High Barrier CPP Films

Cast Polypropylene Films, usually known as CPP films are presumably the most pursued packaging solution, on account of its adaptability, adaptability, cost and power. Accessible in two sorts, General and Metalized high barrier films, CPP films are a one-stop arrangement not only for the food packaging and agricultural industries, yet additionally for the medical care and pharma industries. In this blog, we will examine the advantages of metalized high barrier CPP films. Known for its protection from tear and its strength, metalized high barrier CPP films are broadly utilized for food packaging needs. 

Let’s take a look at the top highlights of this variation – 

• High oxygen barrier – Oxygen is the greatest contributor of food deterioration. This metalized CPP film blocks oxygen and assists with keeping up the time span of usability of the item. The packaging film offer an OTR of < 30cc/m2/day. 

• High moisture vapour barrier – These metalized CPP films likewise give astounding barriers to moisture and humidity. The film offers a MVTR of <0.3g/m2/day 

• High hot tack and low SIT – Hot tack power alludes to the peel force of the sealing region when it isn't totally cooled down.The hot tack is higher than 600gf/inch for a temperature scope of 100 – 140̊C, and a low seal initiation temperature, in this way making it simpler to laminate the film on a wide range of machines. 

• High heat seal strength – At more than 2.3kg/inch, the heat seal strength offered by metalized high barrier CPP films is astounding. 

• Seal initiation – These Packaging films offer a low and wide seal commencement temperature range (90 – 105̊C). The complete thickness range rests between 20 – 30μm. 

• Excellent machinability – Metalized high barrier CPP films are not difficult to measure and offer great printability. 

About Cosmo Films Limited

Established in 1981, Cosmo Films is a global leader in speciality films for packaging, lamination and labeling applications. With engineering of innovative products and sustainability solutions, Cosmo Films over the years has been partnering with the world’s leading F&B brands, packaging & printing converters to enhance their consumer experience.

Company’s film offerings include BOPP and CPP films. Today, the company is the largest exporter of BOPP films from India and also the largest producer of thermal lamination films in the world. Its customer base is spread in more than 100 countries with manufacturing units in India, Korea & Japan.

Flexible Packaging for a Sustainable World

In the last few years, sustainable products have become the top most priority for consumers. The staggering growth of consumer awareness about sustainability, and frequent dialogues on social responsibility have pushed brand owners to do away with traditional packaging methods. The global mood to reduce negative environmental effects of packaging married with technological innovations have driven brands to reduce material usage, use recyclable material in packaging, and develop the use of other sustainable materials. Flexible packaging was born out of the urgent need to address environmental issues and reduce waste, but at the same time carry out the functions of traditional packaging. According to the report “The Future of Flexible Packaging to 2022”, flexible packaging sales were valued at $219.5 billion in 2016, and were predicted to reach $282.6 billion by 2022. The figures do not come as a surprise given that today flexible packaging is widely preferred in consumer and electronic goods to cosmetics and pharmaceutical industries.

Flexible packaging uses the best characteristics of film, paper & aluminium foil and allows its shape to be changed readily. Flexible packages are typically bags, pouches, liners, seals, sleeves, carded packaging and sample packets. However, the packaging industry is witnessing the use of flexible packaging in many innovative ways. Flexible packaging solutions range from single-use pouches, or even from zip locks to resealable closures. Here is why conscious brand owners prefer flexible packaging:

1. Use of fewer resources during production
Flexible packaging uses fewer materials in the first place, and hence the waste generated is also less. Even along the production cycle, the use of resources such as water, energy consumption, green-house emission is less. Furthermore, flexible package tends to be light weight and hence the energy used during transportation and the overall environmental pollution reduces drastically.

2. Zero compromise on performance
Flexible packaging has carefully tried addressing the disadvantages of traditional packaging without compromising on the performance. Flexible packaging maintains freshness, offers barrier protection and durability, great printability and is easy to use. Best of all, it can be used for merchandising myriads of applications ranging from food products to even kids toys.

