Stretch Film 101 Stretch Film 101 WE DELIVER INNOVATION 1 Steelflex AIRFORCE OPEN CORNERBOARD GLOBALPACK Pre-strech Stretch Film 101 Polyethylene Basics How is Polyethylene Made Basic Types of Polyethylene Who are these Resin Companies and why are They so darn powerful 3 Stretch Film 101 Polyethylene Resin Manufacturing Natural Gas Ethane Propane 70 � Butane Cracking process Crude Oil Naphtha 30 � Gas Oils Polymerization Process Ethylene Polyethylene Resin 4 Stretch Film 101 Polyethylene Basic Types LDPE Low density polyethylene High density polyethylene Branched polyethylene LLDPE (main component of stretch film) Linear low density polyethylene Low pressure low density polyethylene Linear polyethylene mLLDPE Linear low density polyethylene copolymer Linear polyethylene produced using a hexene copolymer HDPE High density polyethylene Linear polyethylene 5 Stretch Film 101 Major Resin Companies Exxon Mobil 40% + market share on Stretch Resin Dow Chemical 40% + market share on Stretch Resin Remaining 20% split between several companies • Nova Chemcials • Eastman • Hunstman • Formosa • Equistar • Chevron Phillips 6 Stretch Film 101 Manufacturing Methods Extrusion Process and methods Inherent qualities to each process/ What makes them different? The Industry in Review 7 Stretch Film 101 Extrusion Methods Blown Blown films are produced by pumping melted resin through a heated circular slotted rotating die to form a tube. The tube is filled with air which assisted in determining the gauge. The flow of air cools the film before it reaches the nip rollers. The collapsed tube is then slit into various widths and roll lengths. 8 Stretch Film 101 Web oath Upper Nip Upper Nip A-frame (wood or air booring type) IBC Exhaust Airflow Bubble caos IBC Cooling Airflow Frotaline Air Ring Airflow Sonar Head 4-6 inch Typ Positioning Internal Bubble Cooling Input Air Ring Exhaust Manual Damper Automatic Damper Air Activated Servo Driven 9 Stretch Film 101 Extrusion Methods Cast Co-Extrusion The cast coextrusion manufacturing method consists of melted resin pumped through several extruders through a straight slotted die creating a layered sheet of film. The film is then quickly cooled by a water filled chill roller and slit to size. The cast process usually produces superior quality stretch film with more uniform gauge, and more consistent cling. Cast films traditionally offer better tear strength which results in the prevention of tear propagation. 10 Stretch Film 101 Extruder in operation Chill Roll Vaccum Box Día To Winder Air knife Casting Roll Pine out Roll 11 Stretch Film 101 Differences Blown & Cast Films CAST BLOWN • Superior optics • Hazy • High Gloss • Dull • Lower modulus (stretches easier) • Tough • Tear resistance • Noisy unwind • Good puncture • Tear resistance • Quiet unwind • Migratory cling • Non-migratory • Poor gauge control • Excellent gauge control • Excellent puncture 12 Stretch Film 101 The Industry • 2009 Stretch Film Sales were approximately 1.7-1.9 Billion Pounds • 2009 Capacity was roughly 2.6 Billion lbs • 2008 Capacity was over 2.1 billion lbs • 2008-10 Major reshaping of players due to the mergers and consolidation that the industry has gone through. RECESSION has hurt many small and big players • The top 5 companies have nearly 1.6 Billion pounds of capacity 13 Stretch Film 101 Stretch Film Performance Measuring Hand Film Performance Measuring Machine Film Performance Load Types Hand Film Performance Stiffness Puncture Resistance NECK Down Yield Clarity Holding Force 14 Stretch Film 101 Machine Film Performance Pre-Stretch The amount of stretch achieved between the rollers F2 Stretch The amount of stretch achieved by the load against the unwinding film. Total Stretch The combination of the pre-stretch and the F2 stretch. � of F2 The F2 stretch %/ pre-stretch gear % (Normal is about 10%). Measuring Film Performance Total Stretch � Is measured with a 10” star wheel. Load Retention The amount of force exerted inward by the film. It is measured in lab conditions on a load cell. Cut & Weigh The amount of film cut off the load & measured on a scale. Force to Load Is measured with a flat plat and a pull scale. 15 Stretch Film 101 Load Types “A” “B” Up To 3” Protrusion 3”- 6” Protrusion “C” Greater than 6” protrusion 16 Stretch Film 101 Film Failures Gel Holes A gel is a V shaped break in the film caused by resin imperfection or some other manufacturing problem. Edge Damage An edge tear starts at the top or bottom of a roll and tears in a diagonal direction. A nick in the film edge usually causes it. Application Failure Load Film Film Break An Application failure is when the wrong film is being used for an application. Load type and excessive down gauging are possible causes. Ultimate Breaks An ultimate break is a straight-line break with pointed edges. The break occurs when the film has been pre-stretched beyond its limits. 