience continues to drive the industry, consumers want packaging that not only retains freshness, but is easy to open and reseal. Demand for long-life food products is also bolstering the trend towards retortable plastic packaging. Brand owners aim to differentiate their product from those of their competitors by way of aesthetically appealing packaging.

Another key driver is sustainability. As brand owners respond to legislative and regulatory pressure by downgauging and lightweighting, polyolefins play an essential role as enabler by making products lighter and reducing costs. And as life cycle performance becomes an increasingly important purchase criterion, we at Borealis are working together with our partners to discover and implement novel ways of recycling plastics in new applications and improving the overall image of the plastics industry.

Novel multilayer packaging solutions

At Borealis, we draw on decades of experience and our unique technologies to help our partners find solutions to a wide range of application needs. Enabling our partners throughout the blown film value chain to realise their own goals in the areas of sustainability, cost competitiveness, packaging integrity, and film performance is what drives us in our current and future innovation efforts.

By combining our polymer, application and processing expertise with state-of-the-art machine technology, we demonstrate the best way to deliver high-performance solutions, reduce total cost and help meet customer needs in flexible packaging.

We offer our partners more efficiency by enabling the substitution of expensive multi-substrate packaging structures and simplified recipes, leading to improved processability and reduced energy consumption.

Our film solutions for the blown film market include:

  • Deep freeze film
  • Collation shrink
  • Lamination

Our film solutions for the machine direction orientation (MDO) market:

  • Heavy duty shipping sacks (HDSS)
  • Compression packaging
  • Full polyethylene (PE) laminate structure
  • Label film

Driving innovation in advanced packaging solutions

We have been a leading supplier of superior polyolefin plastics for advanced packaging and fibre solutions for over 50 years. Our unique Borstar® technology supports a broad field of applications in the manufacture of film, fibre, coating and thermoforming products. Thanks to solid partnerships and long-term cooperation with leading machine manufacturers, we can continue to develop revolutionary plastics solutions that inspire the applications of tomorrow while at the same time addressing the challenges of today: from sustainability to cost competitiveness, from film performance to packaging integrity.