Indian market for specialty packaging films

“The Indian Market for
Specialty Packaging Films –
Applications and Opportunities”
-Vijay Shankar (Vice President)
Mamata Extrusion Systems Pvt. Ltd., India.
During
International Conference on MULTILAYER PACKAGING FILMS ‘2014
on
June 24, ‘2014
at
Chicago, Illinois, USA
1www.mamataextrusion.com

1. Introduction
2. Indian Market for Plastics and flexible
packaging films
3. Applications
4. Opportunities
5. A case study of
Edible Oil Packaging Film – Mono to Seven Layer
Contents

Contents (Contd.)
6. Role of Blown Film Technology -
Mono to Co-extrusion Film
6. Role of Indian Packaging Eco-systems – Case
Studies
“Eno” Effervescence Powder Sachets
6. Something about Mamata Group
7. Conclusion
www.mamataextrusion.com 3

Introduction
To understand the Indian market for Specialty
Packaging Films, we have look into the current
consumption of Specialty / Flexible packaging/
non packaging films as Indian market is still
driven by COMODITY films
The Current Driving forces in Indian market is
Lower COST of production/ PRICE
The potential of Indian market is it’s own
population of 1.25 B+ @ 18% of world
population of 7 B+

Introduction contd…
According to the recent studies conducted
,the flexible packaging market in India is worth
USD 8.5 B @4.35% of global market of USD
195 B
This translates into approx. 2.55 MMT of
Flexible Packaging @ 21.6% of Total Plastics
consumed as 11.8 MMT in India

Indian market for plastics & flexible packaging
films
Packaging films :
i. Food Packaging :
Milk Packaging
Edible Oil Packaging
Water Packaging
Bread Bags
Spices – Whole/ grounded
Ready to eat Snacks- Nankeens, Potato Chips
etc.
Chewing Mouth Freshners
Heavy Duty Packing for rice, wheat flour etc.
Snack Food : Oriented PP film
Stand up pouches
www.mamataextrusion.com
6

Film Applications
ii. Non Food Packing :
3 Layer film in flexible lami tube -Huge
market segment growing rapidly
Strech & Cling Film
Shrink Film
Liner Bags
Institution Liner Bags
Bag in Box
Medical packaging
Heavy Duty Sack bags
Plastic Granule Bags
Grocery Sack bags
Agriculture Films
ANTIFOG Films
7

Film Applications
ii. Non Packaging :
Consumer purchased films and articles
Agriculture and Construction films
Diaper and Personal Hygiene films
Mulch, Green House films
Silage bags films
Surface protection films
8

Opportunities –
India as manufacturer base for global market
9
Global market for flexible packaging material is
worth USD 195 billion & growing at a rate of CAGR
3.5% as against 8.5% in India. By this estimate, one
can imagine the growth potential of flexible
packaging in India in coming days which is
tremendous.www.mamataextrusion.com
CAGR %

Plastic Industry Status Report
Total Polymer Consumption 2012-13
Thermoplastics + Thermosets
POLYMER 2012-2013 2016-2017
(Estimated)
DEMAND 11.80 MMT 17.60 MMT
CARG 10.70%

Polymer Consumption – Application wise 2012-13

Total Installed Capacity – Film Plants up to
2012-13
12
Up to 2012-13 No of machine
installed
Installed Capacity
(MMT)
Monolayer Film 9370 1.625
Multilayer 1290 1.050
BOPP 33 0.600
PPTQ Film 2950 0.640
Total 13643 3.915

A Case Study of
Edible Oil Packaging Film
- Mono to Nine Layers

14
3664Ghee
3763Butter
3961Vanaspati
5050Palm
8020Groundnut
8416Soybeans
8812Sunflower
946Mustard /Rapeseed
1090Coconut
Unsaturated fatty acidsSaturated fatty acidsProducts
Types of Edible Oil in India and Fatty Acid Composition of Oils
/ Fats
Higher the unsaturation percentage, fast will be the spoilage

Monolayer to 3 Layer Edible Oil Film
Monolayer Structure
No of Layers 01
Polymer
45% LLDPE + 10% HDPE + 10% LDPE +
30% m-LL + 5% MB
% Thickness 100%
Total Thickness 120 Microns ( 4.8 Mil)
Price (USD/kg)* 2.01
15

