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BoPET

BoPET, or biaxially oriented polyethylene terephthalate, is a thermoplastic polyester film produced by extruding molten PET resin and then stretching it sequentially in both the machine and transverse directions, typically at draw ratios of 3–4, followed by heat-setting at temperatures above 200°C to enhance its crystalline structure and stability.^[1] This process imparts exceptional mechanical strength, with a modulus of approximately 4 GPa, along with high tensile properties, making it durable and resistant to tearing under stress.^[1] BoPET exhibits superior optical clarity due to its fine crystal nuclei formation during orientation, as well as effective barrier characteristics against gases, aromas, moisture, and grease, which contribute to its versatility in demanding environments.^[1]^[2] Developed in the early 1950s through collaborative efforts by Imperial Chemical Industries (ICI) and DuPont, BoPET marked a significant advancement in polyester film technology, with commercial production beginning around 1952 under brand names such as Mylar (DuPont), Melinex (ICI), and Hostaphan.^[1]^[3] The material's biaxial orientation aligns polymer chains, improving dimensional stability, low shrinkage, and resistance to high temperatures and humidity compared to non-oriented PET.^[1] It can also be metallized to further enhance barrier performance, reducing oxygen and water vapor transmission rates, which is crucial for preserving product integrity.^[1] Additionally, BoPET is lightweight, 100% recyclable, and supports circular economy initiatives through advanced recycling methods, including post-consumer resin integration for food-contact applications.^[2] In terms of applications, BoPET is predominantly used in flexible packaging, such as food lidding, stand-up pouches, and metallized films for snacks and dairy products, where its barrier properties extend shelf life and enable high-quality printing.^[2]^[1] It plays a key role in electronics as an insulator for flexible circuits, capacitors, and photovoltaic backsheets, leveraging its electrical properties and thermal resistance.^[3]^[1] Other notable uses include graphic arts for durable labels and overlays, healthcare packaging, and emerging fields like vehicle electrification and renewable energy components, underscoring its broad industrial impact.^[3]^[1]

Chemical structure

Polymer composition

BoPET, or biaxially oriented polyethylene terephthalate, is a linear thermoplastic polyester polymer characterized by its repeating unit of (C₁₀H₈O₄)ₙ, which is formed through condensation polymerization of terephthalic acid and ethylene glycol.^[4] This reaction eliminates water to create ester bonds, linking the monomers into a long-chain structure.^[5] The molecular architecture of PET features ester linkages (-COO-) that connect rigid aromatic rings derived from terephthalic acid, contributing to the polymer's stiffness and thermal stability, while the flexible aliphatic ethylene glycol segments enable chain mobility and processability.^[4] Each repeating unit has a molecular weight of approximately 192 g/mol.^[5] For film-grade PET used in BoPET production, the degree of polymerization is typically 100-150, resulting in a number-average molecular weight of 20,000-30,000 g/mol, which balances melt viscosity and final film strength.^[5] Following biaxial orientation, BoPET achieves a semi-crystalline structure with 30-50% crystallinity, where aligned polymer chains form ordered regions that enhance mechanical properties and barrier performance.^[4]

Variants and modifications

BoPET can be modified through copolymerization to create variants with tailored properties, such as enhanced clarity or thermal stability. One common copolyester variant is PETG, produced by incorporating cyclohexanedimethanol (CHDM) into the polyethylene terephthalate structure, which disrupts crystallinity to yield amorphous films suitable for applications requiring high transparency and impact resistance.^[6] Another notable variant is polyethylene naphthalate (PEN), a naphthalene-based copolyester that replaces the terephthalate units with naphthalate, providing superior temperature resistance and mechanical strength while maintaining biaxial orientation capabilities similar to standard BoPET.^[7] Additives are frequently incorporated into BoPET during manufacturing to improve specific functionalities without altering the core polymer structure. UV stabilizers, such as benzotriazoles, are added at concentrations of 0.1-1% to absorb ultraviolet radiation and prevent degradation in outdoor or light-exposed applications.^[8] Slip agents, often in the form of silica particles, are used to reduce surface friction and prevent film-to-film sticking during processing and handling.^[9] Antistatic agents, typically quaternary ammonium compounds, are included to dissipate static charges, minimizing dust attraction and facilitating smooth unwinding in high-speed operations.^[9] Metallized BoPET involves the vacuum deposition of a thin aluminum layer onto the film surface, typically at a thickness of 20-50 nm, to enhance barrier properties against moisture, oxygen, and light while preserving flexibility.^[10] This modification is achieved through physical vapor deposition in a controlled vacuum environment, resulting in a uniform metallic coating that improves shelf-life in packaging without significantly increasing weight.^[10] Coated variants of BoPET feature applied layers such as silicone or acrylic to impart specialized surface properties. Silicone coatings provide low-adhesion release characteristics, ideal for pressure-sensitive labels where easy peeling is required without residue.^[11] Acrylic coatings similarly offer release functionality, often tuned for compatibility with adhesives in labeling applications, ensuring controlled peel strength and printability.^[11]

History

Invention of PET

Polyethylene terephthalate (PET) was first synthesized in 1941 by British chemists John Rex Whinfield and James Tennant Dickson while working at the Calico Printers' Association (CPA) in Manchester, England.^[12]^[13] Their discovery involved the polymerization of terephthalic acid derivatives with glycols, resulting in a strong, synthetic polyester suitable for fiber production.^[12] The invention was patented in the United States in 1949 as US Patent 2,465,319, though the original work predated World War II efforts to develop alternatives to natural fibers like silk and cotton.^[12] The initial synthesis focused on creating textile fibers through a melt polymerization process, utilizing dimethyl terephthalate and excess ethylene glycol.^[12] This involved an ester interchange reaction to form bis(2-hydroxyethyl) terephthalate, followed by polycondensation under vacuum at high temperatures around 280°C to eliminate ethylene glycol and build molecular weight.^[12] The resulting polymer exhibited a high melting point of approximately 260°C, which posed significant challenges, necessitating specialized equipment capable of handling elevated temperatures and inert atmospheres to prevent degradation.^[12]^[14] Following the patent assignment, Imperial Chemical Industries (ICI) acquired rights to the technology and developed it commercially under the brand name Terylene, launching the first polyester fibers in 1947 after pilot-scale trials.^[14]^[15] Full-scale commercial production began in 1950 at ICI's new facility in Redcar, England, primarily for clothing applications such as suits and dresses, where Terylene's durability and wrinkle resistance proved advantageous.^[15]^[16] By the late 1940s, researchers recognized PET's potential beyond fibers, noting its clarity, strength, and thermal stability as suitable for film extrusion, though widespread adoption for non-textile uses occurred later.^[14]