17 Stretch Film 101 How to sell Stretch film Current Market Conditions & Pricing Questions to Ask Let’s do the Numbers What’s in the Box Who’s my Competiton? 18 Stretch Film 101 Current Market Conditions & Pricing Pricing Factors: Oil and Natural Gas Supply and Demand from Overseas Markets Overcapacity from Fabricators both in North America and international Markets Stretch Film Market still remains very volatile with increases and decreases due to capacity from the mill to excess capacity from the Stretch Film Manufacturers 19 Stretch Film 101 Questions to ask: • Know your N E E D S • What are they using NOW • What Is the EQUIPMENT? • What do they ENJOY about it • Who is the DECISION MAKER • How SOON? • N E E D S • NOW – gauge, width, length, competition, blown or cast Let’s do the numbers How to figure out the weight of a roll (NET POLY) Width x Length x Mill Thickness/2500 = poly wt. Gauge to Micron Gauge x .254 = Micron Micron to Gauge Micron x 3.937 = Gauge MIN FTL on a pallet Weight of pallet/100 20 Stretch Film 101 Performance Formulas Stretch Film performance formulas Find Purpose: To determine the amount of poly on a roll of film Approximate Net Poly Formula: Film Width (inches) x Film length (inches) x Thickness (mil) = Poly lbs. Weight Example: ATT1-2080 20”X(6000’X12”)X8mil/30,000=38.4 lbs Formula: Price Per Roll = Net Cost Per Pound Find Net Pound Per Roll Net Cost Per Pound Example: ATT1-2080@$31.68 per roll $31.68/38.4=83 cents/lb Find Formula: Price Per Roll = Net Cost Per Thousand Linear Feet Net Cost Per Thousand Thousand Ft Per Roll Linear Feet Example: ATT1-2080@$31.68 per roll $31.68/38.4=83 cents/lb Given: Both rollers on the machine are the same diameter, count the teeth Find in the two gears driving the rollers (# of teeth on the Input Roller= RS1, # of Geared Stretch level of teeth on the Output Roller=RS2) a Machine Formula: (RS1/RS2-1)x100=Pre-Stretch% Example: (54/18-1)x100=200% 21 Stretch Film 101 Conversion Chart Microns Gauge Microns Gauge 8.5 0.33 19 0.75 9 0.35 19.5 0.77 9.5 0.37 20 0.79 10 0.39 20.32 0.80 10.5 0.41 20.5 0.81 11 0.43 21 0.83 11. 5 0.45 21.5 0.85 12 0.47 22 0.87 12.5 0.49 22.5 0.89 13 0.51 22.86 0.90 13.5 0.53 23.0 0.91 14 0.55 25.4 1.00 14.5 0.57 27. 9 1.10 15 0.59 30.5 1.20 15.5 0.61 33.00 1.30 16 0.63 35.6 1.40 16.5 0.65 38.1 1.50 17 0.67 40.6 1.60 17. 5 0.69 43.2 1.70 17.75 0.70 45.7 1.80 18 0.71 48.3 1.90 18.5 0.73 50.8 2.00 63.5 2.50 76.2 3.00 22 Stretch Film 101 What is in the BOX? What is in this box, Really? Customer say’s it’s 80 Gauge, But what is it really? Why are WE priced so much higher? We weigh a case and it weighs 30.1 lbs and we know a 80 GA Box should weigh net poly 34.56 lbs 18” x 1500’ +Cores + Box Hi-Performance SOMETHING IS WRONG! Where can they cheat? Width, Length and Gauge 23 Stretch Film 101 How does this effect you? • Customer states he’s buying a 18” x 80 Gauge x 1500’ roll • You do your math from the formula you just learned: 18” x 1500 x .80/2500 = 8.64 lbs/roll • The cores weigh 1 lb each and there are 4 lbs box weighs 1 lb so the total weight for a 18” x 80 x 1500 box • At 4 rolls per case = Net poly weight + Cores + Box • 34.56 lbs net poly weight + 4 lbs cores + 1 lb box = 39.56 lbs • We weighed the box and it comes out to 30.1 lbs and we subtract core and box = Net poly weight is 25.1 lbs • We know he’s getting cheated! • Their cost is 25.1 @ 1.00 per pound = $25.10 a case vs Your cost of 34.56 x .85 a lb = 29.37 a case • You are at a 17% disadvantage. 24 Stretch Film 101 Hand Film Selling Techniques Ask them what they prefer, cast or blown (Noisy or not noisy) Observe how they stretch wrap, if they are pu- lling hard and the film is soft – you can show them a stiff blown or cast film to save their back and money Show them the quick tightness of a stiff cast film vs the film they are using Show them the puncture resistance of the film vs what they are using Show neckdown, more film coverage vs what they are using Weight difference and strain on shoulder, wrist and back Walking forward vs backward – safety Fatigue factor Stonger but thinner = Environmental Source Re- duction Better load retention means less damage 25 Stretch Film 101 Machine Film Buying & Selling Techniques Common Situations What’s your roll price? If you don’t know the application and what the operating parameters are, how can you begin to quote a roll price? Explain how Our Films are different and convert to cost/load.
