Why CPP Films Are Becoming Increasingly Popular

Cast Polypropylene Films or CPP films have earned the reputation of being “versatile films” in the industry, and for good reason. CPP films score high on quality and performance, look aesthetically great, and are an ideal choice for flexible packaging, which is why these films are favoured in both traditional flexible packaging and non-packing applications. In this blog, we will take a closer look at what really makes CPP films special.

CPP films are made from polypropylene. Polypropylene is popular as a packaging material because it has low density and weight, is very versatile and cost-effective, and most importantly, is sustainable.

Let’s look at some of the major benefits of CPP:

Excellent Resistance To Tear – CPP films are very robust. Hence they have a high resistance to any kind of puncture and/or tear.

High Seal Strength and Hot Tack Strength - Both these values are exceptionally high making CPP films very robust and durable.

Multi-Material Structures - All the component properties of multi-material structures come together to optimize the performance, functionality, and total costs.

Offers Good Moisture Barrier - To extend the shelf life of the product, it is crucial that the film successfully protects the product from humidity, temperature and gases. CPP films provide a good moisture barrier and preserve product quality.

High Transparency - CPP films are completely transparent and attractive. Not only do they lend to the aesthetics of the product packaging, but also make it possible to see the product inside.

Good Optical Property - Great optical properties determine the shelf appeal of the product and CPP films with its versatility ensures that the look and feel of the product are not compromised.

Excellent Machinability - These films are easy to process and also offer great printability.

CPP films come in various varieties, but the general CPP and metalized CPP film are the most popular ones. General CPP films find widespread usage in the fields of food, agriculture and  architecture because of its transparency and sealing properties. In fact, the wrappers you see for confectionery and bakery products, or even fresh food are CPP films. From food packaging to  lamination and stationary, there is hardly a place where CPP films are not used. CPP films are used in the health care and pharmaceutical industries as well because these films provide a great  barrier against contamination.  

It is evident that CPP films dominate the Indian market. There are a couple of challenges posed by low-cost material but the advantages of CPP films supersede all of them.

Mr Pankaj Poddar, CEO Cosmo Films says, “We see more and more CPP being used globally as  well as in India as a choice material for packaging applications in food and agriculture owing to  its high transparency vis-a-vis polyethene and excellent sealing performance. Cosmo Films, with  years of experience in the polypropylene space, has worked hard to come up with an extensive  range of CPP films that it offers today both from functionality as well as mono-materialization standpoint.”

Effects and solutions of using plastic in food packaging

The food packaging industry is large and growing. Plastic packaging is widely employed. We explore the reasons why plastic is favored as a packaging material.

• Plastic bags offer ease of recyclability. They need relatively lesser energy to manufactured compared to other packaging materials. Compared to paper plastic bags need 40% less energy to be manufactured and output 80% less solid waste. 
• Plastic packaging is very inexpensive and can be employed by industries regardless of their size. The low-cost model is particularly attractive to smaller players as it enables access to quality packaging options on a low budget. 
• Plastic packaging is durable. This quality lets manufacturers print aesthetic, high quality, unique designs thus ramping up product visibility in a retail environment. 
• It is possible to easily reuse and recycle plastic. Thus, there is lesser wastage of resources and minimum adverse impact on the environment. 
• Plastic packaging can withstand extreme environments. They are resistant to degradation in hot and cold temperatures keeping intact their contents. Plastic offers protection from odours, light, dust, oxygen as well as moisture. 
• Plastic packaging ensures that their contents are well preserved at all times. So, there is no wastage of inventory and reliability in product delivery which boosts brand value. 
• Plastic packaging is a highly adaptable as well as flexible form of packaging. So, manufacturers can tweak its style, size and shape as per the market trends. 
• Plastic packaging is very light weight. It doesn’t take up lot of storage space. Thus, they are very easy to transport minimizing the carbon footprint in the transportation process. 