Development of BoPET

Biaxially oriented polyethylene terephthalate (BoPET) film emerged in the early 1950s through independent efforts by major chemical companies seeking to enhance the properties of polyethylene terephthalate (PET) for thin-film applications. DuPont, Imperial Chemical Industries (ICI), and Hoechst pioneered the biaxial orientation process, which stretches the extruded PET sheet in both machine and transverse directions to achieve superior mechanical strength, clarity, and dimensional stability compared to unoriented PET.^[1]^[17] DuPont commercialized its version under the Mylar trademark, with the first production reels manufactured in 1954 at its Circleville, Ohio facility on the world's initial commercial BoPET line.^[18] ICI launched Melinex around the same time, while Hoechst introduced Hostaphan in the mid-1950s. In 1955, Eastman Kodak became an early adopter, using Mylar as a durable base for photographic film, which allowed for extended 6,000-foot rolls suitable for high-altitude reconnaissance like U-2 flights due to the film's thinness and toughness.^[19] A landmark application demonstrating BoPET's potential occurred in NASA's Project Echo, highlighting its lightweight and reflective qualities. Launched on August 12, 1960, Echo 1 was a 100-foot (30.5-meter) diameter metallized balloon satellite constructed from 0.0127 mm thick Mylar polyester film coated with aluminum particles, enabling it to function as a passive reflector for microwave communication signals between ground stations.^[20] Echo 2, deployed in 1964, employed a similar design but with improved inflation mechanisms and a slightly larger 41.1-meter structure, further validating BoPET's reliability in extreme space environments where the material's low weight—half that of cellophane—and foldability into a compact canister were critical.^[21] These missions, developed in collaboration with contractors like Metallized Products, Inc., marked BoPET's entry into aerospace, influencing subsequent uses in satellite components and protective coverings. The 1960s brought widespread commercialization as demand surged for BoPET in consumer and industrial sectors. DuPont expanded production at Circleville, transitioning from pilot-scale to industrial volumes to supply growing markets, while ICI and Hoechst established parallel facilities in Europe.^[3] This era saw BoPET's adoption in flexible packaging for food and goods, leveraging its barrier properties and printability, as well as in electronics for insulating tapes and capacitor dielectrics, where its electrical stability and heat resistance proved essential.^[22] By the late 1960s, global output had scaled significantly, with DuPont alone reporting substantial investments in extrusion and orientation lines to meet applications in magnetic recording media and protective laminates.^[3] Advancements in manufacturing techniques continued into the late 20th and 21st centuries, focusing on process efficiency and film performance. Sequential biaxial orientation dominated early production, but simultaneous biaxial stretching emerged in the late 20th century as an alternative method, allowing uniform tension in both directions during a single step to reduce defects and enable higher speeds.^[23] Refinements in the 2020s have optimized these techniques for producing ultra-thin BoPET films (below 10 micrometers), improving uniformity and supporting sustainable applications in flexible electronics and lightweight packaging.^[3]

Manufacturing process

Raw materials and synthesis

The primary raw materials for producing the polyethylene terephthalate (PET) resin used in biaxially oriented PET (BoPET) film are purified terephthalic acid (PTA) and ethylene glycol (EG). PTA is obtained through the air oxidation of p-xylene in acetic acid solvent with a cobalt-manganese-bromide catalyst, followed by purification to achieve a purity greater than 99.9 wt% and low levels of impurities such as 4-carboxybenzaldehyde (<25 ppm), essential for high-quality film-grade resin. EG is derived from the hydrolysis of ethylene oxide, which itself is produced by the direct oxidation of ethylene, and is purified to similarly high standards (>99.9%) to minimize side reactions during polymerization. The synthesis of PET resin employs a two-stage melt polycondensation process, predominantly using the direct esterification route with PTA and EG. In the first stage, PTA and excess EG (typically a 1.1-1.2 molar ratio) undergo esterification in a reactor at 200-300°C (commonly around 250°C) under atmospheric or slight overpressure, forming bis(2-hydroxyethyl) terephthalate (BHET) oligomers and releasing water as the primary byproduct. This step is conducted for 2-4 hours until a conversion of approximately 90% is achieved. The second stage involves polycondensation of the oligomers, where the mixture is heated to 280-290°C under high vacuum (50-500 Pa) to drive off EG and residual water, building the polymer chain length while minimizing thermal degradation. This vacuum distillation removes volatile byproducts, including EG (the main condensate) and trace acetaldehyde from side reactions, over 3-5 hours until the desired molecular weight is reached. Alternatively, when using dimethyl terephthalate (DMT) instead of PTA, the initial transesterification step at similar temperatures (around 250°C) produces methanol as the byproduct, though PTA-based processes dominate modern production due to cost and efficiency advantages. Polymerization is accelerated by catalysts, traditionally antimony trioxide (Sb₂O₃) at concentrations of 200-300 ppm (metal basis), which enhances reaction rates in both stages but can introduce trace toxicity concerns in end products. Since the 2010s, there has been a shift toward titanium-based catalysts, such as titanium tetrabutoxide or glycolates at 20-100 ppm, offering comparable activity with reduced antimony content, lower yellowing, and improved environmental profiles for food-contact applications. The resulting PET resin for BoPET film exhibits an intrinsic viscosity of 0.60-0.65 dL/g, indicating suitable melt strength and orientation properties, and is pelletized for storage. Prior to extrusion, these pellets are dried under vacuum or hot air at 150-180°C for 4-6 hours to reduce moisture content below 50 ppm, preventing hydrolysis that could degrade molecular weight during processing.