3. Reduction in overall production cost
Use of fewer resources automatically cuts down production costs. Cost saves are seen across the production spectrum from material to transport. Furthermore, flexible packaging can also be constructed on the spot from roll materials, and therefore additional cost to transport readymade boxes does not exist.

4. High on shelf appeal
Shelf appeal of the packaging is incredibly important and has become a key component for successful marketing. No matter how great the packaging type is, if it doesn’t appeal the consumers, it will fail. Flexible packaging is high on aesthetic value and also offers visibility of contents, which allows brand owners and product designers to think out-of-the-box.

Despite the many advantages flexible packaging boasts of, there are a few challenges as well. Many times, recycled plastic is considered as raw material for flexible packaging. While the idea itself is fantastic, recycled plastic can carry odours that will eventually affect the product. Hence, more research and development is required in the field of flexible packaging to make it even more sustainable. Another big challenge in the use of flexible packaging is the education of consumers. Although it is true that consumers are increasingly demanding far more sustainable packaging solutions, it is hard to tell whether consumers can actually differentiate sustainable packaging from non-sustainable. Once the products are on the shelf, its ultimately the visual and shelf appeal and not the environmental benefits that make the product sell. Hence, a lot of work needs to be done to increase consumer awareness.

There is no doubt that flexible packaging is the most sought-after packaging type for brands these days. They are durable, offer great printability and aesthetics, and above all use less resources and reduce costs during production. Flexible packaging not only help brands make their stand clear regarding sustainability, but it also educates consumers to reuse and recycle wherever possible – and this is a huge step towards a more sustainable lifestyle.

Biodegradable Plastics: Packaging for A Sustainable Future

Wondering how plastics can be sustainable & eco-friendly? You might be amazed by this fact but the infamous plastic is deemed to be the most environment-friendly material for packaging because of its extremely low carbon footprint. This has been proven in a report by the UK government & many other studies conducted worldwide. However, the root cause of its defamation lies in its association with the linear economy that results in waste creation. This is why responsible organizations are now embracing the power of circular economy that draws upon the policy of Reduce, Reuse & Recycle. In this blog post, we’re going to discuss some polymer-based biodegradable & recyclable materials that are here to revolutionize the future of the packaging industry. 

BIOPOLYMERS & BIOPLASTICS FOR BIODEGRADABLE PACKAGING 

Plastics are formed from polymers which can be synthetic & natural. Biopolymers are the ones formed from organic materials like rice which makes them largely biodegradable in a shorter time, unlike synthetic plastics. Some bioplastics are even compostable under suitable conditions. Made from renewable resources, all bioplastics are recyclable which limits the use of fossil fuels. These are used in the production of bio-based conventional plastics like PET (polyethylene terephthalate) & PLA (polylactic acid). 

However, one of the key challenges with these is the cost associated with it which tends to be drastically high. This is why many organizations worldwide have been researching to find cheaper bioplastic solutions & promote their use. At present, the key reliable solution is a move towards a circular economy with eco-friendly alternatives as opposed to non-recyclable packaging. 

CIRCULAR ECONOMY 

The need of the hour is a circular economy which is possible with the switch to better plastics. Responsible companies are making a switch to recyclable plastic to make the closed plastic economy a reality and reduce the pollution from discarded plastic in the environment. 

Europe has witnessed great success in reducing PET water bottles & PE carrier bags. However, it would need drastic alterations at the end of both producers and users to achieve 100% recycling. At present, only 9% of the total plastic produced is actually recycled. One of the key drawbacks is the lack of awareness of users regarding their handling, and the common use & throw attitude which often leads them into landfills instead of recycling stations. 

SHIFT FROM THE THROW-AWAY PLASTIC CULTURE 

Not just the manufacturers but the consumers too are required to keep a check on their attitude towards the use of plastics. Increased collaboration between businesses & consumers can help create awareness amongst consumers to shift from the throw-away culture and facilitate a circular economy. Strengthening plastic waste collection from both households & industries can reduce waste creation and the by-product can, in turn, be used as raw material by other companies. 

