By Cynthia Palmer, labels sales manager – North America, Taghleef Industries

The in-mold supply chain is complex, involving brand owners, printers and molders. The industry values versatility and interchangeability, often focusing discussions on how finishes appear on the final package. That creates challenges for oriented polypropylene (OPP) film manufacturers, as films must look and feel nearly identical across different finishes and regions.

Design and material compatibility
With increased focus on recyclability and material compatibility, in-mold labeling continues to grow as a preferred packaging solution. When inquiries come in for OPP films, my standard response is that the options are nearly limitless – white, clear or metallized.

Clear films deliver a transparent “no label look” so consumers can admire the product’s freshness. Voided white films can provide a variety of textures, depending on their density. Product designers can choose a grainy orange-peel look for a paper-like effect, a matte satin finish, a smooth finish for a more even surface or a glossy look delivered by specially designed solid white substrates. Metallic films offer a shiny, reflective look designed to maximize product appeal and deliver brand-building power.

Sustainability increasingly is important to product designers, and material compatibility is critical for recycling success. For example, pairing PET shrink sleeves with PP containers is not ideal. Most inquiries come from printers and brand owners, and the first step always is understanding the desired look of the finished container and the performance requirements. Achieving the right balance of aesthetics and functionality requires close collaboration among brand owners, printers, molders and film suppliers.

Substrate choice also affects design when assessing product functionality. The push toward thinner materials supports source reduction but can introduce challenges in label dispensing and mold design. In-mold labels for non-durable applications are significantly thicker than many other flexible or roll-to-roll label films, mainly because they must meet specific requirements for diecutting, dispensing and molding. Gauge reduction is possible but could come at a cost to efficiency.

Ensuring all functional requirements are met for both printers and molders is essential when designing new films. It’s also important to ensure products can be manufactured consistently, with the same appearance and performance, across multiple sites. This capability is critical when supporting global brands.

More sustainability considerations
One example of a film development with an eye toward sustainability has been biobased film substrates, made from renewable resources. These bioPP films (see Figure 1) are ISCC Plus certified and supplied on a mass balance approach. They can be used in the same labels and flexible packaging applications as the traditional grades made of fossil-based raw material, thus guaranteeing the same excellent technical performance and machinability. At their end of life, these films are designed to be recycled in existing polyolefin recycling streams.

Also available are PLA films for use with PLA containers for injection IML. Derived from renewable resources and certified for industrial compostability, the films are clear, with a receptive layer optimized for printing and a back side engineered for injection molding.

Future development
North America still has a long way to go in terms of regulations and infrastructure to fully support sustainable packaging. Brand owner engagement is essential for success. Too often, film suppliers are brought into projects late in the process. An ask of the industry is to involve film suppliers earlier so that suppliers can help develop materials that deliver the best performance and sustainability outcomes.

Looking ahead, continued R&D into polymer options – such as producing thicker films with less material – offers opportunities for further source reduction. The industry also is replacing less environmentally favorable polymers and increasing the use of ISCC-certified materials. The in-mold industry is well positioned to compete and succeed in this evolving landscape.

Cynthia Palmer is the Labels Sales Manager – North America for Taghleef Industries, one of the world’s largest manufacturers of PP-based, biobased and biodegradable films for flexible packaging, labels, graphic arts, decorative surfaces and industrial applications. Headquartered in Dubai, Taghleef has US offices in Newark, Delaware and a production plant in Rosedale, Indiana. Taghleef has been involved in the in-mold market globally for many years and continues to innovate by offering new solutions. Operating as a global company brings challenges, particularly ensuring that products purchased in one region perform and appear the same in another. This consistency is critical for global brands. For more information, visit www.ti-films.com.