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Quality Control Operations of Polymer Films.
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Polymer Film
QUALITY CONTROL
UFLEX - FILM TYPES
BOPET : Biaxially Oriented Poly Ethylene
Terephthalate BOPP : Biaxially Oriented Poly Propylene CPP : Cast Poly Propylene METALLISED FILMS (BOPET,BOPP,CPP)
FILM FOR THERMAL LAMINATION (BOPP, BOPET)
QUALITY CONTROL
An Image of the company Ensure fitness to use. Controls Customer complaints. Provide product as agreed. Provide data for development.
WHY TESTING REQUIRED
Testing is necessary to ensure:
The product is matching or surpassing the required properties for smooth usage of the product in entire chain from cradle to grave.
TEST STANDARDS
Test standards are followed to maintain uniformity in testing and understanding among different people, group or companies to ensure a similar platform of product performance
Common standards are: ASTM (American) BS (British) IS (Indian) INTERNAL (Uflex)
PROPERTIES REQUIRED
The film properties can be broadly classified as: Dimensional Optical Surfacial Mechanical Thermal Functional Barrier
DIMENSIONAL PROPERTIES
The appropriate dimensions ensures uniformity during process and helps in effective cost calculation of packaging substrate.
Thickness GSM
Yield (α1/GSM) Roll OD Core ID Roll width
DIMENSIONAL PROPERTIESTHICKNESS
Specification : +/- 3% Instrument Used : Millitron Classification
Spot thickness : Highest accuracy By weight method : Average (100 cm2) By average gauge : Avg. of whole width
Profile analysis : By graph
DIMENSIONAL PROPERTIESTHICKNESS
Procedure : Demo
DIMENSIONAL PROPERTIESGSM / YIELD
GSM : The weight in gms of the substrate per unit square meters surface.
Unit : gm/mts2 GSM = Density * Thickness Measurement method : by weighing 100cm2
of sample in gms and multiplying by 100.
Yield : The area of one kg of film Unit : sq.mts./ kg Yield = 1000/GSM
DIMENSIONAL PROPERTIESROLL DIMENTIONS
Machine Direction (MD) Width of roll
Outer diameter (OD)
Inner Diameter (ID)
MD
TD
TD
OPTICAL PROPERTIES
The optical properties makes the printed image realistic when printed from opposite side of viewing surface, properties are:
Haze Transmittance Gloss Colour : L , a, b Clarity (free from scratches, lines ,marks,
patches, impurities at surface etc.)
OPTICAL PROPERTIESHAZE
The percent of transmitted light that is scattered by a specimen responsible for reducing its contrast and producing smoky field.
OPTICAL PROPERTIESHAZE
Film checked : Clear , Matte Specification
Clear Film : 2.0-4.0 % Matte Film: 40 -70 %
Instrument used : Haze guard plus
OPTICAL PROPERTIESTransmittance /Gloss
• Transmittance : The percent of incident light which is transmitted through the specimen.
• Gloss : It is the surface smoothness responsible for reflecting the light without scattering and thus forming shiny appearance.
SURFACIAL PROPERTIES
The surface properties defines the surface characteristics important for runnability, adhesion and surface morphology:
Treatment / Surface wettability Co-efficient of friction ( α1/Slip) Adhesion Surface roughness Gloss (optical also)
SURFACIAL PROPERTIESTREATMENT
Wetting tension is ability of the surface to wet uniformly with a given liquid.
SURFACIAL PROPERTIESTREATMENT
Liquids of different wetting level is made by mixing proper ration of water, cellusolve & formamide.
In general higher the wetting tension higher the adhesion power.
Units : dyne/cm Minimum level for surfacial adhesion
with ink/adhesive : 38 dyne/cm
SURFACIAL PROPERTIESCOF
The resisting force that arises, when a surface of one substance slides over an adjoining surface of itself or another substance.
COF have a major role in determining the slip behavior of the film and is reciprocal in relation.
MECHANICAL PRPERTIES
Mechanical property is identification of strength, flexibility / rigidity of film to understand its behavior on machine and end application:
Tensile Strength Elongation Modulus of Elasticity
MECHANICAL PRPERTIESTENSILE STRENGTH / ELONGATION
Tensile : It indicates the load applied per unit cross sectional area of the specimen at the time of rupture during streching.
MECHANICAL PRPERTIESTENSILE STRENGTH / ELONGATION
Elongation: It indicates the extension visa vis original length in % while stretching at the moment of rupture.
THERMAL PROPERTIES
The properties ensure the uses without distortion and ensure seal integrity test are;
Shrinkage Machine direction (MD) Transverse Direction (TD)
Heat seal Initiation Temperature Seal strength
THERMAL PROPERTIES SHRINKAGE
Shrinkage : It indicate how much film got shrink in both machine and transverse direction from its original dimension when kept in hot air oven.
Test Condition : PET - 150 deg / 30 min BOPP – 120 deg / 5 min
Specification : FOR PET MD <3.0 and TD <1.0 BOPP : MD/TD :: <3.0 / <2.0
FUNCTIONAL PROPERTIES
The properties ensure the product performance in special conditions which are:
Cold Antifog Hot Antifog F-5 Shrinkage at elevated temperature Sealing with PE film
BARRIER PROPERTIES
The food have a higher shelf life when protected against environmental constrains by not allowing them to pass through the package.
Barrier α 1/ Transmission rate Properties are: O2TR (OTR) : Oxygen Transmission Rate
WVTR(MVTR) : Water (Moisture) Vapour Transmission Rate
METALLIZED FILM TESTING
Thin layer of Alumunium of Aprox. 200 Angstrom is deposited on film (BOPET, BOPP,CPP) and following is checked for adhesion and uniformity:
Optical Density Tape test Treatment1,2 Metal Bond
Various defects on Jumbo
Unflush Ripples
Wrinkles
Various defects on slit rolls
Star marks Ripples
Wrinkles
THANKYOU