Extrusion and orientation

The manufacturing of BoPET film commences with the extrusion of dried PET resin into an amorphous sheet. The resin is melted in an extruder at temperatures of 265–285°C, filtered to remove impurities, and extruded through a flat die onto a water-cooled chill roll traveling at 20–30 m/min, where rapid quenching solidifies it into a uniform amorphous sheet with a thickness of 200–500 μm.^[24]^[25] Following extrusion, the sheet undergoes longitudinal orientation in the machine direction (MD). The film is preheated to 50–70°C, then stretched 3–4 times its original length at 75–85°C using a series of heated rollers, which aligns the polymer chains and begins imparting directional strength.^[24]^[25] Subsequently, transverse orientation (TD) is performed to achieve biaxial properties. The MD-oriented film is gripped by clips in a stenter oven, preheated to 80–90°C, and stretched 3–4 times in the perpendicular direction at 80–110°C, allowing controlled widening while maintaining tension; a sequential MD-then-TD process is most common, though simultaneous biaxial stretching variants are used for enhanced uniformity and reduced anisotropy.^[24]^[1]^[26] The biaxially oriented film is then heat-set to lock in its structure. It is annealed under tension at 200–220°C for 5–10 seconds in a final oven, promoting approximately 50% crystallinity, relieving internal stresses, and ensuring dimensional stability; afterward, the film is cooled, slit to width, and wound into master rolls with final thicknesses ranging from 1 to 350 μm.^[25]^[1]

Properties

Mechanical and physical properties

BoPET film exhibits exceptional mechanical strength due to its biaxial orientation process, which aligns the polymer chains in both the machine direction (MD) and transverse direction (TD), resulting in balanced isotropic properties. The tensile strength typically ranges from 200 to 250 MPa in both MD and TD directions, providing robust load-bearing capacity suitable for demanding applications. This high strength is complemented by a Young's modulus of 3 to 5 GPa, reflecting the film's stiffness and resistance to deformation under stress.^[27]^[28] The film's flexibility is evident in its elongation at break, which measures 100 to 150% in the MD and 70 to 120% in the TD, allowing it to absorb energy before failure without brittle fracture. Tear resistance, assessed via the Elmendorf method, is approximately 3 to 5 g/μm (equivalent to 75 to 125 g for a typical 25 μm film), contributing to the film's durability against propagation of cuts or defects during handling or use. These properties stem directly from the biaxial orientation during manufacturing, which enhances molecular alignment and overall toughness.^[29]^[30] Dimensional stability is a key physical attribute, with shrinkage limited to less than 1% after 30 minutes at 150°C in heat-stabilized variants, minimizing distortion in high-temperature environments. The film demonstrates low creep under sustained loads, ensuring long-term shape retention. The coefficient of thermal expansion is around 20 × 10^{-6}/°C, while the density is 1.38 to 1.40 g/cm³, providing a lightweight yet structurally sound material. Thickness uniformity across the web is maintained within ±2%, critical for consistent performance in precision applications.^[28]^[29]

Thermal and optical properties

BoPET exhibits distinct thermal transition temperatures that define its processing and application limits. The glass transition temperature (Tg) is approximately 78°C, marking the point where the polymer transitions from a glassy to a rubbery state, allowing increased molecular mobility.^[29] The melting point (Tm) occurs at around 260°C, above which the crystalline structure fully melts.^[31] These properties, combined with biaxial orientation that enhances crystallinity, enable BoPET to maintain structural integrity across a wide temperature range.^[1] For practical use, BoPET supports continuous operation from -70°C to 150°C without significant degradation, making it suitable for environments involving thermal cycling.^[29] Its thermal conductivity ranges from 0.15 to 0.20 W/m·K, indicating low heat transfer efficiency typical of insulating polymers. The specific heat capacity is 1.0–1.2 J/g·°C, reflecting moderate energy absorption during heating. Optically, BoPET demonstrates high clarity, with visible light transmission exceeding 90% for films 1–50 μm thick, due to its uniform biaxial orientation minimizing scattering.^[32] The refractive index is 1.66, contributing to its use in optical components where precise light refraction is needed.^[33] Clear grades exhibit haze below 1%, ensuring sharp image quality in transparent applications.^[32] Regarding UV resistance, BoPET absorbs wavelengths below 320 nm, primarily through its aromatic structure, which protects underlying materials from photodegradation.^[34] Stabilized variants show a yellowing index under 2 after 1000 hours of QUV exposure, preserving optical transparency over extended outdoor use.^[29]

Electrical and chemical properties

BoPET demonstrates superior electrical insulating capabilities, attributed to its high dielectric strength, which ranges from 150 to 200 kV/mm, enabling it to endure substantial electric fields without breakdown.^[25] Its volume resistivity exceeds 10^{14} \Omega \cdot cm, signifying minimal electrical conductivity even under prolonged stress.^[35] Additionally, the dielectric constant measures 3.1 to 3.3 at 1 kHz, providing stable capacitance in electronic components.^[36] Certain additives can further modify resistivity to enhance performance in specialized applications.^[37] In terms of chemical properties, BoPET remains inert to dilute acids and bases across a pH range of 2 to 12 at room temperature, ensuring durability in mildly corrosive environments.^[35] It exhibits strong resistance to oils and greases, preventing degradation from common lubricants and contaminants.^[29] However, exposure to hot water above 70°C or steam induces hydrolysis, breaking ester bonds and compromising structural integrity over time.^[38] BoPET provides moderate gas barrier performance, with an oxygen transmission rate of 50 to 100 cm³/m²/day for a 25 μm film under standard conditions, limiting oxygen ingress effectively for many uses.^[39] The water vapor transmission rate is 10 to 20 g/m²/day at 38°C and 90% relative humidity, contributing to its role in moisture-sensitive contexts.^[40] Untreated BoPET film has a surface energy of 42 to 44 mN/m, which can be elevated to 50 to 60 mN/m through corona treatment, improving wettability and adhesion for coatings or laminates.^[41]