Contact your Freedonia Client Services at +1.440.684.9600 or info@freedoniagroup.com. STRETCH & SHRINK FILM Industry Study #3796 | March 2020 This Freedonia industry study analyzes the 2.6 billion pound US stretch and shrink film market. It presents historical demand data (2009, 2014, 2019) and forecasts for 2024 by type (stretch film, shrink film), market (storage & distribution – pallet unitization, bundling and other; product packaging – food, beverages, paper and textile, consumer, other packaging applications), and resin (linear low-density polyethylene, low-density polyethylene, polyvinyl chloride, polypropylene, other resins). Learn More About This Report Report Link: https://hubs.ly/H0nLTtB0 Table of Contents (continued) Table of Contents 1. Executive Summary 9 2. Overview 11 Key Findings 11 Demand by Type & Application 12 Historical Trends 14 Pricing Trends 16 Foreign Trade & International Activity 18 Resin (Multilayer & Metallocene Films) & Machinery Developments 19 Regulatory & Environmental Considerations 21 Pallet Unitization Film 21 PVC Film 21 Recycling 22 Labels 23 3. Stretch Film 24 Key Findings 24 Stretch Film Demand 25 Stretch Film Production Methods (Cast, Blown) 26 Stretch Film Resins 28 Stretch Film Products 30 Demand by Product 30 Stretch Wrap 31 Stretch Hoods 32 Stretch Sleeve Labels 34 Stretch Film Applications 35 Demand by Application 35 Pallet Unitization (Machine Film, Hand Film) 36 Bundling & Other Storage & Distribution 38 Food Packaging 39 Beverage Packaging 41 Paper & Textile Packaging 42 Consumer & Other
Say NO to Plastic Bags Introduction Plastic bags are littering our streets and waterways, and clogging the processing machines at our transfer stations. Some communities have attempted to address the problem using one of three methods. Could any of these work in your community? Bag Bans ▪ Plastic bag bans are placed on a state, city, or town level and can be regulated by code enforcement officers who periodically visit vendors to ensure they are following the regulations. ▪ Violators will be penalized with a fine. Bag Bans ▪ Ban the distribution of plastic bags by chain retailers within a community. ▪ Cuts off supply of plastic bags at the source. ▪ Some bans are based on square footage of the business, i.e.. Retail establishments or food providers with greater than 10,000 square feet in specific store size must comply with the ban. ▪ Small businesses are harder to regulate but are usually brought under the regulation over time. Bag Bans ▪ Works very well in some areas ▪ In Portland Oregon, since 2013, the ban caused a reusable bag use increase of 304% while paper bag use jumped 491%. ▪ Some vendors have found loopholes to this method. ▪ Austin, Texas and Honolulu, Hawaii placed a ban that initially only included bags that were 4- millimeter thick or less. ▪ This caused retailers to start using thicker plastic bags, greater than 4mm that still ended up in the waste stream. ▪ Barrington, Rhode Island ran into the same loophole after enacting the ‘Reusable Check- out Bag Initiative’. ▪ Shaw’s and CVS seized the opportunity and introduced a so called reusable plastic bag that was thicker than the 2.25-millimeter limit.
