Toray Plastics (America), the only United States manufacturer of polypropylene, polyester, metallized and bio-based films, has introduced its new Torayfan – Over-the-Mountain portfolio of biaxially oriented polypropylene (BOPP) films. These new films are designed to prevent packages from bursting when transported in high-altitude and low-atmospheric-pressure conditions. In high altitudes, the air pressure outside the package decreases, causing it to inflate. That inflation places additional stress on the seals and may damage them or cause them to burst. Toray manufactures the new Over-the-Mountain films using its proprietary, modified polypropylene core layer and a proprietary sealant, which work synergistically to provide superior seal performance. Seal strength and hermetic seals help to maintain the integrity of the package and protect the oxygen and moisture barrier that allow food to stay fresh. Studies have shown that these OTM films can survive altitudes of about 17,000 feet before exhibiting a leak and about 38,000 feet before rupturing completely.
Hermetic seals also ensure an excellent seal through any food residue. The proprietary sealant closes channel leaks in challenging seal areas, thus preventing oxygen and moisture from getting into the package and degrading product freshness. The high-performance sealant also prevents any necessary oils in the packaged product from leaking out through the seal areas. Oils that leak can leave a greasy texture on the package surface and stain it and any secondary packaging, compromising the consumer’s experience and tarnishing a brand’s reputation.
These new films are robust enough to allow a switch from a traditional three-ply lamination to a two-ply structure. Simplifying the converting process promotes production efficiencies, and enables cost savings. It also allows for efficient, multi-channel distribution. Toray’s OTM films are designed for use in the manufacture of pillows, pouches, and stand-up pouches (SUP) that are used for salty and savory snacks, cookies, crackers, biscuits, and confectionery items.
“Geographical differences between the four regions of the United States create significant distribution challenges for CPGs,” explains Amanda Whaley, product manager, Torayfan division. “With Toray’s OTM films the incidence of bags bursting can be significantly reduced or even eliminated. This innovation gives CPGs the confidence to distribute their products using traditional interstate highways directly over mountain passes. It also opens up new business opportunities for smaller regional manufacturers, who will now be able to distribute products nationwide.”
The Over-the-Mountain films are compatible with standard VFFS and HFFS equipment that run heat-sealable BOPP film; no changes in converting set up are necessary. The films are available in transparent, metallized, and white versions in a variety of barrier levels.