Applications

Flexible packaging

BoPET plays a pivotal role in flexible packaging due to its excellent barrier properties, mechanical strength, and compatibility with lamination processes, making it ideal for protecting food and consumer products from oxygen, moisture, and light. In lamination applications, BoPET is frequently combined with polyethylene (PE) or aluminum foil to create multi-layer structures for snacks and coffee pouches, where the outer BoPET layer provides durability and printability while the inner layers enhance sealing and barriers. For instance, PET/PE laminates are commonly used in snack bags to ensure product freshness, and PET/aluminum/PE structures offer superior protection for oxygen-sensitive items like coffee. Metallized BoPET grades further improve these laminates by depositing a thin aluminum layer, reducing oxygen transmission rates to below 1 cc/m²/day, which represents a reduction of over 90% compared to plain BoPET films with typical rates of 30-100 cc/m²/day.^[42]^[43]^[44] BoPET's compliance with food contact regulations enhances its suitability for packaging applications. It is approved by the U.S. Food and Drug Administration (FDA) for indirect food contact under 21 CFR 177.1630 as a component of articles intended for repeated use, ensuring safety in food packaging. Overall migration limits for BoPET films are below 10 mg/dm², aligning with FDA and EU standards to prevent excessive substance transfer into food. Additionally, certain BoPET variants are designed for thermal processing, remaining stable during retort conditions up to 121°C for 30 minutes, which supports applications in ready-to-eat meals and sterilized pouches.^[45]^[46]^[47] In printing and labeling, BoPET's high gloss and surface treatability enable vibrant, durable graphics on metallized labels for consumer products, enhancing visual appeal on shelves. For shrink sleeves applied to bottles, specialized BoPET films offer shrinkage of 60-80% at 100°C, conforming tightly to irregular shapes while maintaining clarity and resistance to environmental factors. These features make BoPET a preferred material for beverage and household product labeling.^[48]^[49] As of 2025, flexible packaging accounts for approximately 60% of global BoPET consumption, driven by demand in the food and beverage sectors. This segment's growth is further propelled by the adoption of sustainable mono-PET structures, which use single-material layers to improve recyclability without compromising barrier performance, aligning with regulatory pushes for circular economy practices.^[50]^[51]^[52]

Electrical and electronic uses

BoPET, also known as biaxially oriented polyethylene terephthalate, plays a critical role in electrical and electronic applications due to its high dielectric strength, thermal stability, and flexibility. Its ability to serve as an effective insulator and substrate enables reliable performance in devices requiring compact, durable components under varying electrical loads.^[53]^[54] In motors and transformers, BoPET is widely used in insulation tapes, where it provides robust electrical isolation and mechanical support. These tapes, often coated with adhesives, achieve a Class B thermal rating of 130°C, allowing operation in moderate-temperature environments without degradation. Typical thicknesses range from 25 to 50 μm, balancing insulation efficacy with ease of application in coil windings.^[55]^[54] For flexible circuits, copper-laminated BoPET serves as a base material in printed circuit boards (PCBs), particularly for wearables and compact electronics. This configuration supports tight bending radii below 5 mm, enabling conformable designs that withstand repeated flexing without cracking or delamination. Its cost-effectiveness compared to alternatives like polyimide makes it suitable for consumer-grade devices requiring moderate thermal resistance.^[56]^[57] BoPET films coated with indium tin oxide (ITO) are essential in display technologies, such as touchscreens, where they function as transparent conductive layers. These coatings achieve over 85% optical transparency while maintaining a surface resistivity of approximately 100 Ω/sq, supporting capacitive sensing with minimal visual distortion. The flexibility of BoPET allows integration into curved or foldable displays.^[58]^[59] As a dielectric in capacitors, metallized BoPET films enable high-voltage operation up to 2 kV, leveraging a thin evaporated metal layer for electrode formation. The self-healing property, where localized dielectric breakdowns vaporize the metal to isolate faults, enhances reliability and extends service life in power electronics. This feature, combined with BoPET's inherent dielectric strength exceeding 200 kV/mm, minimizes catastrophic failures under stress.^[60]^[61]^[53]

Insulation and protective coverings

BoPET, often metallized to enhance its reflective properties, serves as a key component in thermal insulation systems for building envelopes. In radiant barrier applications, metallized BoPET films are laminated with foil to create reflective layers that minimize heat transfer through radiation. These barriers can reflect up to 97% of radiant energy, significantly reducing summer heat gain and winter heat loss in structures such as attics and walls.^[62]^[63] By installing these laminates in air spaces, buildings achieve improved energy efficiency, with studies showing potential reductions in cooling costs by up to 10-20% in hot climates.^[64] In the automotive sector, BoPET-based window tint films provide essential protection against solar radiation while maintaining visibility. These films typically offer visible light transmission ranging from 5% to 50%, allowing customizable levels of privacy and glare reduction without compromising safety standards. Additionally, they block over 99% of ultraviolet rays, safeguarding vehicle interiors from fading and UV damage to occupants.^[65]^[66]^[67] For marine and aviation applications, BoPET films function as solar control interlayers and protective coverings in windshields and windows. In laminated glass assemblies, these films incorporate low-emissivity (low-e) coatings that reflect infrared radiation, reducing interior heat buildup by up to 60% while preserving optical clarity. This is particularly valuable in high-exposure environments like boats and aircraft, where solar control films help maintain comfortable cabin temperatures and enhance energy efficiency in HVAC systems.^[68]^[69]^[70] BoPET overlamination provides durable protective coverings for paper-based materials such as books and menus, enhancing longevity through superior abrasion resistance. When applied via thermal lamination, these films create a glossy, scuff-resistant surface that withstands over 500 cycles in Taber abrasion tests using CS-10 wheels under 500g load. This resistance protects against everyday wear, making it ideal for high-traffic items like restaurant menus and book covers.^[71]^[72]^[73]

Scientific and specialty applications

BoPET, also known as biaxially oriented polyethylene terephthalate, finds niche applications in scientific research and specialized technologies due to its high tensile strength, dimensional stability, and low permeability. In space exploration, aluminized BoPET films have been employed in solar sail prototypes for their reflective properties and lightweight nature. For instance, the Planetary Society's Cosmos 1 mission in 2005 attempted to deploy a solar sail using 5-micrometer-thick aluminized BoPET sheets spanning 600 square meters, aiming to demonstrate photon pressure propulsion, though deployment failed due to launcher issues. Pressure balloons for atmospheric research utilize BoPET envelopes to maintain constant volume at high altitudes, enabling long-duration flights for studying wind patterns and cosmic rays.^[74] In laboratory settings, BoPET serves as a versatile material for advanced fabrication and analytical techniques. Vacuum bagging processes for composite materials often employ BoPET films, such as Mylar, as release layers to achieve smooth surface finishes and prevent resin adhesion during curing under vacuum pressure, typically at thicknesses of 25-50 micrometers.^[75] For filtration in chromatography, track-etched BoPET membranes with precise 0.2-micrometer pore sizes are used to separate biomolecules and particulates; these hydrophilic polyester track-etched (PETE) filters offer high solvent resistance and uniform porosity, facilitating reproducible results in high-performance liquid chromatography (HPLC) applications.^[76] Acoustic technologies leverage BoPET's exceptional stiffness-to-weight ratio, which minimizes distortion in high-frequency reproduction. In tweeter speakers, Mylar diaphragms—typically 25-50 micrometers thick and dome-shaped—enable extended frequency responses up to 40 kHz with low resonance, as seen in neodymium bullet tweeters like the B&C DE35, where the material's tensile modulus exceeds 4 GPa.^[77] For vibration damping in microphones, metallized BoPET films act as compliant barriers to isolate capsules from mechanical noise, preserving signal integrity in condenser and dynamic models. Medical applications highlight BoPET's biocompatibility and barrier properties in specialized contexts. Sterilization wraps utilize BoPET films for their chemical resistance and ability to maintain sterility post-processing, such as in ethylene oxide or steam cycles; FDA-cleared pouches combine BoPET with Tyvek for breathable yet microbial-impermeable enclosures, supporting up to one-year shelf life for surgical instruments.^[78] Historically, BoPET served as the base substrate for X-ray films from the mid-1950s onward, providing dimensional stability and clarity for emulsion coating, though it has been largely replaced by digital imaging.^[79] In dialysis, copolyethylene terephthalate membranes, blending PET with polyoxyethylene glycol, enhance permeability for urea and creatinine removal while reducing protein adsorption; these copolymers achieve ultrafiltration coefficients of 10-20 mL/h/mmHg/m² in hollow-fiber dialyzers.^[80]