Cosmo Films, as a responsible organization, to become a part of this change, has taken various steps. With a range of products engineered using PP (poly propylene) based material, we aim to promote reuse & recycle of plastic & sustainable development. To tackle the high-cost challenge of bioplastics, our global R&D teams have been working on creating low-cost biodegradable solutions. We’re in this together and we will change this together! Let’s create a better future by switching to sustainable plastics. 

Heat Resistant BOPP Films

Innovation is at the heart of everything we do at Cosmo Films. Our innovation is driven by the desire to cater to the current requirements and stay ahead of the times. In today’s times, ease of recycling of packaging laminates has become highly critical, and our heat resistant (HR) films facilitate mono-material structures and in turn recycling. Apart from recyclability, barrier heat resistant films also help with laminate structure rationalization without compromising on aesthetics, printability, machinability and user friendliness. 

Let’s take a quick look at what makes our latest product so special and why we are so proud of it.

Recyclability – Recyclability and sustainability are the future of packaging industry and if as a brand, enough stress is not laid on these two factors, then it might impact consumer outlook. Cosmo has specifically designed this film to replace BOPET film as printing layer in multi-layer laminates. With heat resistant films, we can now have BOPP/CPP structures or BOPP/PE structures which are part of the same family and therefore more conducive to recycle than PET/PE structure. 

Barrier features – For packaged food, the barrier features of a film are paramount. The BOPP based heat resistant films are also available in a barrier variant. The end pack made with barrier heat resistant film can be used for all food and personal care applications where moisture & oxygen barrier is of utmost importance. 

Grease resistance – The grease resistance offered by the films makes this category an ideal choice for oily snack food. It offers a clean grease barrier for greasy or oily food products. 

Versatility – The new heat resistant films are clear, non-heat sealable and both sides treated films with excellent printability and go mostly for reverse printing. The thermally stable films have excellent hot slip properties and good machinability, and therefore work well on high speed FFS packaging machines. 

Structure rationalization – The heat resistant films can be used for both two and three ply laminates. Since the barrier version of the film enables both printing as well as barrier, it enables construction of even 2 ply laminates. BOPP/CPP structures are common with the use of this film. 

Let’s take a look at other key values. 

• Our new films are generally used as a printing layer in a duplex/triplex laminate structures either as BOPP/MET BOPP/PE or BOPP/CPP. 
• The heat resistant BOPP films are available in 15, 18, and 20 microns.
• The films are well suited for both adhesive as well as extrusion lamination. 

Cosmo Films is a global leader in speciality films used for packaging, laminating and labeling applications. Our films offerings include bi-axially oriented polypropylene (BOPP) films and cast polypropylene (CPP) films. Our new heat resistant BOPP films are not only a far better option in terms of sustainability but its barrier version also offers an enhanced shelf life to the packaged product. Contact us to know more about our heat resistant BOPP films.

Printing Guide for Flexible Packaging

In the last decade, the packaging industry has seen many trends come and go, but the one thing unanimously agreed upon is the bright future of Pressure Sensitive (PS) Labels. PS labels are continuous flexible strips of plastic, paper, film or any other material coated with an adhesive. They sticks to different types of surfaces at room temperature with a light application of pressure without the use of heat, water or a solvent. These Labels are becoming increasingly popular owing to their versatility. From the ease-of-use to the cost-effectiveness, these labels are used in nearly 80% of the products in the market today.

Several analysis and studies conducted by various research bodies across the globe suggest a stellar growth for the PS Labels market. According to one report, the global PS Labels market was valued at US$86.8 bn in 2017. The global PS Labels market is likely to show a CAGR of 5.2% over the forecast period of 2017-2022, and is likely to emerge with a valuation of US$112 bn by 2022.

In this article, we explain some of the most important trends of pressure sensitive labels, and why these are here to stay.