There are rising concerns manifesting as a result of climate change. They include waste as well as breakdown of plastics in the natural environment. Hence the development and use of biodegradable plastics. The latter is employed in food packaging and disintegrate naturally into organic agents from contact to natural environment elements such as heat as well as moisture. Traditional plastics are produced employing petroleum. However biodegradable plastics are generally manufactured employing plant sources such as corn.

The process involved in producing Biodegradable plastic consumes 65% less energy compared to generate traditional petroleum-based plastics. This talks a lot about this new plastic version’s energy efficiency. Also, this type of plastic makes use of renewable sources such as potato starch, corn as well as sugar cane.

Presently efforts are on to develop plastic eating bacteria to consume plastic waste already accumulated on our planet. The plastic waste is a hazard to both domestic animals as well as wildlife. Many animals, birds and fish have died or suffered by consuming plastic waste.

Biodegradable plastic is the future. Hopefully increased awareness will lead to its widespread adoption.

Barrier Films in Food Packaging

The most common challenge faced by the food industry is preserving, protecting and extending the shelf-life of food products. The quality of most food products gradually deteriorates over a period of time and affects attributes such as flavor, texture, taste and colour of the products. The shelf-life of food products can be shortened based on the interaction between a number of intrinsic (pH, preservatives, water activity) and extrinsic (temperature, humidity, gaseous environment) parameters.

Keeping this in mind, Cosmo Films has developed a range of solvent-free BOPP barrier films that can be used for a wide range of FMCG packaging applications. These barrier films not only help in extending the shelf life of food products but also reduce packaging material consumption through laminate rationalization.

What are barrier films? 

Barrier films are impervious packaging solutions, usually made up of single or multiple layers of flexible films, the material of which depends on the area of application. Barrier films are also coated on either side by different lacquers/resins to obtain desired results.

The effectiveness of a barrier film was earlier measured in terms of its ability to prevent the ingress of oxygen, carbon dioxide and moisture. However, in recent times protection against migration of mineral oil and UV light is also considered important. This impervious nature allows barrier films to protect products such as food from the loss of nutrients and functional properties such as taste, aroma, texture and colour.

The barrier films that are manufactured by Cosmo Films are solvent-free Bi-axially Oriented Polypropylene (BOPP), generally used in duplex or triplex laminate structures. BOPP started out as a replacement for cellulose film, which was used over 50 years ago, but it can now be used for a vast array of applications.

In typical manufacturing processes, a tenter frame is used to stretch the molten film in both machine and cross dimensions. The biaxial orientation of the film aids in reducing stretching, puncturing and tearing of the film.

Applications of barrier films in the food industry 

Barrier films can be used to preserve and protect a wide array of food types and products, some of which are listed below:

Bakery Goods – These products require the use of perforated films in order to protect them from loss of humidity, while simultaneously preventing water retention so that their crispness stays intact.

Biscuits – These products are usually degraded by humidity uptake which leads to a loss of crispness. Products with chocolate and cream can be affected by oxidation and odor loss or uptake.

Dehydrated foods and beverages – These products require a very high barrier to water, aroma, and oxygen, so as to preserve their long shelf life.

Frozen foods – Raw, semi-cooked, cooked meats, and other frozen foods are highly perishable and need to be packaged using materials that can withstand minus degree temperatures.

Pet food – Wet pet food needs to be packaged using films that are impervious to oxygen, light, and contamination by odor.

Chips and snacks – These products usually degrade through rancidity and require packaging solutions which provide excellent moisture barriers.

Dry fruits, fruits and, nuts – These products need to be packaged using films that offer high gas, oxygen, and moisture barriers.

Types of barrier films
Cosmo Films manufactures three types of barrier films as below-

 1.Metalized Barrier Films :

[a] High Moisture Barrier (HMB): It is a metalized film that is corona treated on both sides and can be used for sandwich layer lamination in snack foods, shampoo sachets, dry milk powder and powdered drinks sachets/packs and all other products where loss of moisture is a prime concern.

[b] High Speed Barrier with High Hot Tack (HSB): The metalized moisture and oxygen barrier film has a High Hot Tack and Low SIT which enables FFS machines to run at a higher speed, thus helping to improve productivity.

