Market Growth and Opportunities for Biaxially Oriented Polypropylene (BOPP) Films: A Forecast to 2030

According to a market report released in January by Research and Markets, the biaxially oriented polypropylene (BOPP) films market is projected to grow at a compound annual growth rate (CAGR) of 6.5% from 2022 to 2030.

Polypropylene can be stretched both in the machine direction and across the machine direction, a process that endows BOPP films with superior printability, low gauge, clarity, flatness, and twist retention.

Additionally, BOPP films offer UV resistance, a smooth surface, and excellent chemical resistance. In recent years, BOPP has seen a surge in popularity and demand due to its exceptional barrier properties against water vapor, oil, and grease, as well as being recyclable and free from harmful emissions.

The increasing utilization of BOPP films by industries such as food, pharmaceuticals, and cosmetics has spurred significant demand, presenting vast market opportunities for the coming years. However, stringent government regulations regarding BOPP film production pose a significant challenge to market growth during the forecast period.

Market Segment Insights

Flexible packaging, and packaging in general, is seen as one of the most lucrative industries due to its wide applicability across food and beverage, personal care, and pharmaceutical sectors. The growing demand for BOPP in packaging spans markets such as snacks, cakes, bread, ready-to-eat packaged foods, frozen foods, and candy.

The food sector is anticipated to be the fastest-growing application segment by the end of the forecast period. Additionally, the increasing need for pressure-sensitive tapes in mechanical packaging presents lucrative opportunities for leading players in the BOPP market.

Globally, the rising demand for consumer electronics and electrical goods creates a profitable growth opportunity for BOPP films. Due to their superior mechanical and thermal properties, these films are ideal for wrapping wires and cables, serving as excellent insulators.

Biaxially oriented polypropylene films are also used to prevent the oxidation of pharmaceuticals and cosmetics, a particularly challenging task. This demand contributed to North America holding the largest revenue share for BOPP films in 2021.

In terms of applications, the bags and pouches subsegment generated the largest market share in 2021. These flexible formats are water-resistant and can be printed with high-resolution images. BOPP bags and pouches have diverse uses in packaging animal feed, pet food, seeds, and other consumer goods, allowing for a broader market reach.

In recent years, the demand for tobacco packaging has increased due to the rising number of new product launches and higher disposable incomes.

Geographically, the Asia-Pacific region is expected to experience the highest market growth rate.

Introduction to TAM DUONG PACKAGING LIMITED COMPANY’s New PE Bag Production Line

We are excited to introduce the latest addition to TAM DUONG PACKAGING LIMITED COMPANY: our state-of-the-art PE bag production line. This advanced manufacturing setup represents our commitment to innovation, efficiency, and excellence in the packaging industry.

Cutting-Edge Technology

Our new PE bag production line is equipped with the most modern and sophisticated machinery. Designed to enhance productivity and precision, this line ensures that every PE bag we produce meets the highest standards of quality. The automated processes and rigorous quality control mechanisms embedded in our production line help us maintain consistency and excellence in our products.

Superior Quality

At TAM DUONG PACKAGING LIMITED COMPANY, quality is our top priority. Our new production line allows us to deliver PE bags that are not only durable and reliable but also versatile to meet various customer needs. Whether for industrial, commercial, or personal use, our PE bags are crafted to provide optimal performance and satisfaction.

Cost-Effective Solutions

We understand the importance of cost-efficiency for our customers. With the implementation of our new production line, we can streamline our manufacturing process, reduce waste, and optimize resource utilization. These improvements enable us to offer our premium PE bags at the most competitive prices in the market, ensuring you get the best value for your investment.

Commitment to Excellence

Our dedication to innovation and customer satisfaction drives us to continuously improve and expand our capabilities. The new PE bag production line is a testament to our ongoing efforts to stay ahead in the industry and deliver products that exceed expectations. We are confident that this new addition will help us maintain our reputation as a leading provider of high-quality packaging solutions.

Conclusion

The launch of our new PE bag production line marks a significant milestone for TAM DUONG PACKAGING LIMITED COMPANY. We are excited to offer superior quality products at unbeatable prices, backed by our commitment to excellence and customer satisfaction. Thank you for your continued support, and we look forward to serving your packaging needs with our enhanced capabilities.

For more information about our products and services, please visit our website or contact our customer service team. We are here to assist you with all your packaging requirements.

Part 2: Cutting, Component Manufacturing, and Sewing

Are you curious about how bulk bags are made and how they’re strong enough to hold thousands of pounds of material? In Part 1, we reviewed how our bulk bag fabrics are produced through extrusion, weaving, and coating. Now, let’s dive into the second phase of production, which includes fabric cutting, component manufacturing, and sewing.

Cutting

In the cutting stage, the woven fabric rolls produced during weaving are moved to the cutting floor. Here, the fabric is cut into specific shapes and sizes based on the finished bag’s specifications. These cuts determine the shape of the bag’s body panels, base and top panels, duffle or spout dimensions, and overall bag style. Measurements are programmed automatically to ensure precise and equal cuts according to the specifications.

Component Manufacturing

This stage involves two sub-stages: printing and webbing.

Sub-stage 1: Printing

After the fabric is cut, the printing plan is defined by the planning team. Once print plates are produced, the data is sent to an automatic printing machine. Impressions, company logos, and colors are then applied to the fabric panels before any sewing processes begin.

Sub-stage 2: Webbing

During this stage, various webbing components are produced, including lift loops, perimeter bands, belly bands, and web ties. Polypropylene tapes are woven on flat looms in the warp direction, and multifilament yarn is woven in the weft direction to produce webbing that supports a 6,000 lb break strength. The Quality Team then checks and approves the mechanical properties and appearance of the fabric.