Environmental aspects

Recyclability

BoPET, a biaxially oriented form of polyethylene terephthalate (PET), carries the resin identification code 1, facilitating its recognition in recycling streams. Mechanical recycling of BoPET involves sorting the material from waste streams, followed by washing to remove contaminants, grinding into flakes, and re-extrusion into pellets or sheets for reuse. This process can achieve over 90% purity for post-industrial BoPET waste, enabling high-quality recycled products suitable for non-food applications.^[81] Chemical recycling offers a more thorough approach by breaking down BoPET into its constituent monomers. Glycolysis, a common method, uses ethylene glycol to depolymerize the polymer into bis(2-hydroxyethyl) terephthalate (BHET), which can be repolymerized into new PET.^[82] Depolymerization techniques, such as hydrolysis, can yield up to 95% terephthalic acid, a key building block for virgin PET production.^[83] Emerging enzymatic methods, developed in the 2020s, enable the degradation of BoPET in mixed films by using engineered enzymes to selectively hydrolyze ester bonds, achieving near-complete monomer recovery even from contaminated sources.^[84] Global recycling rates for PET films, including BoPET, are estimated at approximately 10% as of 2025, significantly lower than for PET bottles which reach around 30%, with post-consumer packaging often sorted using near-infrared (NIR) spectroscopy to identify and separate PET from other plastics in municipal waste streams.^[85]^[86]^[87] Despite these advances, recycling BoPET presents challenges, particularly with thin films under 12 μm thick, which tend to fragment and contaminate other recycling streams due to their low bulk density and tendency to cling to machinery.^[88] Multilayer structures incorporating BoPET require delamination for effective recovery, often necessitating advanced techniques like plasma treatment to modify surfaces and facilitate layer separation without degrading the material.^[89]

Sustainability and impact

The lifecycle assessment of BoPET reveals a carbon footprint of approximately 2-3 kg CO₂ equivalent per kg, encompassing production, use, and end-of-life phases, higher than that of glass packaging (around 1 kg CO₂ eq per kg) but comparable to or higher than paper-based alternatives (1-2 kg CO₂ eq per kg) for certain applications due to energy-intensive polymerization processes.^[90]^[91]^[92] This relatively efficient profile supports BoPET's role in lightweighting strategies, contributing to a projected global market size of $15-23 billion by 2025, as reduced material weight lowers transportation emissions compared to heavier substitutes like glass or metal.^[93]^[94] Despite these advantages, BoPET films contribute to microplastic pollution through fragmentation in waste streams, where thin film particles persist in landfills and waterways, exacerbating environmental contamination.^[95] Regulations such as the EU Single-Use Plastics Directive (2019) address this by restricting non-recyclable multilayer plastics, including those incorporating BoPET, to promote designs that minimize shedding and enhance recoverability, thereby curbing microplastic releases from packaging waste. The EU Packaging and Packaging Waste Regulation (PPWR), effective from February 2025, mandates all packaging be recyclable by 2030 and sets minimum recycled content targets, influencing BoPET use in compliant designs.^[96]^[97] Sustainability efforts in BoPET production include the adoption of bio-based variants, such as those using plant-derived glycols to achieve up to 30% bio-content by 2025, which integrates renewable feedstocks while maintaining material performance.^[98] Broader circular economy initiatives under EU frameworks target at least 30% recycled content for plastic packaging by 2030, with further increases planned toward higher shares in the 2030s, fostering closed-loop systems that reduce virgin material demand and align with waste hierarchy principles.^[99]^[100] In comparison to alternatives, BoPET offers superior gas barrier properties over BOPP, which exhibits higher oxygen permeability, making BoPET preferable for oxygen-sensitive goods despite BOPP's stronger moisture resistance.^[101] Relative to cellophane, a biodegradable option derived from cellulose, BoPET provides greater tensile strength and durability, though cellophane's natural decomposition avoids long-term persistence but at the cost of mechanical robustness.^[102] Recent advancements in recycled BoPET (rBoPET) further enhance sustainability, achieving up to 20% reductions in lifecycle emissions through efficient recovery processes that substitute virgin resin.^[103]