C o p y r i g h t , C S C P u b l i s h i n g , P o w Choosing the right method for wrapping pallets d e r a n d B u l k Uffe S. Kristiansen Lachenmeier A/S E n g i n e he most common mistake in e Selecting the best method for secur- ple costo de la maquinaria y el r i choosing a method for wrapping n ing loaded pallets depends on sev- material de empaque. Este artículo g pallets is to focus on only two I eral factors, not just the cost of the enumera los factores y examina n T t factors: the cost of packaging material e machinery and the packaging tres opciones para empacar pale- r and the cost of the machine. These are n material. This article lists these fac- a tas: envoltura por elástico, en- t i important factors, of course, but they o tors and examines three pallet- voltura con elástico termosensible y n show you only half the picture. a wrapping options: conventional estirado de forro. l stretch-wrapping, thermal shrink- wrapping, and hood-stretching. Other important factors to consider are labor requirements, storage, energy Choisir la bonne méthode pour cost, capacity, customer acceptance, and l’enveloppage des palettes after-sale service. Le choix de la meilleure méth- ode pour la consolidation de Labor requirements. If you choose a chargements de palette tient less-expensive semi-automatic machine compte de plusieurs facteurs, instead of a fully automatic one, will the pas seulement du coût de la ma- savings be consumed by the extra labor chinerie ou du matériel d’em- needed to operate the machine? ballage.
Temperature-Sensitive Cargo Protection Complies with Time & Temperature Sensitive Cargo Regulations ™ ® TEST DATA – DUPONT TYVEK AIR CARGO COVERS DuPont™ Tyvek® Air Cargo Covers provide excellent Temperature comparison ‘all-in-one’ protection against temperature excursions Control (stretch wrap) When it comes to managing the risk of temperature excursions throughout the cold chain, protecting your products against ambient temperature extremes is important. However, solar ºC radiation may be the most critical–and under-appreciated–threat you face. That’s because 56.2 solar radiation is the leading cause of high-temperature spikes on the tarmac. We have conducted various trials for the Tyvek® Air Cargo Covers (including an environmental chamber test, sun exposure trial and real life scenario trial). Please contact AmSafe Bridport (details overleaf) to request the full Qualification Report and the Validation Reports. Are you focused on the right R? Reflectivity or R-value? Tyvek® Air Cargo Cover Tyvek® Air Cargo Covers offer multi-threat protection that helps reduce temperature excursions by providing: 22ºC Superior protection from solar radiation as a result of their unique reflective outer surface Excellent protection from ambient temperature extremes–hot and cold–without the weight or bulk of alternative covers Simply stated, Tyvek® Air Cargo Covers provide excellent ‘all-in-one’ protection against the threats of solar radiation Test conditions: covered pallets on simulated tarmac in Lakeland, FL, November 2012 at ~11 a.m. Full sun with and extreme ambient temperatures. ambient temperature at 20°C. Giving you peace of mind that your cargo will reach its destination safely amsafebridport.com/cargo Solar radiation technical study At low thermal mass (empty boxes in test case below), the temperature inside a pallet can far exceed ambient temperature3.
Cor-Pak® Stretch Hoods powered by Nano VpCI® PRODUCT DESCRIPTION Stretch hoods are among the fast- est growing packaging techniques for shipment of palletized goods. Cortec® offers specifically de- signed plastomer material solu- tions for stretch hood packaging. Cor-Pak® Stretch Hoods powered by Nano VpCI® are the ultimate high-performance stretch hood films for corrosion protection of ferrous and non-ferrous metals. The film is suitable for industrial use to stabilize loads and ensure pallet integrity for efficient pack- aging and delivery. This film is co-extruded using state of-the-art resins, offering superior strength and stretch characteristics as well as multi-metal corrosion inhib- iting properties that only VpCI® technology can deliver. Cor-Pak® Stretch Hood Film powered by PACKAGING AND STORAGE ® Nano VpCI delivers puncture re- ® sistance and load holding, which Cor-Pak Stretch Hoods are available in pallet sizes and custom made. ® allows a user to down-gauge, con- Contact EcoCortec Customer Service for custom requirements. tain aggressive loads and produce To ensure best product performance, store in original packaging, indoors, a better package at reduced cost. and out of direct sunlight at 4- 38 °C (40-100 °F). Shelf life: 2 years The combination of enhanced polyethylene resins with VpCI® FEATURES Technology makes Cor-Pak® Stretch Hoods powered by Nano • Elastic (788.4% elongation at ® VpCI the most advanced corro- break) sion inhibiting stretch film avail- able today on the market. • Excellent puncture resistance • Meets NACE TM0208-2018 ® Cor-Pak Stretch Hoods can eas- standard for corrosion ily be recycled and are compatible with commercially available man- protection ual and automatic stretch wrap- • Meets German TL-8135- ® ping equipment.
