BOPE - THE NEXT BEST ALTERNATIVE ..?

The worldwide market for food packaging continues to grow, driven by increasing demand for convenience, sustainability, and food safety. According to Fortune Business Insights, The global food packaging market size was valued at USD 479.73 billion in 2023 and is projected to grow from USD 505.27 billion in 2024 to USD 808.40 billion by 2032.

In India - Post COVID era, the growth of Food packaging is in double digit.

We can see high level of interest and activity in BOPE across multiple global regions, and I am anticipating a rapid expansion of these films in many packaging segments.... specially at Monolayer structure.

Several common food packaging film materials have also emerged within this industry, each with unique properties and applications. These include linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), biaxially-orientated polypropylene polymer (BOPP), and biaxially-oriented polyethylene terephthalate (BOPET), biaxially-oriented polyamide (BOPA).

Among these materials, biaxially-oriented polyethylene (BOPE) film is gaining attention and has been seeped into areas of sustainable businesses.

What is BOPE Film?

The BOPE film, a high-performance film material, uses polyethylene resin with a unique molecular structure as the base ingredient and employs biaxial orientation technology. Once the polymer material undergoes stretching and formation, its properties are enhanced. BOPE films are manufactured on a specialized-design BOPE/BOPP hybrid line, which brings an exciting upgrade of PE film performance by successfully applying polyethylene resin into biaxially-oriented production technology.

Features of BOPE Film

Excellent Sealing Properties

BOPE films provide good heat-sealing capabilities, which is essential for packaging applications that require tight and secure seals to preserve freshness and prevent contamination.

High Tensile Strength

BOPE film exhibits superior mechanical properties, with tensile strength exceeding traditional LDPE films, which enables thinner gauges and eventually results in material savings and reduced packaging costs.

Excellent Puncture Resistance

Due to its unique molecular orientation, BOPE film offers outstanding puncture resistance, ensuring the integrity of the packaged products and reducing the risk of damage during transportation and handling.

Low-temperature Impact Resistance

BOPE film maintains its mechanical performance at low temperatures. It is suitable for cold chain applications and frozen goods packaging, where conventional films might become brittle and prone to failure.

Tear-ability

Thanks to biaxial orientation technology, BOPE gives better toughness and is easier to teared than other PE films like MDOPE.

Recyclable

Since it gives rise to mono-material packaging, BOPE leads to fully recyclable food packaging, which supports the global push for a circular economy and reduces environmental impact. Its compatibility with existing recycling streams makes it a striking alternative to traditional, less sustainable packaging materials.

BOPE Film Common Applications

BOPE film is a multipurpose and strong material for numerous packaging applications due to its exceptional tensile strength, superior optical properties, and outstanding puncture or low-temperature impact resistance. Widely employed in the packaging of heavy-weight products, BOPE's high tensile strength and puncture resistance ensure the reliability and sturdiness of the package. In the realm of frozen food packaging, BOPE's low-temperature flexibility and seal-ability offer excellent protection against freezer burn and prolonged shelf life. For packaging liquid detergent or edible paste in a pouch, BOPE, with outstanding mechanical properties, prevents your products from drop leakage.

• Food / FROZEN Packaging: Preserving freshness and extending shelf life. BOPE films are ideal for frozen food packaging due to their excellent low-temperature performance, maintaining flexibility and integrity even at freezing temperatures without becoming brittle.
• Stand-Up Pouches : Due to its mechanical strength and heat-sealing properties, BOPE is often used in the production of stand-up pouches, commonly seen in products like sauces, pet food, and dry goods.
• Pharmaceutical Packaging: Employed for the sterile packaging of drugs and medical supplies, ensuring safety and hygiene.
• Industrial Product Packaging: Suitable for packaging industrial products like electronics and mechanical parts, offering protection and moisture resistance.
• Consumer Goods Packaging: Packaging for everyday items like detergent and dish soap, facilitating storage and transportation.

As an environmentally friendly alternative to BOPET, BOPE has gained traction for its recyclability and compatibility with existing recycling streams, making it a favored choice for a sustainable mono-material packaging solution in numerous industries.

Let me also share some dis-advantages of BOPE films.

Cost of Production:

BOPE films require a complex biaxial stretching process that can be more expensive compared to other types of polyethylene films (such as mono-oriented or non-oriented films).

Limited Barrier Properties:

While BOPE films offer decent mechanical strength, their barrier properties (against moisture, gases, and odors) are inferior to other specialized films like BOPP (Biaxially Oriented Polypropylene) or BOPET (Biaxially Oriented Polyester). This can limit their use in applications requiring high barrier protection.

Limited Heat Resistance:

BOPE films may not perform well at high temperatures compared to other materials like BOPET. This can restrict their application in environments that require thermal resistance, such as in sterilization processes or high-temperature packaging.

Mechanical Limitations:

Despite being strong, BOPE films may not have the same level of stiffness and rigidity as other materials (e.g., BOPP or BOPET), which can be a disadvantage in certain packaging or industrial applications that require more structural integrity.

METALLIZING CHALLENGES :

BOPE is non Polar material with low surface energy / smoothness which Impact the Metallizing adhesion quality. Uniform metallizing is a challenge. BOPE may not hold metallized layers as effectively as other films like BOPET or BOPP. This can lead to suboptimal barrier performance, especially in long-term applications. Heat sensitivity of film & tension control is also a need to be taken care. Metallization processes typically involve high temperatures, which can potentially cause distortion, shrinkage, or changes in the film’s physical properties. In summary, metallizing BOPE films requires careful surface treatment, precise control of process parameters, and consideration of the film’s properties to achieve good adhesion and barrier performance.

PRINTING ISSUES WITH BOPE

Due to the material's specific characteristics. Here are some common disadvantages related to printing on BOPE films

Smudging and Fading: BOPE films may be more prone to ink smudging or fading, especially if the ink doesn’t adhere well or the film isn’t properly treated. Over time, printed labels or designs may degrade faster than on other materials like BOPP or PET.

Print Quality Issues: Achieving high-definition print quality on BOPE films can be more challenging due to the film's flexibility and surface characteristics. Fine details in graphics or text may not be as sharp or clear, which can be a concern for high-end packaging.

Limited Printing Techniques: Some printing methods, such as offset printing, are not well-suited for BOPE films. Flexographic and gravure printing are more commonly used, but these techniques may require specialized equipment and inks, increasing production complexity.

Scratch Resistance: Printed designs on BOPE films may lack scratch resistance, which can lead to degradation of the print surface during handling, shipping, or shelf life. Protective coatings may be required, adding another layer of complexity.

Static Electricity: BOPE films can generate static electricity, especially during the printing process. This static buildup can interfere with printing equipment and cause ink misalignment or poor transfer, resulting in a lower-quality print.

Cost Implications: Due to the need for surface treatments, specialized inks, and adjustments in the printing process, printing on BOPE films can be more expensive than printing on other types of films, such as BOPP or BOPET.

Hope the Film Industry will try to eliminate the challenges & BOPE will be a preferred film for with sustainability advantages.