• Sustainability​ – With the growing consciousness regarding sustainability in the minds of the consumer, more and more brands are turning to sustainable solutions for packaging their products. In many cases, the facestock of PS Labels are made from recycled material. Technological advancements have allowed companies to create special adhesives, which do not interfere with the process of recycling.
• Durability​ – Not only do PS Labels have a very durable finish, but they are also manufactured to last. There has been an increase in PS Labels that can withstand rough handling and extreme conditions such as on chemical drums.
• RFID​ – RFID is a game changer for PS Labels. RFID, which stands for Radio- Frequency Identification, uses radio waves to collect and send information. It is an inlay that can be embedded in objects, labels or packaging and allows tracking, storing and transmitting data. RFID inlays can be embedded with PS Labels to offer “intelligent labeling” solutions. These labels are widely used for tracking, authentication and anti-counterfeit of goods.
• Growth in Anti-Counterfeit Labels​ – ​Anti-counterfeit labeling is the process of secure labeling that prevents imitation and confirms safety of the goods. Anti-counterfeit measurements are taken by companies, which helps them minimize losses due to counterfeiting in-term of revenue and loyalty. PS Labels are mostly used in food and pharmaceutical product labelings to reduce counterfeiting by using barcodes for tracking or RFID technology.
• High Self Appeal – ​P.S Labels also need to offer great aesthetics as products vie for neck to neck attention on the retail shelves. ​Different PS label materials available to label printers include rich textured specialty papers; vibrant metallised foils; films in ​clear, metalized, matte varieties ​to striking holographic; textile and even wood veneer products.​ ​Converting embellishments could range from die cut shapes to die cut text and logos to debossed or embossed images to rough graining areas or spot varnishing to metallic or holographic foil stamping.
• Growth of Removable and Repositionable Films as Facestock​ – These films facilitate easy removal and repositioning specially in case of beverage labeling where the machine speeds are quite high. They also find usage in pharmaceutical labeling considering the small surface area and precision application.

At Cosmo Films, we manufacture different kinds of PS label films. These films are universal printable films and are compatible with all ink-based systems. The films available in white, clear, metalized and matte varieties offer great printing performance as well as excellent adhesion with hot/cold foils. These films also offer good stiffness for conversion & dispensing operations. They find applications in most of the personal care product labeling, food & beverages & pharmaceutical product labeling as well as liquor labeling.

What’s next?

Responsible innovation will be the driving force for Pressure Sensitive Films. The demand for high-tech and yet responsible solutions will see technology and sustainability come together to offer more advancements in PS Labels. Rapid growth in e-commerce and international trade, demand for transportation and logistics services are some of the most important factors that stimulate this growth. The future of Pressure Sensitive labels is very bright and positive.

COSMO SYNTHETIC PAPER: PRINTING RECOMMENDATIONS

Engineered by industry experts, Cosmo Synthetic Paper has turned out to be the best replacement for pulp based paper. What makes it the first choice of businesses today is its non-tearability, moisture & chemical resistance and excellent Printability. CSP is compatible with diverse printing technologies like Conventional Offset, UV Offset, UV Flexo printing, Water based Flexo printing, Thermal Transfer, Screen, Letterpress, UV Inkjet, HP Indigo & HP Latex printing and selective Laser Print technologies. Here are some of the printing recommendations for printing on Cosmo Synthetic Paper. 

Printing Recommendations* 

• Off-set Printing 
Off-set printing for CSP requires some additional care than a wood-pulp paper. This is because on a normal paper, the ink dries by absorption and oxidation but on CSP, the ink would only be able to dry out with surface oxidation. Thus, the process would take a little longer and if not allowed to dry properly, the user might face ink set off issues. To avoid this, following precautions are necessary: 

1. Pre-print stacking – The advisable limit is not more than 3000 sheets. Air conditioning should be adequate before you could start the printing in order to ensure smooth movement of sheets. Vacuum can cause suction marks and thus, needs to be reduced. 