[c] Ultra High Barrier (UHB): This metalized ultra high barrier film can be used to replace aluminum foil from multi-layer laminated structure since it offers an exceptional MVTR and OTR

Cosmo Synthetic Paper - Non Tearable

Cosmo Synthetic Paper (CSP) looks and feels like the traditional paper we use, but with plenty of added benefits. You can print on it, fold it, cut it and even write on it, but unlike ordinary paper, CSP is known for its durability and longevity. It is very difficult, and bordering on impossible, to tear. Apart from this, CSP does not soak in liquid or crumble under humid conditions, in fact you can wipe of the liquid if it pours on the surface. It is chemical resistant and can be used in environment where regular paper would not survive. It is therefore safe to say that CSP is not just water-proof but weather-proof.

Now you might ask, what is CSP:

CSP is made from a recyclable plastic based film which resembles paper in appearance. It is engineered to be durable but, it appears and prints like normal paper. CSP is printable with most available printing technologies including:

• Wet & UV offset printing
• Wet & UV flexographic printing
• Letterpress
• Screen printing
• Thermal transfer
• Rotogravure
• Most digital toner technologies

CSP provides an ease of conversion for slitting, scoring, folding, die-cutting, perforations, embossing, foil stamping and even lamination. It offers excellent lay flatness for sheet printing. Another advantage is CSP’s optimized drying time.

Prior to synthetic paper, printers would coat or overlaminate paper to achieve added durability or gloss, however now with CSP they gain these attributes with just one stock. This eliminates an added step on press, which increases turn around speed and also lowers cost.

The versatility of CSP is reflected in the vast number of applications where it can be used:

1. Commercial Printing- Maps, Calendars, Posters, Coasters, Menus, Children’s Books, Time Tables, Wristbands, Mouse Pads, Hospital Folders, Religious Books, Brochures and Leaflets, Recipe Books, Instruction Manuals, Bibs.

2. Tags & Labels- Apparel and Footwear Tags/Labels, Paint and other Container Labels, Chemical Drum Labels, Construction Site Stickers, PS Labels for HDPE/PP/PET Containers, Track and Trace Labels/Tags for Supply Chain, Logistics and Inventory Management, Warning Labels on Appliances, Airport
Transfer Tags

3. Retail & Packaging- POP Graphics, Posters, Indoor Billboards, Vertical Banners, Backlit Displays, Swing Stickers, Catalogues, Danglers, Gift Wrapping Paper, Carry Bags

4. Identification and Credentials- Visiting Cards, Airline Tags, Healthcare/Insurance Cards, Library Cards, Student ID Cards, Degree Certificates and Marksheets, Membership Cards, National ID Cards, Drivers’ License, Voter ID Cards, Birth and Merit Certificates, Land Documents

5. Outdoors – Horticulture Identification Tags, Outdoor Billboards, Signages and Displays, Frontlit and Backlit Displays, Storefront Displays, Displays and Advertisements on Public Transport Vehicles, Bus Shelter Displays, Train Station and Airport, Signages and Displays

And the list goes on, the only limit to the possible applications of CSP is your imagination. It is made to cater to all business specific applications and printing technology requirements.

Overall, Cosmo Synthetic Paper offers technical expertise, performance benefits, and a level of versatility that is unparalleled, so that you can make the most of your investment.

CPP Films – The Versatile Polymer

Polypropylene film or PP is a low density plastic film. The most important types of PP are cast polypropylene (CPP) and bi-axially oriented polypropylene (BOPP). Cosmo Films offer both these types of PP films. While BOPP is a more commonly known polypropylene film, the use of CPP in the food, pharmaceutical, flower, textiles and several other industries are consistently gaining popularity.

Some of the differences between CPP and BOPP are listed below for better understanding: 

1. CPP is a soft film like polyethylene, whereas BOPP is a bit stiff and crinkly 
2. CPP does not dead-fold well due to its natural living hinge, whereas BOPP has better dead-fold characteristics. 
3. CPP can be ultrasonically or thermally sealed without the use of any specialty coatings, whereas BOPP does not heat seal well without the use of specialty heat seal coatings. 
4. While BOPP films have better barrier properties than CPP, CPP has better barrier properties than most other polyethylene and PVC films. 