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1939 - First commercial production of polyethylene in UK by ICI. 1939 ... 1950 - ICI opens new factory at Redcar to produce Terylene. 1951 - Festival of ...Missing: date | Show results with:date<|control11|><|separator|>
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Celebrating ICI - SCI
The company was set up in 1926 through the merger of four of Britain's leading chemical companies – Brunner, Mond, Nobel Industries, United Alkali and British ...
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What Is Mylar | Mylar Definition, Uses, Properties - ThoughtCo
Aug 5, 2024 · The BoPet film was developed by DuPont, Hoechst, and Imperial Chemical Industries (ICI) in the 1950s. NASA's Echo II balloon was launched in ...
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70 Years of Mylar® Polyester Films
Apr 11, 2024 · In 1954 the first reels of Mylar® polyester film were manufactured in Circleville, Ohio on the world's first commercial BOPET production line. ...Missing: DuPont | Show results with:DuPont
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PET Protective Film
Nov 9, 2023 · ... 1955 Eastman Kodak used Mylar as a support for photographic film and called it "ESTAR Base".[5] The very thin and tough film allowed 6,000 ...
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Echo's Legacy | NASA Spinoff
Material selected was mylar polyester, with a reflective layer of tiny aluminum particles so fine that Echo's skin had a thickness half that of cellophane on a ...Missing: BoPET | Show results with:BoPET
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Satellite skin, Echo 1 | National Air and Space Museum
Aluminized mylar, lightweight and durable, provided the mirror-like surface. To manufacture this material, clear mylar was coated with aluminum in a vacuum.Missing: BoPET | Show results with:BoPET
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DuPont | Circleville Ohio | Kapton | Production Plant
Mar 13, 2019 · DuPont opened the Circleville plant in 1953 to make Mylar film, which is used in packaging. In the early 1960s, the plant started to produce ...Missing: commercial | Show results with:commercial
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What Are Polyester Films (BOPET) and Where Are They Used?
Feb 20, 2025 · They have great physical, chemical and optical properties. It is available in many variants as well; for example, Biaxially Oriented Polyester ...Missing: copolyester | Show results with:copolyester
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Sequential vs. Simultaneous Biaxial Film Stretching
Feb 15, 2022 · During simultaneous stretching, the web is restrained in the tenter clips and suspended in air while being stretched in both the machine and ...Missing: PET 1980s 2020s<|control11|><|separator|>
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Bopet Films Market Size, Share & Analysis 2033 Report
Sep 15, 2025 · More than 40% of packaging companies are shifting toward thinner, stronger BOPET films, with a 22% reduction in thickness in newer formats.Missing: 2020s | Show results with:2020s<|control11|><|separator|>
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Production process of BOPET (Biaxially Oriented Polyester) film
... oriented polyethylene terephthalate (BOPET) film is develop in the 1950's at first, through the development of decades, product develops into present ...
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What is Mylar? A Comprehensive Technical Guide to BoPET Film for ...
May 30, 2025 · Mylar is, in fact, a well-known brand name for a specific type of polyester film chemically known as Biaxially-oriented Polyethylene Terephthalate, or BoPET.
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BOPET-Biaxial stretching of film - LD PACK
May 22, 2025 · The biaxially oriented polyester (BOPET) film production process includes a casting system consisting of a die, chill roll, and casting attachment device.<|control11|><|separator|>
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Hostaphan® | Pütz Folien | Applications & Benefits
Hostaphan® is a high-performance BOPET film (biaxially oriented polyethylene terephthalate) with excellent mechanical and thermal properties. ... 200-250 MPa ...
[30]
[PDF] Polyester (PET) Film as a Substrate - The Society of Vacuum Coaters
It is also important to note that the polymerization reaction to form PET also produces low molecular weight species. The most common is the “cyclic trimer ...
[31]
What Is BOPET Film? The Complete Guide to High-Performance ...
Mar 18, 2025 · During biaxial stretching, polymer chains align in both directions, creating a balanced film with isotropic properties. This orientation ...
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[PDF] ZERO PERM FOIL VAPOR BARRIER - Insultherm
Tensile strength. Yield strength. Tear resistance (Elmendorf). 119 Mpa (17,300 psi). 70 N /cm (40 Ibs/inch). 400 g /mm. Flame spread. 15 ASTM E-84. Smoke ...Missing: BoPET | Show results with:BoPET
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Comparative data for plastic films - Mitsubishi Polyester Film GmbH
Here you can find a direct comparison of the properties of different plastic films in a clearly arranged table.Missing: polyethylene terephthalate
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Polyethylene terephthalate - Wikipedia
Polyethylene terephthalate is the most common thermoplastic polymer resin of the polyester family and is used in fibres for clothing, containers for liquids ...
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Ultimate Guide to BOPET Films - Pilcher Hamilton Corporation
Oct 22, 2025 · What are BOPET Films?: BOPET, or biaxially oriented polyethylene terephthalate, is a high-performance polyester film produced by stretching ...
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Refractive index of (C10H8O4)n (Polyethylene terephthalate, PET)
Complex refractive indices measurements of polymers in visible and near-infrared bands, Appl. Opt. 59, 2337-2344 (2020) (0.4-2 μm)
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Degradation of Mechanical Properties of A-PET Films after UV Aging
Oct 20, 2023 · Over a period of 670 days, the glass transition temperature of aged bottles in a dark room increased from 74 °C to 78 °C, and in a sunny outdoor ...Missing: BoPET continuous
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PET Film
### Electrical Properties of PET Film
[39]
Dielectric analysis of polyethylene terephthalate (PET) and ...
[20] PET has dielectric constant ~ 3.3 over a broad range of frequencies. PET has significantly higher dielectric loss which increases with temperature and ...
[40]
What is Polyester Film for Electrical Insulation | Dehui
Jan 15, 2022 · Polyester Film for Electrical Insulation Technical parameter ; Volume resistivity, Ω.m, 1.0×1014 ; Ralative dielectric constant(48Hz-62Hz), 3.0 ...
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Guide to Polyethylene Terephthalate (PET) - USEON
Oct 8, 2024 · ... PET production expanded accordingly. Using PTA as a raw material, PET polymer production involves two main reactions: first, PTA reacts with ...
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Uflex launches Flexpet F-PGB-12
Jan 19, 2017 · An untreated BOPET normal film of 12 micron has an OTR as high as 135 cm3/m2/day; a normal film requires in-line or off-line PVDC/EVOH coating ...
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Comparison of Packaging Films Based on Oxygen (OTR) and Water ...
Aug 2, 2025 · OTR (Oxygen Transmission Rate): The amount of oxygen that passes through a film over a given area and time. WVTR (Water Vapor Transmission Rate): ...
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Tek Tip - Polyester Surface Treatment | Tekra, LLC
