Brückner, FP Corporation and the really big thing

Contract conclusion for a new stretching line for ultra-thick simultaneously stretched film applications

Japanese FP Corporation (FPCO), a leading manufacturer of food containers, has made a groundbreaking advancement in film technology with the development of the world’s first ultra-high-rigidity biaxially oriented polypropylene (OPP) sheet. This innovation is the result of a collaboration with many different companies and Brückner Maschinenbau with their advanced film stretching technology – and has now culminated in a contract for a new stretching line.

A decade of innovation and collaboration

Over the past 10 years, FPCO has conducted extensive research and testing at Brückner’s technology center and pilot line. This partnership has optimized FP Corporation’s material as well as Brückner’s simultaneous stretching technology LISIM^® to produce high-class thick BOPP films for a variety of applications, ranging from food containers to industrial uses such as for the automotive industry.

Revolutionary new film types

FP Corporation has successfully developed two new types of polypropylene sheets:

1. The world’s first ultra-high-rigidity biaxially oriented polypropylene sheet for various applications

Innovative food trays

The new BOPP sheet has pioneered a new category of food tray used for “frozen to microwave” due to superior cold & heat resistance. Namely, meeting the growing demand of frozen foods in the field of food trays, the newly developed BOPP sheet can be used for production of a food tray for frozen food and can also be used for microwave oven cooking as it is.

Industrial applications and home furnishings

• Inherent characteristics as PP: Light weight, chemical resistance, recyclability
• Characteristics from biaxial stretching: Transparency & high gloss, high rigidity & toughness, cold resistance
•  Remarkable characteristics: Excellent formability, decorativeness, mono-material

The new OPP sheet with a thickness of 150-300 microns, exhibits excellent mechanical features such as high rigidity and high toughness, when utilized as a sheet for “In-Mold Labeling” (IML), rigidity and toughness of the molded article can be significantly enhanced. Therefore, compared to a conventional IML article, the amount of injection resin can be decreased to 20% by mass in order to attain the same level of mechanical strength of the conventional IML article.

Moreover, if the sheet is decorated with printings on injection side, it can be produced a decorated IML article that contributes to paint-free system. This makes the IML article suitable for automobile parts and other industrial parts, and this advancement contributes to reducing environmental impact.

2. A laminated OPP sheet

• Features: High rigidity, impact resistance, toughness, light weight, thermo-formable, and excellent decorative properties due to superior transparency
• Applications: Automotive, home furnishings, solar cells, and as a partial replacement for materials like steel, aluminum, and carbon-fiber-reinforced plastics

The laminated OPP sheet with a thickness of 1-3 mm is suitable as building material, including windows, waist-high walls, carport roofs and solar panels, supporting materials due to its transparency, mechanical strength, and light weight. Furthermore, when arranged as a decorated sheet, it can be used in several fields such as automobile exterior, automobile interior, housing & furnishings. In particular, when used as exterior material for automobile, it also enables paint-free system, and significantly contributes to the reduction of environment impact.

Boris Pasternack, Brückner Maschinenbau’s Head of Sales East Asia says: “After more than 10 years of intensive collaboration with FP Corporation, we are thrilled to see this innovative development move into production – a remarkable example of German-Japanese partnership and pioneering spirit.”

Yoshihiro Nishie, FP Corporation’s General Manager of Comprehensive Research Institute and Basic Technical Engineering Dept. adds: “Over a decade since the commencement of foundational research, the world's first BOPP sheet technology has been successfully developed, thanks to a fruitful partnership with Brückner. This achievement can be attributed to the culmination of both companies' technical expertise.”

Future Prospects

The new OPP sheets have already received positive recognition across various industrial fields. FP Corporation is currently designing a new plant to start production in late 2027, with plans to market these products through alliances with related industries. This collaboration not only highlights the innovative capabilities of both companies but also sets a new standard for sustainable and high-performance materials in the industry.

First picture below shows from left to right: Mr. Yoshihisa Saito (Assistant to the Executive General Manager); Mr. Hiroshi Ogawa (Executive Vice President and Director, Executive General Manager of Global Trading Division), both FP Corporation; Mr. Boris Pasternack (Head of Sales East Asia); Mr. Hosoya Hiroyuki (Senior Sales Representative), both Brückner Maschinenbau