2 Polypropylene Films: 2.2 Cast Film

2 Polypropylene Films
Teresa Calafut
Polypropylene film is one of the most versatile excellent impact strength, and low moisture perme-
packaging materials. It is economical due to its low ability but provide only poor barriers to gases, such
density and is replacing other materials, such as as oxygen and carbon dioxide, some perfumes, and
polyethylene, polyvinyl chloride, polyester, and cel- oil such as peppermint oil. Clarity of unoriented ran-
lophane, in packaging applications. Almost 90% of dom copolymer film is moderate and is affected by
plastic packaging is used in food applications; other processing conditions. Because its physical proper-
applications include film packaging for stationery ties are balanced, unoriented film is easier to pro-
products, cigarettes, and textiles (Goddard, 1993; cess on bag-making equipment than cast-oriented
Graves, 1995; Shell Polypropylene Film Grade film, and slitting and sealing is easier in the trans-
Resins Guide, 1992). verse direction. Applications include packaging for
Both random copolymers and homopolymers are shirts, hosiery, bread, and produce, used as a
used in film production. Films can be unoriented, uni- strength and barrier layer in disposable diapers, and
axially oriented, or biaxially oriented and are defined used in electrical capacitors (Barnetson, 1996;
as sheet materials that are less than 0.254 mm Fortilene Polypropylene Properties, Processing, and
(10 mil) in thickness; thicker films are referred to as Design Manual, 1981; Himont, 1992; Miller et al.,
sheets. Resins with melt-flow indexes of B2 8 g/ 1991; Moore, 1996; Polymers in Contact with Food,
10 min are generally used in films, although higher 1991; Thompson et al., 1987).
melt-flow rate resins are also used. Higher melt-flow
resins are used in cast film processes (Fortilene
Polypropylene Properties, Processing, and Design
Manual (1981); Capshew (1997). 2.2 Cast Film
Cast processes are usually used to produce uniaxi-
ally oriented film, oriented in the machine direction.
2.1 Unoriented Film Physical properties of the film depend on the degree
of orientation, and a film is produced with different
Unoriented polypropylene films can be produced surface properties on each side. Oriented cast poly-
by casting or blown film processes. Chill roll casting propylene film is clear and glossy, with high tensile
and tubular water quenching are commonly used. strength. It is about three times stiffer and stronger
Conventional air quenching, widely used for polyeth- than low-density polyethylene film. Cast film pro-
ylene, produces brittle films with poor clarity in poly- vides good moisture barrier properties and scuff resis-
propylene; however, newer polypropylene resins and tance at low cost. Low-temperature brittleness is a
copolymers developed for air-quenched processes problem with homopolymer polypropylene film; this
can provide economical alternatives to polyethylene. can be overcome by the use of a copolymer resin
The tubular water-quench process is commonly used (Fortilene Polypropylene Properties, Processing, and
to produce monolayer film (Barnetson, 1996; Design Manual, 1981; Graves, 1995).
Fortilene Polypropylene Properties, Processing, and A water bath is sometimes used instead of a chill
Design Manual, 1981; Himont, 1992; Miller et al., or casting roll; the water bath process quenches the
1991; Moore, 1996; Polymers in Contact with Food, melt on both sides at the same time, producing a
1991; Thompson et al., 1987). film with the same surface properties on each side.
Unoriented films have a very soft hand and are The machine direction orientation in the water bath
easily heat sealed. They exhibit good heat stability, process is somewhat different than that obtained
low flexural moduli, excellent puncture resistance, using the casting roll, and the very rapid quenching
Ebnesajjad: Plastic Films in Food Packaging. DOI: http://dx.doi.org/10.1016/B978-1-4557-3112-1.00002-8

© 1998 Elsevier Inc. All rights reserved. Reproduced from a chapter in: Maier, Polypropylene — The Definitive User’s Guide and Databook (1998). 17

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2 Polypropylene Films

Ebnesajjad: Plastic Films in Food Packaging. DOI: http://dx.doi.org/10.1016/B978-1-4557-3112-1.00002-8

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