Flexible Packaging

Non-rigid packaging structures used to package and protect products. According to the Flexible Packaging Association, flexible packaging is any package or any part of a package whose shape can be readily changed. Common examples of flexible packaging are bags and pouches.

Converting is simply changing something into a different form. In the case of flexible packaging, converting would be the process of utilizing films, foils and resins and through the process of lamination, forming them into a multilayer structure.

Extrusion coating is the coating of a molten web of synthetic resin on to a substrate material. The actual process of extrusion coating involves extruding resin from a slot die at temperatures up to 610°F/320°C directly onto the moving web, which is then passed through a nip consisting of a rubber covered pressure roller and a chrome plated cooling roll. The latter cools the molten film back into the solid state and also imparts the desired finish to the plastic surface.

Learn more about extrusion coating.

Extrusion lamination uses a similar process as extrusion coating, except the extruded hot molten resin acts as the bonding medium to a second web of material.

Learn more about extrusion lamination.

Adhesive laminating is a process that laminates multiple webs of material together using adhesives instead of molten plastic resin. There are multiple types of adhesive lamination systems for flexible packaging, including solventless, solvent-based, and water-based.

Mono-extrusion is the extrusion of a single resin, whereas co-extrusion is the simultaneous extrusion of two or more different resins into a sandwich-like film with clearly distinguishable individual layers.

No, we supply custom-engineered, printed or unprinted:

• multilayer flexible packaging rollstock
• premade pouches (such as stand-up pouches) which are formed, filled, and sealed by contract packaging companies or by manufacturers with packaging equipment

We work with an extensive network of contract packaging companies and can refer you to a contract packaging company if you need forming, filling, and sealing capabilities.

Generally, in order for us to provide a quote we need details such as company name, contact information, item/project name, structure, web width, quantities, and specifications.

If you aren’t sure what flexible packaging structure you need, we have an experienced team of packaging engineers that can assist with structure suggestions and provide resources such as product/package compatibility testing. If you need structure suggestions, it is helpful for us to know the type of filling equipment that will be utilized, the ingredients of the product, and the method of distribution.

For printed items, additional details that will need to be determined are the cut-off, package size, and the number of colors in the art.

Our experienced service team is available to walk you through the process.

Typically, for standard new orders, lead times are four to six weeks, and for repeat orders, lead times are two to four weeks. Raw material availability may add to these time frames.

If you're under tight deadlines, let us know and we'll do our best to meet your needs.

For lead times on ExpressWeb narrow web packaging films, please see the Narrow Web Flexible Packaging FAQ's below.

Once a credit application has been approved, the four categories of information that need to be established are:

• Purchase Order: Includes information on quantity, item identification, requested delivery date, shipping location, invoicing location, special instructions, etc.
• Artwork: Artwork files, PMS colors or samples of specific color matches, and contact information.
• Layout: Front and back copy orientation, graphic position, eyespot location, size, etc.
• Specifications: Material structure, roll dimensions, etc.

Please contact us for assistance with placing an order.

Glenroy’s packaging engineers can reverse engineer a supplied package and offer a structure suggestion based on the results. This is referred to as “material breakdown analysis” or “analysis of construction.” This process takes approximately one week from receipt of a sample.

Learn more about reverse engineering.

Glenroy offers many services that will help assist your organization in understanding materials that are fit for use. Glenroy can provide suggestions and product/package stability testing, but it is up to each product manufacturer to understand how their product acts over time in a specific type of packaging.

Learn more about custom engineered laminations.

Glenroy does provide material used in child resistant applications. We can offer a material suggestion based upon the application and final usage. The only way to truly deem a structure child resistant is to have child-resistant protocol testing performed.

This is a process that helps to determine if a material is resistant to chemical degradation or physical change caused by the product.

Learn more about product/package compatibility testing.

Product/package compatibility testing is a screening process to determine if a given product might have any adverse effects on the packaging structure. The most common adverse effect is a reduction in the adhesion levels between the layers of the structure. The reduction in adhesion levels can range from slightly noticeable to full delamination. The more severe the interlayer adhesion level reduction, the more difficult it will be to tear open the package and the lower the package burst strength will be. The product/packaging compatibility testing will help to determine the most cost effective structure for the product.

Learn more about product/package compatibility testing.

We request that you send between 20 and 32 ounces of product.

Barex is an impact modified acrylonitrile copolymer sealant film. Raw materials manufacturers have ceased production of the material, but various Barex alternatives are available. For example, Anobex™ has very similar properties to Barex.

Yes, we offer various options that can meet similar requirements as Barex. Please contact us for further details on what flexible packaging films may be a good candidate for your needs.

Anobex™ is an acrylonitrile methyl acrylate copolymer with excellent chemical resistence and gas barrier properties. It is a high-barrier material designed for applications where chemical resistance, oxygen barrier, gas barrier, flavor protection, and/or odor protection are critical.

Surlyn is a specialty sealant resin made from ethylene acid copolymer.

Surlyn is known for its high hot tack strength, wide range of sealability, and ability to seal through contaminates, such as powders. Surlyn also provides an excellent barrier for oily or greasy products.

EAA (Ethylene acrylic acid) is a copolymer of ethylene and acrylic acid monomers EMA (ethylene methyl acrylate) & EMAA (ethylene methacrylic acid) do not bond as well to aluminum foil.

LLDPE stands for linear low-density polyethylene and is a substantially linear polymer (polyethylene). LLDPE has higher tensile strength and higher impact and puncture resistance than LDPE. It is very flexible and elongates under stress. It can be used to make thinner films, with better environmental stress cracking resistance. It also provides good resistance to chemicals and to ultraviolet radiation.

MVTR stands for moisture vapor transmission rate, or the rate at which water vapor passes through a substance. OTR is Oxygen Transmission Rate, or the rate at which oxygen passes through a substance.

Typically customers choose sealant films in the 3.0 mil mm range for this type of application. However, not all sealant films perform the same at this thicker gauge. Please contact us for assistance in engineering flexible packaging structures for your sample packets.

Typically customers choose sealant films in the 2.0 mil mm range when packaging for a mailer.

In the flexible packaging industry, MI means "thousand impressions".

MSI means "thousand square inches".

MMSI means "million square inches".

Yes, in addition to our stocked ExpressWeb flexible packaging films, we can custom-manufacture unprinted flexible packaging laminations ideal for narrow web printers.

Glenroy’s stock narrow web films are carried in 40", 45" & 52" widths, which can be slit to accommodate the needs of an application.

Please visit our narrow web flexible packaging page for further for details on our ExpressWeb surface printable flexible packaging films.

ExpressWeb surface printable flexible packaging films are stocked and ready to ship within two to three business days.