3 Layer Structure
# of Layers 01 (Outer) 2 3 (Inner)
Polymer
45% LLD + 10%
HD + 10% LD +
30% m-LL + 5%
MB
75% LLD + 10%
HD + 10% LD +
5% MB
60% LLD + 10% LD
+ 30% m-LL
% Thickness 20% 60% 20%
Total Thickness 100 Microns ( 3.93 Mil)
Price(USD/kg) * 1.95
16

Benefits
Distinct skin layers – slip on sealant & non slip on
surface
Low COF on inner layers
Chances of least pin holes
Coloured master batch only in middle and outer
Possibilities of using PP, HDPE & PE in desirable
blends in different layers
3.42 % SAVING ( USD 0.06 PER KG ) IN RECIPE
COST AS COMPARED TO MONO LAYER
17

5 Layer Generic Structure - A
5 Layer Structure
# of Layers 1 (Outer) 2 3 4 5 (Inner)
Polymer
62% LLD
(C4) +
10% LD +
20% m-LL
+ 8% MB
Tie
Poly
Amide
Tie
60%
LLD(C4) +
10% LD +
30% m-LL
% Thickness 38% 6% 12% 6% 38%
Total
Thickness
100 Microns ( 3.93 Mil)
Price
(USD/kg) *
2.44
Benefits
Excellent Gas Barrier Properties in 5 Layer (Shelf Life up to 3-6 months).
18

7 Layer Generic Structure - A
7 Layer Structure
# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner)
Polymer
70% LLD
(C4) +
10% LD +
20% m-LL
82% LLD
(C4) +
10%
LD+8%
MB
Tie
Poly
Amide
Tie
82% LLD
(C4) +
10%
LD+8%
MB
60%
LLD(C4) +
10% LD +
30% m-
LL
%
Thickness
19% 19% 6% 12% 6% 19% 19%
Total
Thickness
Price
(USD/kg) *
2.41
Benefits
Lower Sealant Cost & hence lower over all cost of the film
19

5 Layer Generic Structure - B
5 Layer Structure
# of Layers 1 (Outer) 2 3 4 5 (Inner)
Polymer
62% LLD
(C4) +
10% LD +
20% m-LL
+ 8% MB
Tie
Poly
Amide
Tie
60%
LLD(C4) +
10% LD +
30% m-LL
% Thickness 20% 15% 30% 15% 20%
Total
Thickness
Price
(USD/kg) *
3.05
Benefits
Excellent Gas Barrier Properties in 5 Layer (Shelf Life up to 6 – 12
months).
20

5 Layer to 7 Layer Generic Structure – B1
7 Layer Structure – Break up PA
Layer# of Layers 1
(Outer)
2 3 4 5 6 7 (Inner)
Polymer
62% LLD
(C4) +
10% LD +
20%
mLL+ 8%
MB
Tie
Poly
Amide
Tie
Poly
Amide
Tie
60%
LLD(C4) +
10% LD +
30% m-LL
% Thickness 25.5% 7% 14% 7% 14% 7% 25.5%
Total
Thickness
Price
(USD/kg) *
2.91
Benefits
As 30% Nylon may crack & loose barrier in long run & hence it is
addressed by splitting the Nylon Layer to make structure 7 Layer.
Split Nylon layer to 14% &14% to make ~ 30% single layer of Nylon.
0.14 USD / KG in 7 layer recipe cost as compared to 5 layer Generic
Structure - A
* SEA CIF Prices
21

7 Layer ( Generic Structure – B2)
7 Layer Structure – With EVOH
* SEA CIF Prices
# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner)
Polymer
62% LLD (C4)
+ 10% LD +
20% m-LL+
MB 8%
Tie PA EVOH PA Tie
60% LLD(C4) +
10% LD + 30%
m-LL
% Thickness 41% 3% 4% 4% 4% 3% 41%
Total
Thickness
Price
(USD/kg) *
2.55
Benefits
EVoH with almost ~ 5 times barrier than Nylon at ~ 2.5 times price, with
capability to have a sandwich layer with Nylon on both sides without Tie layer
brings over all price down without compromising on Barrier Properties.
0.36 USD Per kg in recipe cost w.r.t 5 Layer Generic Structure-A
22

