Metalised Polyester Films are increasing in popularity for imparting high barrier properties to laminated flexible packaging structures. However, it has been often experienced that poor adhesion of metal with the base polyester film can result in laminate failure, thereby decreasing product performance

There has been an increasing demand for cost-effective films with high metal adhesion for superior barrier applications in harsh environments. However, the solutions that are currently available in the market are limited and costly.

With this problem statement at hand, Flex Films (USA) Inc. has engineered FLEXMETPROTECTTM F-HMB film which is a high barrier metalised polyester film. The film is either untreated or corona treated on the other surface, while metalisation is carried out on the specially treated composite surface imparting metal adhesion or bond strength of >1200 gram-force/inch. Flex Films is the global film manufacturing arm of India’s largest multinational flexible packaging materials and solution company Uflex Limited. All the film manufacturing plants of Uflex, i.e. in India, UAE, Poland, Egypt, Mexico and USA can supply FLEXMETPROTECTTM F-HMB film.

Talking more about the new development, Dr. Steven J. Sargeant, GM, Technology at Flex Films (USA) Inc. said, “The adhesion of metal on BOPET base film is the sum of chemical and mechanical adhesion. Our proprietary surface treatment on the base film allows increased levels of chelation or reaction with the metal being deposited, thereby resulting in a much better adhesion profile. The specialised surface treatment comprises materials with unique and enhanced properties thereby leading to much enhanced mechanical bonding. It took us almost 18 months to engineer this film.”

Explaining the benefits that the newly developed film brings to the convertors, and elaborating upon its use, Vijay Yadav, Business Head, Flex Films (USA) Inc. said, “The film offers class leading high adhesion to metal under most aggressive environmental conditions. It demonstrates improved scuff, scratch and craze resistance thereby improving yields up to four percent and offering unparalleled robustness in processing and performance for converters. It has OTR of 0.6cc/m2/day at 23 degrees C and 0% RH and MVTR of 0.6 g/m2/day at 38 degrees C and 90% RH offering high barrier properties thereby bringing new concepts to the market. Complies with EU and FDA regulations for food grade applications and happens to be cost effective. FLEXMETPROTECTTM F-HMB Film finds extensive use in liquid packaging, stand up pouch applications, barrier layer in challenging applications like ‘Bag in Box’, chemical packaging, pharma packaging, hot fill applications up to 80 degree C. among others. This film is available in 8 – 50 micron thickness range.”

Sharing his views about the potential of the new product, Anantshree Chaturvedi, Vice Chairman & CEO, Flex Films International – the global film manufacturing arm of Uflex Limited said, “Flex Films is focusing on speciality substrates that add real value to the business of convertors and that of their customers by enhancing the quality and profile of the resultant packaging. Our expansion strategy hereafter will be niche product driven and not commodity driven. FLEXMETPROTECTTM F-HMB is a technologically superior film with encouraging demand. If we talk about the US itself, the market for this specialised film is expected to be about 25% of the current metalised film market.”

Congratulating his engineers, Ashok Chaturvedi, Chairman & Managing Director, Uflex Limited said, “FLEXMETPROTECTTM F-HMB is a classic example of value engineering that shall bring substantial benefits and cheer to the converting fraternity not only in the US but globally. This is innovation to create value added differentiation.”