Camvac ups recyclability game with metalized machine-direction orientated PE film

27 Sep 2021 --- Camvac is unveiling a high-barrier metalized machine-direction orientated (MDO) polyethylene (PE) film primarily aimed at the food and converter markets, including chips packaging and similar end-uses. The MDO PE film is available in 20- and 25-micron gauges.

The UK-based metalized and clear barrier films supplier highlights that MDO film has a growing presence in consumer packaging, with demand particularly high in confectionery and snack markets.

The requirements include a barrier coating suitable for conversion and lamination to similar product family materials, enabling a mono-film laminate solution for conversion into end-product packaging.

Camvac says its solution facilitates recycling within the circular economy. The single-web metalized MDO PE offers the converter a high barrier, OTR and MVTR, PE film that can be laminated to another PE substrate, creating a monomaterial film for conversion into a recyclable flexible packaging pack.

“MDO PE film offers chips manufacturers an all PE-based, mono-material packet, which has the potential to be widely recyclable, as long as the local recycling streams will accept mono-material PE substrates,” Gary Chalkley, development director at Camvac, tells PackagingInsights.

MDO technology
MDO material processing enhances film properties and offers numerous benefits, including reduced film thickness and cost and high pressure resistance and barrier performance.

MDO PE films offer the potential for wide recyclability, subject to local infrastructure.“MDO films are incredibly stable compared to ‘standard PE,’ facilitating reduced gauge and material savings, which in turn leads to a reduction in product packaging, transport costs and carbon footprint,” explains Chalkley.

“The films are made by heating a polymer film to a temperature, marginally below the film’s melting point, and then stretching the film in a set orientation. The processed film can be cast on a specific MDO machine or introduced at the final production stage within blown film manufacturing.”

Camvac used its unique, patented technology to add a barrier to the film via its Camplus Extra process. The technology produces MDO polythene films with improved metal adhesion, offering higher inter-ply bond strength and enhanced barrier.

Overcoming film processing challenges
The company set out to develop a high-barrier metalized MDO PE which can be recycled. Its technical and production teams worked in parallel to develop the solution, utilizing Camvac’s barrier technology.

“This is the first development at Camvac whereby an MDO film has been processed,” continues Chalkley. “The main challenge was understanding how the film processed through each production phase, ensuring waste levels remained low, and machine efficiencies could be maintained.”

“Utilizing our unique patented Camplus Extra technology to metalize the PE Camvac has delivered the barrier requirement for the snack market.”

“This is Camvac’s first commercially available MDO PE film, and we are already close to launching clear barrier solutions. Once metalized and clear barrier solutions are commercially available, we will look to continue this development and create an all-PE laminate structure.”MDO films have a growing presence in consumer packaging, with demand particularly high in confectionery and snack markets.

Recycled content?
Chalkley adds that the recycled PE food contact grades are not yet commercially available, meaning Camvac cannot produce a barrier MDO PE with recycled content for food packaging applications.

PackagingInsights recently spoke with Camvac CEO Greg Kingham about raw material availability issues conjured up by the COVID-19 and Brexit “perfect storm.”

“As the PCR-grade raw material becomes available, this will lead to continued developments at Camvac. Without doubt, when the raw material is available, we will develop a solution using PCR grade films to enhance the its sustainability further,” says Chalkley.

The MDO film joins Camvac’s growing range of sustainable packaging solutions within its Camvert films range, primarily targeting the food and converter market.

Camvac is now accepting commercial orders for the metalized MDO PE. Available in 20 and 25 um gauges, 1500 mm width for the 20 um film and 1350 mm for the 25 um. The company will supply the film globally, direct to the end-user and converter, via distributors or local agents.

PackagingInsights recently discussed trends in snack packaging with Mondi and Constantia Flexibles, exploring how aligning plastic materials with recycling infrastructure can aid the segment’s transition to circularity.

By Joshua Poole