9 Layer ( Generic Structure – B2)
9 Layer Structure – With EVOH
* SEA CIF Prices
# of
Layers
1 (Outer) 2 3 4 5 6 7 (Inner)
Polymer
67% LLD
(C4) + 10%
LD + 20%
m-LL+ MB
3%
90% LLD
(C4) + 10%
LD
Tie PA EVOH PA Tie
90% LLD
(C4) + 10%
LD
57% LLD(C4)
+ 10% LD +
30% m-LL
% Thickness 20% 21% 3% 4% 4% 4% 3% 21% 20%
Total
Thickness
Price
(USD/kg)
*
2.51
Benefits
The sealant layer costs reduced
23

Role of Blown Film
Mono to Co-extrusion

Why Co-extrusion Blown Film
As there are still many MONO Layer
Blown film lines in market, there is a
need to either upgrade / replace them
to/ with at least a 3 Layer line.

Film Properties : Multilayer Vs. Monolayer
26
Film property, Unit Monolayer
film LDPE
(50 micron)
Multilayer
3-layer film
LL/LD/LL
(30 micron)
Benefit (%)
Yield Tensile strength MD, MPa 9.5 12.3 + 29.5
Yield Tensile strength TD, MPa 9.0 13.0 + 44.0
Ultimate Tensile stress MD, MPa 26 28.2 + 8.0
Ultimate Tensile stress TD, Mpa 21 27.4 + 30.0
Ultimate Elongation MD, % 245 415 + 69.0
Ultimate Elongation TD, % 650 745 + 14.6
Specular Gloss, % 60 65 + 8.3
Tear Resistance MD, g/mil 38 50 + 31.5
Seal ability property Moderate Excellent improved
Note:
• All the above figures are merely indicative and for academic intent. They are not a commitment for any
offered model of Film Plant and must be discussed in advance. Types of materials and material blends can
reduce / enhance the characteristics mentioned above.

The output rates of individual layers in a multilayer
die are very much lower than for equivalent size of
single layer die. The results in reduced shear rate and
longer resistance time in the die spirals, leading to
better homogeneity and additional relaxation of
melt. Hence, the inherent benefits of Co-extrusion is
improvement of film quality.
27
FILM QUALITY

Ultimately there will be no need of any MONO Layer
as 3 Layer will be able to offer a BETTER & CHEAPER
solutions as it can now produce films using all PEs
(LDPE/LLDPE/mLLDPE/HDPE etc.) & PPs (Homo as
well Co- Polymer) through an ENGEENIRED
STRUCTURE in a 3 Layer Blown Film Line.
28
Present Future

This trend will need a joint co-operation with
Machine manufacturers, Resin manufacturers & film
producers to ADD VALUE to the whole process in
phased manner.
29

Future Trends in Co-Extrusion
The SLIM packaging ahead will force the Industry to control
the RESOURCE by producing thinner & thinner films without
compromising the core properties. A film today of say 1 mil
(25 micron) will have to be down gauged to ultimately be of
12- 15 microns. To achieve this, we will have to develop very
high line speed based Post Extrusion Equipment.
30
Low Speed PEEs
High Speed PEEs
1 mil (25 microns)
0.5 mil (12-15 microns)
Film Thickness Blown Film Line
Post Extrusion Equipment (PEEs)

Looking into the future concerns globally
to be kept this EARTH as GREEN as
possible, we need to produce 100%
recyclable flexible packaging laminates.
This means we will have to produce blown
films to replace existing non- recyclable
substrates like PET, BOPP etc. Hence, there
is a need to produce the blown film which
could be having HIGH CLARITY & HIGH
STIFNESS using say Homo Polymer PP
blend in core & LL/mLL/LD blends in skins
as usual to get a Double FROST line based
film.
31
Future Trends in Co-Extrusion

Future Trends of Co-Extrusion
This film needs to be further processed for
Double Bubble/ Triple Bubble operations for
highest possible across the width strength due to
higher BUR. The film has to pass further through
MDO (Machine Direction Orientation) process for
enhance machine direction strength to enable
film be running at very high line speed during
printing with negligible STRTCHING. All the above
processes has been achieved by Industry very
successfully on individual operation base. Now
the need of the hour is to marry them all together
which is a challenging mile stone ahead. The
reverse printed Blown film will then be laminated
with another Blown film as sealant layer to offer
recyclable LAMINATES.