Hand Stretch Film HIGH-PERFORMANCE HAND STRETCH HAND STRETCH FILM Hand Stretch Wrap is the best packaging technique using to secure boxes to pallets. A superior high performance film providing enhanced load stability and real Available in several different gauges ‘wrap cost per pallet’ savings. (thicknesses) for different load capacities. The high stretching gives good quality Smooth and easy release. with the minimum thickness. High clarity - no problems with barcode Available in several different gauges reading and load identification. (thicknesses) for different load capacities. HAND STRETCH FILMS HIGH PERFORMANCE HAND STRETCH FILMS CASE DISCOUNT/PRICE PER ROLL CASE DISCOUNT/PRICE PER ROLL SKU SIZE RLS/CS GAUGE SKU SIZE RLS/CS GAUGE 4 8 16 24+ 4 8 16 24+ STR158015CS 15" x 1500' 4 80 $14.89 $14.14 $13.40 $12.65 STR181615CXHS 18" x 1500' 4 16 MIC $10.86 $10.32 $9.78 $9.23 STR1510010CS 15" x 1000' 4 100 $12.41 $11.79 $11.17 $10.55 STR1512010CS 15" x 1000' 4 120 $14.89 $14.14 $13.40 $12.65 PRE-STRETCHED STR1810010CS 18" x 1000' 4 100 $12.90 $12.26 $11.61 $10.97 HAND FILM STR1810010BS 18" x 1000' 4 100 $13.85 $13.15 $12.46 $11.77 STR1812010CS 18" x 1000' 4 120 $15.52 $14.74 $13.97 $13.19 Hand Eco Stretch Wrap. Better Cling for applications including cold storage. Higher Force to load eliminates OPAQUE HAND STRETCH transit damage. Opaque Hand Stretch Wrap recommended for product concealment, outdoor storage and Reinforced Edges for tear resistance.
The New Plastics Economy Rethinking the Future of Plastics
THE NEW PLASTICS ECONOMY • • • 1 The New Plastics Economy Rethinking the future of plastics THE NEW PLASTICS ECONOMY RETHINKING THE FUTURE OF PLASTICS 2 • • • THE NEW PLASTICS ECONOMY THE NEW PLASTICS ECONOMY • • • 3 CONTENTS Preface 4 Foreword 5 In support of the New Plastics Economy 6 Project MainStream 8 Disclaimer 9 Acknowledgements 10 Global partners of the Ellen MacArthur Foundation 14 EXECUTIVE SUMMARY 15 PART I SUMMARY OF FINDINGS AND CONCLUSIONS 22 1 The case for rethinking plastics, starting with packaging 24 2 The New Plastics Economy: Capturing the opportunity 31 3 The New Plastics Economy demands a new approach 39 PART II CREATING AN EFFECTIVE AFTER-USE PLASTICS ECONOMY 44 4 Recycling: Drastically increasing economics, uptake and quality through compounding and mutually reinforcing actions 46 5 Reuse: Unlocking material savings and beyond 62 6 Compostable packaging: Returning nutrients to the soil for targeted packaging applications 68 PART III DRASTICALLY REDUCING LEAKAGE OF PLASTICS INTO NATURAL SYSTEMS AND MINIMISING OTHER EXTERNALITIES 74 7 Drastically reducing leakage into natural systems and associated negative impacts 76 8 Substances of concern: Capturing value with materials that are safe in all product phases 79 PART IV DECOUPLING PLASTICS FROM FOSSIL FEEDSTOCKS 86 9 Dematerialisation: Doing more with less plastic 88 10 Renewably sourced plastics: Decoupling plastics production from fossil feedstocks 92 Appendix 97 Appendix A. Global material flow analysis: definitions and sources 98 Appendix B. Biodegradation 100 Appendix C. Anaerobic digestion 101 Glossary 102 List of Figures and Boxes 105 Endnotes 106 About the Ellen MacArthur Foundation 117 4 • • • THE NEW PLASTICS ECONOMY PREFACE The circular economy is gaining growing attention as a potential way for our society to increase prosperity, while reducing demands on finite raw materials and minimising negative externalities.