Untreated PET has a surface energy of 42-46 dyne/cm; corona treatment yields 54 dyne/cm and above. Corona treatment is not uncommon, though its treatment ...
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PE Laminated | Materials, Benefits & Applications Explained
Sep 6, 2025 · For example, a common snack bag is often a PET/PE laminate. The outer PET layer provides strength, printability, and a glossy finish, while the ...
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The most common packaging film materials for coffee bag packaging
Apr 5, 2021 · Common materials include BOPP, PET, aluminum foil, metallized PET, AlOx PET, LDPE, and PLA biodegradable film for coffee bag packaging.
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[PDF] B-UHB-M - Outstanding Barrier Metallized BOPP Film
The film has exceptional barrier to oxygen, moisture, aroma and mineral oil. ... RATE (380 C & 90% RH). OXYGEN TRANSMISSION RATE. (230 C & 0% RH). F-1249. 0.91.Missing: ingress reduction
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Technology - Terphane
These films were approved for direct food contact by Anvisa (Brazil), FDA (the United States), and EFSA (Europe).
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[PDF] Regulatory Compliance Certificate - Süper Film
In accordance with Commission Regulation (EU) 10/2011, the overall migration shall not exceed 10 mg/dm² from plastic materials and articles, with the exception ...
[50]
BOPET Films - The Perfect Solution for Flexible Packaging Converters!
We manufacture a wide range of Biaxially Oriented Polyethylene Terephthalate (BOPET) Films under the brand name FLEXPETTM.
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Medium Shrink Film - Garware Hi-Tech Films
This mono-axially orinted co-polyester PET film has shrinkage of about 60% in transverse direction. This film is one side coated to have the slip effect.
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BOPET Packaging Films Market Size & Share Report, 2025-2034
The global BOPET packaging films market size was valued at USD 10.3 billion in 2024 and is estimated to grow at CAGR of 5.9% to reach USD 18.2 billion by 2034.Missing: 2020s | Show results with:2020s
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Why Monomaterial Films Are The Future Of Sustainable Packaging
PET-based monomaterial structures involve layering various PET films to achieve desired performance while staying within the PET recycling stream. This approach ...Missing: growth | Show results with:growth
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Why BOPET Film Is Ideal for High-Performance Electrical Insulation
Jul 17, 2025 · BOPET film delivers exceptional electrical insulation with dielectric strength up to 300 kV/mm and thermal stability from -40°C to 150°C.
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Polyester Film for Electrical Insulation - DyFilm - Coveme
These films are used for in motors, transformers, capacitors and cables, and the manufacturing of tapes and laminates. It is available as hazy (medium ...Missing: BoPET 25-50
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AT4004 Coil Insulation Polyester Tape Class B 130°C
AT4004 is a polyester tape for coil insulation, with high electrical strength, high breaking load, high temperature and solvent resistance, and is UL ...Missing: BoPET 25-50 μm
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Choosing the Right Flexible PCB Material for Smart Clothing
Jun 27, 2025 · PET: The Cost-Effective Alternative. PET, or polyethylene terephthalate, is a polyester material commonly used in lower-cost flexible PCBs.
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Transparent PET Flex PCB: What It Is & How It Compares To PI
Sep 9, 2025 · PET flex PCB is a circuit built on a clear polyester film. Consider the polyester flexible circuit to be a transparent, flexible board for ...Missing: BoPET | Show results with:BoPET
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ITO Coated PET Films - Diamond Coatings
Standard sheet resistances include 50 and 100 ohms/sq. Custom sheet resistances available on request. To aid handling/fabrication, Diamond Coatings ITO ...
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Touch Screen Layer ITO Film – Precision and Transparency - wanty
Aug 18, 2025 · Over 85 percent of light can be transmitted through ITO films ... ITO Coated PETI (or) B (or) U Coated PET Film. Applied to flexible ...
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Metallized BOPP BOPET Film Mpp MPET Film for Capacitor Use ...
Rating 4.0 · Review by MIC_BUYERBase film, PP, PET. Normal thickness, 2.0μm ~12.0μm, 1.9μm ~12.0μm. Margin type, Single, two margins. Coating metal, Zinc-Aluminum alloy,Aluminum.
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The Self-Healing Affect of Metallized Capacitors - ECI
Self-healing is the ability of a metallized capacitor to clear a fault area where a momentary short occurs due to dielectric breakdown under voltage.
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Radiant Barriers Films For Insulations. - PE Coated Metalized Film ...
The material provides excellent insulation: reflects up to 97% of radiant energy in addition to reflective sheeting resisting other types of heat transfer from ...
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Metalized PET Film for Thermal Insulation - ONE Plastic
May 25, 2023 · Explore the thermal insulation capabilities of metalized PET film. Learn how it improves energy efficiency, reduces heat transfer, ...Missing: metallized | Show results with:metallized
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Reflective Metallized PET Film
Due to its reflective properties, it helps in reducing the heat entering the interior of vehicles and buildings, thereby reducing the energy costs significantly ...
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98% Ultraviolet Rays Block Anti-UV BOPET Film
Anti-UV BOPET Film can block more than 98% ultraviolet rays in sunlight, protect body and eyes from UV injury, defer the aging on interior decoration.
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100% UV Reflective Automotive Window Tint Film UVT-5095
Sunvase® UVT-5095 automotive window tint film is middle level visible light transmission,which is 50% VLT.but very high IR rejection rate and 100% UV blocking.
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Sustainable Window Films: Eco-Friendly Solutions for Buildings and ...
Sep 27, 2025 · Automotive tints, primarily BOPET-based, provide UV protection, heat rejection (up to 65%), and privacy. Ceramic-based tints, like LLumar's CTX ...Solar Control Films · Automotive Window Tints · Environmental Impact And...<|control11|><|separator|>
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Marine - Tekton Performance Films
Marine tinting is often overlooked, but window films help to reduce your operating costs by reducing the amount of incoming solar heat. Cooling your vessel is a ...Missing: BoPET interlayers control e IR
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Heat and Glare Control Boat Window Films - Solarglide Limited
Solarglide's Type Approved window films reduce solar heat and glare, while leaving the windows fully transparent, with a contemporary adhesive window tint.<|control11|><|separator|>
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Low-E Window Film For Heat Reduction - Solar Gard
Solar Gard low emissivity window film provides year-round heating & cooling savings. Featuring Ecolux Low-E and Steel AG Low-E products.Missing: BoPET interlayers IR reflection aviation
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https://www.cloudflexfilm.com/bopet-film-for-packaging/
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Anti Scratch Lamination Film: 9H Hardness & 500+ Test Results
Aug 12, 2025 · Discover how PET-based anti-scratch lamination film achieves 9H hardness and 550+ Taber cycles, extending product life by 3 years.