Role of Indian Packaging Eco-friendly
system –
i. ENO Sachets

Eno Pouches – Eco Friendly System
34
Earlier Present

Something about Mamata Group

Mamata Group
36
The Flagship company of the GroupThe Flagship company of the Group
A Fully owned subsidiary of MamataA Fully owned subsidiary of Mamata to make
Multi layer Blown Film Line Systems and elements
A Green Field ProjectA Green Field Project to propogate Usage of Solar
Thermal Energy for Purpose of Cooling & Heating
applications.
Engineering & Marketing Arm of MamataEngineering & Marketing Arm of Mamata
MachineryMachinery in USA at ILLINOIS & FLORIDA

How we started:
In 1989, MAMATA MACHINERY introduced a unique
concept in Bag Making Machines. Mamata was one of
the very few companies in the world to have offered
Microprocessor controlled Machines at that time.
Mamata has been exporting it’s product historically,
Infact, Mamata exported it’s 1st
machine in 1990 itself.
Mamata has developed Machines which are specifically
targeted for the markets of Europe and United states of
America.
Mamata introduced Vega series Machines in Europe in
1998 and introduced Machines in USA in 2003.
Bag making machines
37

Where we are today:
Today, Mamata has significant presence in USA. Mamata USA
Inc. was formed and became operational in 2003 to service
USA, Canada and Central South American Markets.
With over 3000 Machines in more than 75 countries, Mamata
Machinery Pvt. Ltd. Has emerged as one of the Leading
companies in this field Globally.

Fastest System in world for Zip inserted Wicket Bags.
Bag making machines
39

Fastest system in world for making Flower Sleeve / Bags
Bag making machines
40

Fastest system in the world for making slider zipper
pouches
Bag making machines
41

More than
110 machines supplied to USA in 100 months.
300 machines running in Europe.
200 machines supplied to South Afirca.
800 machines supplied to rest of African Countries.
Undisputed leadership in Indian market with more than
1000 machines
Bag making machines
42

Manufactured based on design from
Klockner, Germany.
Basic design was based on clutch and
brake technology for indexing. Sealing
jaw movement was cam driven.
We changed film indexing and sealing
jaw movement in line with our design
philosophy with servo technology.
First machine became ready for
commercial sale in ‘2000.
Since then we have sold 13 machines for
applications to pack powders / liquids.
43
Packaging machines

44
M-200 HFFS Pouch Machine
Setting New Standards in Pouch Making

45
MAMATA ENTERPRISES INC.
MONTGOMERY, ILLINOISwww.mamataextrusion.com

Facilities / Locations…
Head Office & Manufacturing facility at:
Ahmedabad, Gujarat, INDIA
Pre-sales & After sales service centre &
showroom:
Montgomery, IL-60538 USA.
Agent Network in:
Over 15 countries in…
Europe
Middle East
Far East
Africa

Blown film lines
MES has dedicated facility of
140,000 Sqr. Feet. For Assy. and
testing of Blown Film Line
With Canadian technology platform,
we manufacture -
Blown Film Lines of 1000 mm to
3000 mm width, output range from
120 kg/hr to 1000 kg/hr.
Basic 3 Layer Lines & State-of-the
art, Fully Automated Lines with
Internal Bubble Cooling Systems for
higher output and critical
applications.

Conclusion
PE-PE laminate for bulk packaging application
PE-PE laminate for environment /recyclability- major thrust
by MNC globally
As can be seen, monolayer is not a market but a phase in
many part of the world as ultimately any monolayer has to
upgrade itself into co-ex with 2 0r 3 layer to go away from
the problems of Pin Holes, Strength Properties / Process
ability /down gauging and finally cost per square meter of
Film. With recent advance in Die Design and Air Ring
designs, Co-Extrusion Blown Films have far more benefits
in terms of cost savings with optimum film properties by
varying layer ratios in range of 1:2:1 and can go up to
1:5:1 and even up to 1:8:1.

Indian market for specialty packaging films

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