2. Inks – Oil-based offset printing inks are the most compatible with CSP as they undergo evaporative and oxidative polymerization drying mechanisms. On the other hand, conventional inks can also be used but would need more time to dry. While choosing an ink for CSP, following things should be kept in mind: – Ink should be able to set quick or dry fast – Ideal for two side printing – Results in even surface to reduce set off – Compatible with UV curable inks 

3. Dampening System – The dampening level should be minimal as otherwise, it can cause set off. Multicolour printing contains excessive water and thus can lead to improper ink transfer. 

4. Dampening Water Criteria – Following characteristics should be maintained for great results: – Water Level: Minimum as per machine parameters to eliminate emulsification – pH Level: 4.5 to 5.5 (Acidic) to avoid emulsification of inks used – Temperature: 8-10° C – Alcohol Content: 5-10% for faster drying of dampening water 

5. Delivery – Generally, up to 3 inches of stacking is recommendable. That said, it can vary as per the sheet size, ink deposition, amount of powder sprayed and printing pattern. 

• Flexographic Printing
CSP is compatible for flexography too. However, it may require proper ink selection for which you may consult the manufacturer. Tension should be set at the lowest level possible to avoid misregistration. You also need to maintain an ideal temperature of not more than 80° C during printing & thereafter, close to room temperature. 

• Digital Printing 
For this, the below precautions need to be taken: 

– Selecting correct media setting carefully 

– Conducting tests of the material prior to its use 

– Conditioning sheets in the printing environment for 24 hours 

– Fanning the required number of sheets for jam-free feeding 

– Maintaining temperature between 20-25° C 

– Setting adequate fusing temperature & pressure as per OEM recommendations 

– Lamination is recommended post printing for extended life 

• Thermal Transfer (TTR) 
This process of printing uses carbon ribbon which is moved to substrate upon heating. It is recommended to test suitable energy & speed combinations for printing with different ribbons. Some compatible Resin Ribbons are Armor AXR 7+, Ricoh B110CR, Mastercorp TTR Z400. Amongst Wax Resin Ribbons, Armor AXR FH 7+ and Ricoh B110A are compatible. 

• Digital Laser Printing (Dry Toner) 

Laser Printing with dry toner is tested to be suitable for one of CSP’s variants, namely, Matte White Both Side Coated. Liquid toner, on the contrary, cannot be used as CSP does not facilitate ink drying through penetration but surface oxidation. Some recommendations for printing through this technology are- 

• Proper fanning of sheets is required prior to loading in the tray 
• It is recommended to involve the service engineer for media setting 
• If required, adjust image transfer current to get good quality print results 
• Please ensure proper earthing of the machine 
• Suggested to use external static eliminator device for higher productivity 
• Maintain room temperature between 20-25 degree C & relative humidity at 55% +- 10% 

• Apart from the above, CSP has been tested to be suitable for Letterpress and Screen Printing technologies as well. 

*Disclaimer: These printing recommendations are applicable to all variants of CSP. In case of top-coated products, printing is recommended only on the coated side. A few trials should be carried out before using it in bulk to ensure smooth functioning. 

Converting Recommendations of CSP 

With properties of both plastic film & paper, CSP can be folded (scoring or 30 minutes nipping is recommended for optimal results), perforated, guillotined and punched. It can also be used for die cutting and hot foil stamping.

 

Cosmo Synthetic Paper has made everything simpler than ever with its versatility in terms of printing, features and usability. It can replace pulp based paper in applications requiring durability and longevity, thus providing an eco-friendly solution to the problem of cutting down trees to make paper.

The Journey of Plastics from a Linear to a Circular Economy

Plastic in India majorly constitutes 4-7% of the total waste in landfills, and only 1% remains in the system after being picked up and recycled. Still, plastic waste is given more attention due to its visibility in the system when compared to other more pressing issues in need of importance. Plastic, the wonder material has become omnipresent in our modern lifestyle. The strength, durability and malleability of plastics has made it the first choice of manufacturers. It has been able to replace other traditional materials, that too under a very short span of time; one of the causes behind our inexperience with the material and its properties. We’re still discovering and rediscovering information about its uses and management. It can be said that the human race is yet to solve the huge mystery of plastic disposal and its management.

