PP film producer scales up for a global marketplace

Already the largest supplier of CPP and BOPP in South America, OPP Film has set its sights on the North American market. A new plant outside of Lima will fuel growth.

This BOPP line has been in operation since October.
This BOPP line has been in operation since October.

Ask people what they know about Peru and they’ll likely say something about its cuisine, its astonishing collection of Inca ruins, or the diversity of its flora and fauna. But Peru is also home to OPP Film, part of the Oben Holding Group and one of the largest producers of Cast Polypropylene (CPP) and Biaxially Oriented Polypropylene (BOPP) in the world.


“We’re part of the overall growth economy that has characterized Peru over the past few years,” says Alfredo Barreda, OPP Film vice president.


“But,” adds technical director Erik Sosa, “our opportunity also had a lot to do with the condition of the market here in South America. Those who were producing BOPP or CPP were not doing it in large volumes, nor were they focused on large markets. As things started changing with the spread of globalization, we recognized what it meant and built a business plan accordingly. We started small with a plant in Ecuador, but even then we aimed to produce in large volumes and to produce as efficiently as possible.”


And where do the bulk of these two materials, CPP and BOPP, get used in flexible packaging applications? Most often they’re part of an adhesive lamination for salty snack or pasta packaging. BOPP, for example, with the increased molecular orientation it undergoes when it is stretched in both the machine direction and across the machine direction, has clarity, moisture-resistance, high gloss, low haze, and high stiffness. However, it lacks sealing properties and tear resistance. So converters frequently combine BOPP and CPP in a lamination where each provides the properties the other lacks. Add metallization to the BOPP layer and you get excellent gas barrier properties, too.


Already the leading supplier of CPP and BOPP in South America, OPP Film is now targeting North America, primarily through its subsidiary PackFilm North America. Management believes that once the four new lines in its new building are in full production, the company will be able to produce commodity quantities so efficiently that converters in North America will add OPP Film to the list of suppliers who currently meet their CPP and BOPP requirements. Adding to OPP Film’s competitive edge, management believes, is that because the four new lines represent the latest technology available, it will be able to combine commodity pricing with consistently excellent quality.


Two Lima facilities
At OPP Film headquarters in Lurin, just outside of Peru’s capital city of Lima, OPP Film has two major manufacturing facilities. One is a brand new building measuring 390,000 sq ft. By July or thereabouts, this new facility will house two new BOPP lines (one has been operating since last October) and two new CPP lines (one has been operating since 2008). All four lines, from resin infeed at the beginning to the winders at the end, are supplied by Brueckner.


The distinguishing characteristic of these new lines is their size. When the second CPP line is installed later this year, its 6.6-m wide die will make it the biggest CPP line in the world.


A recent Packaging World tour of the new facility in Lurin began with the Brueckner BOPP line that has been running since October. Four tons per hour is its throughput, and the finished film it produces has a final width of 8.7 m (28.5 ft). Like all of the firm’s product, the material produced on the new BOPP line is a three-layer A-B-C coextrusion. A core layer representing 90% of the finished structure is brought to the feed block of the coextrusion die by way of a twin-screw extruder. The skin layers on either side of the core layer are introduced to the feedblock by single-screw extruders.


Exiting the chill roll and water bath at a width of 1,100 m (43.3 in), the film enters the MDO portion of the process, or Machine Direction Orientation. The 18 preheat rollers, six stretching rolls, and 4 annealing rolls are all servo driven as opposed to the more traditional systems that rely on belts and pulleys and gears. It’s this newer, more accurate, more controllable technology that enables the firm to meet its efficiency and consistency targets.  

Another recent development from Brueckner is what’s called “multi-gap stretching.” In a more conventional scenario, film is only stretched in the gap between stretching rolls A and B. But with six stretching rolls-three on top and three below, stretching occurs three different times in three different gaps. It results in better control of stretching and of the film’s final thickness, which at OPP Films is in the 15- to 20-micron range, depending on the job in production.

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