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BOPET Film for Packaging - CloudFilm
May 17, 2024 · The film also exhibits low haze and high light transmission rates, making it an excellent choice for applications requiring a clear view of ...
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PET Film - Mylar® - ACP Composites
Out of stockMylar is a multi-use polyester (PET) film which can provide a smooth glossy finish on the surface of the laminate when vacuum bagging.
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PETE Track Etched Membrane | GVS
PETE Track Etched Roll Membrane, Pore Size 0.2µm, Width 12'', Length 650ft. Pore size (µm): 0.2. Thickness (µm): 12. Width: 12'' (30.5cm). Lenght (ft): 650.
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https://www.accessdata.fda.gov/cdrh_docs/pdf22/K221377.pdf
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Ultra Thin 8 Micron Aluminum Metallized Mylar Film For Microphone ...
In stock Rating 3.6 (90) · $452.97 deliveryBOPP Thermal Lamination Film is not only heat sealing, but also printable. It is mainly used in composite, printing, bag making and other industries.
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[PDF] December 22, 2022 Wipak OY Amanda Singleton Consultant ...
Dec 22, 2022 · After completion of the sterilization process, the Pouch maintains sterility of the enclosed medical devices until the seal is opened. These ...
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History of Film Types Timeline - National Park Service
Dec 18, 2019 · 1955 – First polyester-based films (most commonly found in: sheet films after 1970s, x-ray films after 1955, aerial films after 1960s). NB ...Missing: BoPET | Show results with:BoPET
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Transport properties of a new dialysis membrane - Brauman - 1971
The dialysis and flow properties of a selected copolymer system, consisting of polyethylene terephthalate and polyoxyethylene glycol, have been studied in someMissing: BoPET | Show results with:BoPET
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[PDF] technological considerations regarding the mechanical recycling of ...
packaging waste (purity of over 90%) can be achieved in continuous flow and at low cost. Acknowledgements. This work was supported by a grant of the Ministry ...<|control11|><|separator|>
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Highly Efficient, Co-solvent Assisted Glycolytic Depolymerization of ...
Aug 9, 2025 · This study presents an efficient solvothermal process for the depolymerization of PET into bis(2-hydroxyethyl) terephthalate (BHET) using co- ...
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[PDF] Chemical Recycling of Poly(ethylene terephthalate) (PET) by ...
May 20, 2018 · The process results in a good yield (97%) to terephthalic acid (TPA). The catalyzed glycolysis of post-consumer PET was carried out in a short ...<|control11|><|separator|>
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Efficient Recycling of PET-PE Multilayer Packaging Materials ... - NIH
May 29, 2025 · This study demonstrates the applicability of enzymatic hydrolysis for the recycling of PET-PE multilayer materials and highlights its general ...Missing: 2020s | Show results with:2020s
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28% of PET bottles are being recycled, The Recycling Partnership ...
Aug 20, 2024 · PET bottles are now estimated to have a 28% recycling rate in residential systems, according to data shared by The Recycling Partnership. A PET ...<|control11|><|separator|>
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NIR Plastic Sorting & its Impact on Packaging - Paramount Global
Jun 13, 2024 · NIR plastic sorting uses a near-infrared scanner to detect the wavelength signature of resins, for example separating PET from HDPE bottles.
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Plastic film recycling has a problem with staying power
Oct 24, 2025 · Plastic film recycling has a problem with staying power. As technological advancements contribute to more facilities opening to mechanically or ...
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[PDF] Improved recyclability of complex plastic waste using low ...
The technology proposed is the treatment of the waste fractions in a plasma reactor and thereby etch away the parts of the plastic materials that prevent the ...
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A review of carbon emissions in the lifecycle of plastics production
PVC has the highest carbon footprint at 7.83 kg CO2-eq (Liang and Yu, 2023). PE follows, with HDPE at 2.9 and LDPE with 2.6 kg CO2-eq (Benavides et al., 2020).Missing: BoPET | Show results with:BoPET
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Replacing Plastics with Alternatives Is Worse for Greenhouse Gas ...
Jan 31, 2024 · In comparison, aluminum cans release twice the emissions of PET bottles, and glass bottles release three times the emissions. PET has the lowest ...
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Biaxially Oriented Polyethylene Terephthalate (BOPET) Films
Jan 22, 2025 · The Biaxially Oriented Polyethylene Terephthalate (BOPET) Films Market size was valued at USD 16.7 billion in 2023 and is expected to reach USD 28.4 billion by ...
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BOPET Films Market Size, Trends and Growth Forecast Report - 2032
Rating 5.0 (227) Oct 1, 2025 · The BOPET Films Market is projected to grow from $ 13.50 Billion in 2024 to $ 21.20 Billion by 2032, at a CAGR of 5.9% from 2025 to 2032.<|control11|><|separator|>
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[PDF] Comparative environmental life cycle assessment of PET/LDPE ...
Sep 21, 2022 · When reaching a hypothetical 100% recycling rate for packaging films, 36%, 40% and 30% reductions in global warming potential (GWP) are observed ...<|separator|>
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Single-use plastics - Environment - European Commission
The EU is tackling 10 single-use plastics, like cotton bud sticks and plastic bags, by banning them where alternatives exist, and limiting others through ...
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Sustainable Plastic Films: BOPET, BOPP, CPP, Blown, and ...
Sep 26, 2025 · Bio-Based Options: Green BOPET films with 30% bio-MEG reduce carbon emissions by 20%. Lower Emissions: PP-based films emit 1.7 kg CO2e/kg, less ...
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New EU Packaging Regulation: Key Changes for Electronics ...
Feb 20, 2025 · Key changes include stricter recyclability, PFAS limits, new labeling, mandatory recycled content, and increased reporting for electronics ...
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Recycled content minimums - Washington State Department of ...
By 2036, all packaging for covered products must contain at least 50 percent PCRC, except for trash bags, which will reach a minimum of 20 percent by 2027.
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BOPP vs BOPET: Understanding Films - PMMI ProSource Directory
May 24, 2020 · Orientation (or “stretching”) thins the polymer web proportionally to the orientation or stretch ratios. For example, to get to a 1-mil finished ...<|control11|><|separator|>
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BOPP film VS BOPET film VS BOPA film - Knowledge - Weshare
Jul 31, 2023 · The performance difference between BOPP film, BOPET film and BOPA film is shown in the table ... and moisture permeability, and poor heat ...Missing: comparison | Show results with:comparison
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[PDF] Comparative Environmental Life Cycle Assessment of PET/LDPE ...
Sep 22, 2022 · The chemical recycling of films has reduced the GWP impacts by 24% for PET/LDPE films, 51% for mono PET films, and 27% for mono PE compared to ...