The only solution is to adopt a circular economy, which aims to eliminate waste by its restoration and regeneration. What is actually waste for one, can be food for another? Same is the case with plastic waste. While we may have no use of the plastic package post the consumption of the product inside, but the same packaging can be recycled and made into something useful without being disposed of in landfills.

But human psychology has been following an entirely opposite route of “take, use and dispose” instead of take, use, dispose and recycle which has led to permanent damage to our planet. If everyone starts working according to the norms of Circular Economy, Earth will be a planet free from wastage and trash.

The circular economy offers you both, environmental as well as economic advantages. Let’s take a look at a few of them:

1. Economic Growth-

Circular Economy is the direct accelerator to the economic growth of a nation. It contributes to an increase in GDP and National Income. This is a result of an increase in the number of job opportunities and cheaper production by extracting the maximum use from all the waste. Implementing this directly increases the income and decreases the expenditure of each household.

2. Substantial Resource Saving-

Moving towards sustainable development is one of the most significant features of a Circular Economy model. As mentioned earlier, it proves to be a helping hand in saving resources as the focus remains on manufacturing products that are least acquired from natural resources.

3. Land Productivity and Soil Health-

With the help of the principles of a Circular Economy, we can bring a remarkable difference in productivity and health of the land. Because of a consistent effort to manipulate the uses of waste material disposed, we are making sure that land pollution is minimized at its best.

4. Fewer Emissions-

The aim is to counterattack the overload and exploitation of the ecosystem by reuse and dematerialization of waste materials being produced. Less use of non-renewable energies and fossil fuels promotes fewer emissions of toxic materials and greenhouse gases.

Plastics are also termed as a perfectly imperfect material. Perfect, because of its multiple uses, and Imperfect due to its non-recyclability. Most of the plastics look similar to each other and are difficult to distinguish with the human eye and hand, therefore, they are hard to segregate and recycle. If all the plastics had the same features and characteristics, we probably wouldn’t be having this conversation. But due to different components, types, chemicals, and colors plastic recycling has become extremely challenging for us. Their segregation is laborious, time-consuming as well as expensive. But in recent times, science has come across some miraculous ways to recycle and reuse it. Who would have thought of building roads with plastic or even generating electricity from the same material? HDPE (High Density Polyethylene), a kind of plastic, is recycled to make raised garden beds. Some of the other plastics that are also used in product packaging such as polyethylene terephthalate (PET or PETE), polyvinyl chloride (PVC), polypropylene (PP), are used in the construction of roads. They are first segregated and then shredded to mix with bitumen to create the mixture for roads. These plastic types can also contribute in the making of oils or construction of tiles or Plastones. There are many more ways to recycle and manage plastics instead of just dumping it in landpits post-consumption. It totally depends on us whether to plan plastic or to ban it.

One of the ways to recycle plastic is Heat Compression, in which all kinds of plastic polymers are taken together in huge containers, churned and then finally melted. This process does not require segregation of plastics for recycling. Another way to adopt Plastic Recycling is by using Monomer Recycling. This process involves Reverse Polymerization. The polymers are condensed within the same plastic which causes chemical components to reverse, creating a more stable recycled plastic.

The technical challenges have been solved by science and great minds but the major challenge lies in the behavioral change required in the society. The perspective and vision of humankind need to change when we talk of plastic and its reuse. This reckless behavior has triggered an avalanche of waste dumps in open areas. In order for humanity to co-exist with the earth, there is an urgent need to adopt a circular economy model and recycle our plastic waste in an efficient manner. Using plastics in a systematic manner can turn the tables around for the manufacturers as well as consumers. Instead of eliminating plastics from our lives, we can focus on how to implement their uses to get out of the Linear Economy phase. Reusing them smartly will be a revolutionary move for us as responsible human beings. Something to bring under the focus is that Circular Economy is not easy to implement. However, if we are able to put the wings of growth and sustainability on our economic system, then probably after centuries from now people will say that it was the Circular Economic Revolution that inaugurated a brand new era of development and prosperity in the nation.