Cast polypropylene film is gaining favour as the material of choice in both traditional flexible packaging as well as non-packing applications. CPP has a higher tear and impact resistance, and better cold temperature performance and heat-sealing properties as compare to BOPP. There are various type of CPP films like general CPP, retort grade CPP, metalized CPP, solid white CPP and several other applications depending on the requirement and end application.

Some of the major benefits of CPP are listed below: 

• Excellent heat seal strength, high puncture and tear resistance 
• Excellent packaging integrity at extreme temperatures and high heat resistance 
• No impact on the coefficient of friction (COF) control 
• High yield per unit area and low specific weight (0.91 g/cm3) 
• Offers good moisture barrier 
• High transparency 

The health care and pharmaceutical industries use CPP films for packaging of drugs for extended periods of time since CPP films can protect against contamination. Application in other industries includes stand-up re-closable pouches, multi layered laminations, side-weld seal bags, flower and twist wraps.

Some of the major applications of CPP are listed below: 

• Food Wraps or Candy/Confectionery packaging 
• Bakery Products 
• Lamination 
• Garment Bags 
• Retort Packaging 
• Stationery Packaging 
• Vacuum Metallization 
• Deep Freeze Application 
• Over Wrap 
• Floral Wraps 

Metalized and General CPP films are the two leading types of CPP films used in the market. While the demand for CPP is higher in more developed countries like U.S, Canada, UK, Germany, the two countries that dominate in the use of CPP in the Asia Pacific region are India and China. With manufacturing units in India, Korea, and the USA, Cosmo Films is one of the leading manufacturer & exporter of CPP & BOPP films in polypropylene films category.

Unique Features of Thermal Lamination Film for Packaging

Thermal lamination films are surface coated with resin or a thermal adhesive that melts even in low temperature. This feature ensures that the lamination of paper products is possible simply by applying pressure and heat. There are three types of thermal films that come in two or three finishes.

1. Biaxially oriented polypropylene film (BOPP)
2. Biaxially oriented polyethylene terephthalate film (PET) 
3. Biaxially oriented nylon-6 film (Nylon) 

Features of BOPP thermal laminating films

In this type of thermal laminating films biaxially oriented polypropylene is the base material. The process used to combine the layers of BOPP film and thermal laminating adhesive is extrusion coating. Therefore, the film has the properties of BOPP film on one side and the other side is heat sensitive and is used for dry lamination.

Advantages Of BOPP Thermal Laminating Film 

• The BOPP films are available in various decorative shades. People use this type of film to give an aesthetic look and feel to their products. 
• The density of this film is approximately 0.90 g/m3 and is therefore cost effective when compared to polyester films. 
• There is a myriad type of BOPP films for various purposes ranging from Silky matte, Matte to Glossy finish. 
• It can be used for lamination purpose too. 
• The other features include high transparency, superior moisture barrier, amazing chemical resistance and excellent gloss. 

Applications of BOPP thermal laminating films include diaries, cosmetics, leaflets, brochures, textbook covers, leaflets, shopping bags and so on. 

Features of Polyester Thermal Film (PET) 

Though it’s a popular thermal film, it comes with a high price. It is generally used for two-sided printing.

• The thickness of this thermal film ranges between 1mil up to 10-15 mil. 
• Its most sought after because it’s not easily breakable. 
• PET film comes in both gloss and matte finishes 
• This is used to laminate the menu cards in restaurants 
• The identification cards with magnetic strips can also be laminated using PET films. 

Features of Nylon Thermal Film 

Compared to the polyester thermal film, Nylon films are expensive. However, it’s used as book jackets as it has strong abrasion resistance. This thermal film is also known as a breathable laminate as it allows moisture inside the laminate.

These are three types of superior quality thermal films that are easily available in the market. You have to choose them wisely from a reputed vendor and brand for your business purposes.