Poligal BOPP Film Production Plant, Wroclaw, Poland


Poligal, one of the leading biaxially oriented polypropylene (BOPP) film manufacturers in Europe, started construction on its new BOPP film production plant in Poland in January 2015.

Part of the Barcelona-based Peralada Group, the company produces a wide range of films used in packaging for consumer products, labels and lamination.

The new plant involves an investment of €30m ($34m) and will help Poligal to become competitive in product segments, including label films. It will also ensure the company to strengthen its capabilities in film development for speciality applications.

Project background

The new plant is being built as part of Poligal's strategic plan 2012-2016, which emphasises on growth, internalisation and technological development.

"The new plant involves an investment of €30m ($34m) and will help Poligal to become competitive in product segments, including label films."

By increasing the number of investments in fast-growing markets, the company aims to grow in size and expand its geographical coverage. However, Poligal intends to remain as a medium-sized player with more focus on producing and delivering high-quality products and top-quality service, in addition to maintaining healthy relationship with clients.

Poligal's BOPP film production plant location

The new plant will be located in Skarbimierz, which is located 60km south of Wroclaw, the largest city in western Poland.

Skarbimierz was chosen as an ideal location as it is at the heart of the fast growing flexible packaging market in Poland and is just two hours away from Germany. By residing close to clients, the company aims to offer quick service, which is much essential in the European markets.

BOPP plant details and production

The new plant will feature an 8.7m-wide, five-layer BOPP extrusion line supplied by Brückner Maschinenbau. The plant is scheduled to become fully operational by third quarter of 2016.

Upon completion, the plant will have a production capacity of 40,000t/y of BOPP film. It will adhere to the European standards and Poligal policies of safety and environmental protection.

Poligal is also planning to add metallisation capacity to the plant. Along with the existing plants in Spain and Portugal, the new plant will enable a strong backup production and therefore help the company to provide its European converters and end users with a wide range of products.

Sustainability features of Poligal's new plant

The entire lifecycle of the products at Poligal follows sustainable approaches, including the use of energy-efficient measures and raw materials, minimising waste and emissions.

Electricity and useful heat will be generated in the plant using cogeneration process. The heat will be used for the production processes whereas the cold resulting from the process will be used for conditioning the premises, thus helping to reduce the electricity consumption at the plant.

Stora Enso is a renewable materials and packaging company with its headquarters in Finland and Sweden.

The plant will have a recycling unit to reprocess the waste generated during the extrusion process. The processed waste will be reused for producing film grades for specific applications.

Features and applications of BOPP film

BOPP is a polypropylene film used in a variety of packaging applications. BOPP film is of low density and has good mechanical, optical and barrier properties because it is produced by stretching PP film in both the machine and cross directions.

BOPP films are available in different sizes and types such as films of 12µm to 60µm thickness, as well asplain, multi-layer, high-clarity, opaque and metallisable films.

BOPP films offer excellent clarity, low-electrostatic charge, good dimensional stability and flatness, resistance against oil and grease, barrier properties against water vapour and good recyclability, as well as puncture and crack resistance at a wide range of temperatures.

BOPP films are traditionally used for packing snacks, confectionaries, crisps and noodles. Modern applications of the film include wrap-arounds, shrinkable labels, synthetic paper and high-barrier films.