Sewing

Once all the fabrics are cut, components are produced, and the technical team has reviewed the production plan, the materials are brought onto the production floor for sewing. The line plan is set up based on the attachments and components of each bag. Sewing generally follows this sequence: spouts are attached to their appropriate panels, the body panels of the bag (the “box”) are sewn together using a single safety stitch, and finally, the web components and accessories are attached with the finishing stitch. Different operations are carried out at their respective workstations by trained specialists to produce the finished FIBC bag.

HOW BULK BAGS ARE MADE: PART 1

Part 1: Extrusion, Weaving, Coating

Bulk bags are crucial for transportation, but how are they crafted to be so robust? Here’s a breakdown of how FIBC fabrics and bulk bags are made.

What is FIBC fabric? FIBC fabrics, primarily made from polypropylene, are coated with a synthetic film of polypropylene and polyethylene. These fabrics are designed to be strong and versatile, ideal for transporting dry and flowable products.

How is FIBC fabric made? FIBC fabrics are created through the following process:

  1. Extrusion
  2. Weaving
  3. Coating (Lamination)

Extrusion In the extrusion process, raw materials are melted into tapes of specific measurements. The ingredients include polypropylene granules, a small amount of calcium carbonate, a UV stabilizer, and colored pigments if needed. These tapes are then loaded onto bobbins for weaving.

FIBC Fabrics typically consist of:

  • Polypropylene 94.33%
  • Calcium 3.77%
  • UV treatment 2%

Weaving During weaving, the polypropylene tapes from the extrusion process are loaded onto looms. The fabric that forms the bulk bag’s body is woven into shape with warp (vertical tapes) and weft (horizontal tapes) generally at 10-warp x 10-weft tapes per square inch. This fabric has small gaps, making it breathable, which is excellent for some materials but not suitable for others.

Coating (Lamination) For certain applications, the fabric is treated with a laminate coating. In this process, the fabric passes through a thin liquid film of PP & LDPE material, then solidified by chilled rollers. This coating seals the weave’s voids, enhancing the fabric’s physical properties, making it suitable for transporting fine or flowable products and protecting them from moisture.

The lamination material typically consists of:

  • PP 350 FG 75%
  • LD 1070 LA17 25% (No filler used in the lamination process)

After coating, if applicable, the woven fabric is wound onto large spools and stored until it enters the cutting process, marking the start of Phase 2 of production.

What Is A BOPP Bag and Why Your Business Needs It

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There’s a common thread running through automotive components, reusable containers of different types, plastic parts, packaging and labeling, loudspeakers, polymer banknotes, stationery, textiles, carpets, ropes, and thermal underwear. It is Polypropylene, abbreviated as PP. PP is a recyclable thermoplastic polymer widely used in these applications. Rugged and unaffected by different chemical solvents, acids, and bases, the PP recycling code is as per the type of resin used, as in the case of all plastic products – PP’s resin identification code is 5. The global demand for PP materials is quite high. Transparency Market Research has indicated that presently the PP market worldwide is valued at more than $80 billion. By 2023 it should touch $133.3 billion according to the research agency.

PP recycling is vital for the environment

Of all plastic packaging products in the United Kingdom and the United States, PP is the single most used plastic packaging, thanks to its melting point and strong bearing. In the year 2010 alone five billion pounds of PP was produced in the United States. Sadly though, it has been revealed by the American Chemistry Council that PP is one of the least recycled post-consumer plastics, at a rate of below 1 percent for post-consumer PP foam. And this is a bad thing for the environment.

PP has a short life, so most of these thermoplastics land in landfills to be wasted. Twenty percent approximately of solid waste produced comprises some form of plastic which includes PP according to the US Environmental Protection Agency. This PP contained solid waste degrades very slowly in landfills, about 20 to 30 years to be fully decomposed. Naturally, this poses a severe threat to the environment. Additives used in plastic products may contain toxins such as lead and cadmium. Cadmium contained in plastic products has the potential to permeate and can affect some bio-systems. If you burn thermoplastics like PP it can discharge toxins and vinyl chloride. Against this backdrop Recycling Polypropylene assumes importance.

The Polypropylene Recycling Process

The Polypropylene Recycling Process comprises the collection, sorting, cleaning, reprocessing by melting and then producing new products from the recycled PP.. The reprocessing by melting and then producing the new product from the recycled PP are important steps in the Polypropylene Recycling Process. In the reprocessing phase, collected PP products are fed into an extruder where it is melted at 4640F (2400C) and cut into granules. The pellets are then ready to be used in the production of new products. Current technologies enable the melting of PP and its usage in the production of new items.

The power of Polypropylene

Polypropylene produces less solid waste by weight than PET, PS or PVC. Thus many recycling applications exist for Polypropylene: battery cases, paint cans, home storage, flower pots, pallets, crates, composite lumber, and more. In the US, out of the 51 largest US municipalities of the state, 44 collect polypropylene.

Polypropylene and high-density polyethylene (HDPE) produce significantly less CO2 equivalents by weight than PET, PS, and PVC. And Polypropylene parts can be 100% recycled for various useful purposes. A market for recycled PP (rPP) exists in an extensive range of products such as automotive applications, buckets, caps and closures, garden furniture, pallets, pipes, and more.

The Environmental Benefits of Recycling PP

When PP is recycled, there is a reduction in the consumption of raw, finite resources, such as oil and propane gas. Around 8% of the oil used worldwide (around 400 million tons) is implemented in the traditional methods of plastic production with 4% as ‘feedstock’ and another 4% in manufacturing. There is also an 88% reduction in energy usage if plastic is produced from plastic. So plastic to plastic recycling is environmentally friendly.

Given its inherent flexibility, PP can be recycled back into many different products, including clothing fibers, industrial fibres, food containers, dishware etc.