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Engineered Polythene: Solving Problems with Polymer Engineering

All packaging boils down to problem-solving; stuff needs protection, branding, and a way of holding it all together. Thanks to never-ending material innovation, polythene keeps developing as an excellent choice for solving those problems.

Polymer engineering and custom polythene have transformed industries that require advanced solutions – because polythene is an extraordinarily customisable material. It’s such a prolific material because it’s the most adaptable option for today’s demanding industrial and logistics applications; no other material comes close.

But at the root of it all, polythene engineering starts with the problem. And as one of the few UK polythene manufacturers, it’s our job to solve those problems for our local and global customers.

Let’s look at the ways we work with our materials and manufacturing processes to deliver custom polythene solutions for demanding applications. 

 

Abstract image of neon lights in rainow colours on a black background. Looks almost like an image from the LHC – or a physics experiment.

 

Polymer problem-solving: developing tailored solutions

Engineered polythene is all about problem-solving. Every industry has unique demands of its packaging – from high durability and chemical resistance, to extended flexibility and temperature control. Sometimes, addressing these needs means developing custom polymer blends from the ground up, using specialised additives, or adapting the manufacturing process to create different results.

Using a combination of methods, blends and additives, we’re able to create advanced polythene materials tailored to meet highly specific requirements.

Designing polymer blends and additives for enhanced performance

While creating custom polythene does go through repeatable phases, it is definitely not a one-size-fits-all process! For example, some industries (like food and medical) cannot tolerate anything but virgin material – so recycled blends are out of the question. This may also be the case where strength is paramount, as recycled material (while still perfectly usable for most applications) can be less robust than a first-time extrusion.

On the flipside, in industries where cost is everything, recycled blends offer tax advantages – and using MDPE as the base polymer allows for equivalent strengths at far thinner gauges than LDPE, offering significant weight savings over large quantities.

It all depends on the problem that needs solving; cost, weight, sterility, strength… And these aren’t necessarily unique to single industries or applications. 

By blending polymers and using additives, manufacturers can enhance the properties of polythene. Polymer engineering allows for modifications in molecular weight, density, and the branching of the polymers to achieve desired properties – and stretching at different angles during extrusion can create a “grain”, improving tensile strength in all directions.

Additives play a crucial role, too – whether it’s UV inhibitors for sun resistance, anti-static additives for electronics, or antimicrobial additives for healthcare. This huge range of possibilities makes polythene versatile enough to serve an incredibly diverse catalogue of industries; from medical and food packaging, to construction.

We have also reverse-engineered polymers for our customers, to solve complex problems with existing materials while offering a more bespoke solution.

Advanced manufacturing techniques in polythene production

Manufacturing advanced polymers into a final product involves a sequence of processing steps designed to optimise the material’s properties. Extrusion, rolling, stretching, and controlled cooling are employed to control the molecular structure of the polythene – which results in enhanced durability and performance. Overseeing the entire manufacturing process allows us greater control over physical characteristics, from flexibility to transparency and thickness. This gives us an adaptable framework to meet different industry standards.

The important of expertise

We have been an active member in the polythene manufacturing world since 1968.

With decades of expertise, tailoring solutions for different industries has become second nature. By integrating our knowledge of polymer science with the practical needs of various sectors, NPF Packaging can address and solve the specific problems of each company. 

From consumer products to automotive and healthcare, our case studies show how engineered polythene packaging can be modified at the polymer level, to serve a vast range of industrial applications.

Smart design leads to better packaging

Beyond the base polymer and additives, engineered polythene benefits from a range of smart design features that boost its functionality. Colour additives aren’t just useful for branding; they are often required for compliance. But, aesthetics are useful for product differentiation, too, and with custom printing, cost-savings on printed literature, labelling and paper can be made.

Smart additives provide properties like flame resistance, anti-fogging, and chemical barriers essential for food and medical packaging.

The versatility of polythene lets us create precisely what your industry needs. With properties that range from durable to lightweight, and colours that are anything from vivid opaque to near-transparent, engineered polythene and our expertise in solving packaging problems is what sets us apart.

Get custom polymer blends – and packaging designed for your product

Talk to the polythene experts at NPF Packaging – and design your own custom polythene packaging. Enquire online to get a quote now, or call us on 01773 820415 to find out more about our manufacturing and design process.