Experiencing Scuffing on Your Packaging? Here’s How to Combat it
It’s essential for your packaging to ensure product protection and maintain a clean, scuff-free appearance, especially for consumer-facing goods. While antiblocking agents help prevent film layers from sticking together, they can sometimes leave unwanted marks or scuffs on your packaging. These blemishes can affect product presentation and even reduce consumer confidence. With the right strategies, you can minimize or eliminate scuffing without sacrificing performance.
What are Antiblocking Agents?
Antiblocking agents are used in flexible packaging to reduce the adhesion between film layers or surfaces. When films are manufactured, especially thin ones like polyethylene or polypropylene, they tend to stick together due to smooth surfaces and static electricity, making them difficult to separate. Antiblocking agents create a micro-rough surface that minimizes contact area between layers.
The most common form of antiblocking agent is silica, a finely ground sand. It may also be referred to as diatomaceous earth or crushed sea shells. Talc, a very soft crushed rock, is also an option. Lastly, antiblocks may also be drawn from feedstocks.
Why Do They Cause Scuffing?
When examined under an electron microscope, the surface will have a “moonscape” appearance with peaks and valleys. Scuffing of the film surface can sometimes result as an undesirable effect of antiblocks. Scuffing can happen at any moment when the films or bags slide against each other. It might happen during winding at extrusion, unwinding during converting, shipping and packaging, or handling. As a result, the packaging may have a powdery appearance. It may be a visual concern to some, but it is not harmful to the products inside.
How to Avoid Packaging Scuffs from Antiblocking Agents
There are several considerations to keep in mind that can help you avoid scuffing.
Type of Antiblock
Different types of antiblocks will be more or less prone to scuffing. Choosing a lower-abrasion antiblock material can help reduce scuffing.
Particle Size
Particle size and consistency of particle size play a big role in scuffing. Large or irregularly shaped antiblock particles can create more micro-abrasions on the film surface. A finer, more uniform particle distribution reduces the potential for scuffing.
Dispersion
Poor dispersion of antiblock particles can create uneven surfaces, leading to localized areas of scuffing. Your packaging manufacturer should optimize the masterbatch formulation to improve particle distribution.
Roll Wind
If rolls are wound too tightly, it can increase pressure between the film layers. This can potentially embed particles into the surface and increase scuffing. Looser winding may reduce friction and lessen surface damage.
Boxing and Packaging
Movement within boxes during shipping or storage can cause scuffing as film layers rub against each other. Proper packaging techniques, such as interleaving sheets or optimizing case fit, can help.
Gauge
Thicker films contain higher concentrations of antiblock additives, which may lead to increased surface roughness and scuffing risk. Adjusting the formulation for heavier-gauge films can help mitigate this issue.
Consumer Handling
In retail environments, consumers may handle packaging films, which can cause scuffing. Using coatings, laminated structures, or alternative film blends can help improve scuff resistance.
Work with PPC Flex for Your Packaging Needs
At PPC Flex, we have everything you need to create high-quality packaging solutions. As an advanced flexible packaging manufacturer, we’ve been providing powerful, purposeful packaging solutions for decades. Through our experience, we’ve seen the profound impact packaging can have on a business. That’s why we develop a deep understanding of your needs to deliver the best packaging, every time. We’ll help you grow by finding the right flexible packaging solutions that preserve products, create incredible shelf presence, and deliver a better product experience.
When you work with us, you get an experienced team that handles everything from the initial design to the final shipment. We’ll handle all the complexity so you can focus on what truly matters — growing your business.
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Want to learn more about what we can do for you? Reach out to our team for an initial consultation.