BOPP Films

Biaxially Oriented Polypropylene — BOPP — is one of the most widely used substrates in flexible packaging. It is produced by stretching a polypropylene film simultaneously in both the machine direction and the transverse direction, a process that aligns the polymer chains and dramatically improves the mechanical, optical and barrier properties of the base material. The result is a stiff, clear, printable film with excellent moisture barrier, high tensile strength, good chemical resistance and a surface quality that accepts print and lamination extremely well.

At NytronPackaging, BOPP film is a core material across many of our product ranges — from printed roll stock and laminated pouches to labels, wraps and overwraps for food, tobacco, bakery and consumer goods applications. We supply BOPP-based structures both as a finished packaging format and as a component substrate within more complex laminated film constructions.

---

How BOPP Film Is Made

The production of BOPP film begins with the extrusion of a thick polypropylene sheet, which is then stretched — biaxially, meaning in two directions — using a tenter frame process. Stretching in the machine direction increases tensile strength and reduces elongation. Stretching in the transverse direction improves stiffness, dimensional stability and optical clarity. The combination of both gives BOPP its characteristic balance of properties that neither unstretched polypropylene nor mono-axially oriented film can match.

After orientation, the film surface is corona treated to improve ink adhesion and lamination bond strength. The film may also be coated — with PVDC, acrylic or metallised coatings — to enhance barrier properties, improve heat sealability or achieve a specific surface appearance such as matte, pearlescent or metallised silver finishes.

Types of BOPP Film We Supply

Not all BOPP film is the same. Different grades and coatings are suited to different applications, and specifying the correct film for your product and process is important for achieving the right result on your filling and sealing line as well as in the finished package.

Clear BOPP is the standard grade — transparent, glossy and suitable for direct print or as an outer lamination layer over a sealant web. It is widely used in snack food packaging, bakery overwraps, biscuit packaging and label stock.

Heat-Sealable BOPP has a co-extruded sealant coating on one or both sides, allowing it to be sealed directly on conventional heat-seal equipment without the need for a separate sealant layer. This makes it particularly efficient for overwrap and flow wrap applications on high-speed lines.

Metallised BOPP is produced by vacuum depositing a thin layer of aluminium onto the film surface, creating a metallic appearance and significantly improving both oxygen and moisture barrier properties. It is widely used in snack, confectionery, tobacco and personal care packaging where barrier performance and shelf presence are both important.

Pearlised BOPP incorporates a mineral-filled layer that gives the film a white, opaque, pearl-like appearance. It is commonly used in labels, confectionery packaging and applications where a premium, tactile surface finish is required.

Matte BOPP has a surface treatment that reduces gloss and creates a soft, flat finish. It is increasingly used in premium food, cosmetic and health product packaging where a matte aesthetic communicates quality and sophistication.

White BOPP is an opaque white film used where full opacity is required — for example in labels for dark or coloured containers, or in packaging where the product should not be visible through the film.

BOPP film in roll form ready for printing and conversion

Applications of BOPP Film

BOPP film is used across a remarkably wide range of packaging applications, which is a testament to how versatile the substrate is when specified correctly and combined with the right coatings, laminations and print processes.

In the food sector, BOPP is the standard film for snack food bags, biscuit and cracker packaging, bread bags, bakery overwraps, confectionery twist wraps and flow wraps, noodle packaging and dry food pouches. Its moisture barrier keeps products crisp and dry, its clarity showcases the product, and its stiffness and machinability make it compatible with high-speed automated packaging lines.

In labelling, BOPP is the dominant substrate for self-adhesive labels — particularly where a waterproof, tear-resistant, high-gloss or matte label is required. BOPP labels outperform paper in humid, cold or wet environments, making them the preferred choice for beverage, dairy, personal care and household product labelling.

In tobacco packaging, BOPP overwrap film is used to wrap cigarette cartons and packets, providing tamper evidence, moisture protection and a premium surface finish. In personal care and cosmetics, BOPP is used in sachet packaging, labels and flexible pouch formats. In industrial applications, BOPP tape is widely used for carton sealing and pallet wrapping.

BOPP in Laminated Structures

BOPP film is frequently used as the outer printed layer in a laminated flexible packaging structure. In this configuration, the artwork is reverse-printed onto the inner surface of the BOPP film — so that the ink is protected between the outer film and the inner sealant web — and the two layers are then bonded together through adhesive lamination. This approach protects the print from scuffing, moisture and handling damage, and produces a packaging structure with a consistently high-gloss or matte surface finish depending on the BOPP grade used.

Common laminated structures incorporating BOPP include BOPP/CPP (biaxially oriented polypropylene over cast polypropylene) for dry food applications, BOPP/PE for general food and consumer product packaging, and BOPP/VMPET/PE or BOPP/VMBOPP/PE for applications requiring enhanced barrier performance alongside a printed outer layer.

Print Performance

BOPP is an excellent print substrate. Its smooth, dimensionally stable surface accepts flexographic and rotogravure inks consistently across high-speed print runs, and its optical clarity allows colours to appear bright and saturated against the film background. Surface corona treatment is applied to all our BOPP film to ensure consistent ink adhesion and bond strength in lamination.

For reverse-printed laminated structures, we print onto the inner surface of the BOPP and laminate immediately, protecting the ink layer within the structure. For surface-printed applications — labels and overwraps — the ink is applied to the treated outer surface and may be protected with a varnish or overlaminate depending on the abrasion and moisture resistance requirements of the end use.

Barrier Properties

Standard BOPP film provides good moisture vapour barrier and moderate oxygen barrier — sufficient for many dry food and confectionery applications where the primary concern is keeping moisture out rather than excluding oxygen. Where higher oxygen barrier is required, BOPP can be combined with EVOH in a laminated structure, or the metallised BOPP grade can be specified, which provides a significant improvement in both oxygen and moisture barrier performance at a lower cost than foil-based structures.

We will always advise on the most appropriate barrier specification for your product based on your stated shelf life target, the sensitivity of your product to oxygen and moisture, and your storage and distribution conditions. Getting the barrier specification right matters — over-specifying adds unnecessary cost, while under-specifying risks product quality and shelf life failure.

Sustainability Considerations

BOPP is a mono-material polypropylene-based film, which gives it an advantage over multi-substrate laminated structures from a recyclability perspective. Where the complete laminated structure uses only polypropylene-family materials — for example a BOPP outer layer laminated to a CPP sealant — the resulting packaging is compatible with polypropylene recycling streams in markets where collection infrastructure exists.

We offer all-PP laminated structures for brands working toward recyclable flexible packaging targets, and can advise on the performance trade-offs relative to conventional multi-substrate structures. We also supply BOPP films with post-consumer recycled content where this is technically feasible for the intended application.

Working With Us

Whether you need BOPP-based roll stock for your own converting operation, a finished laminated structure incorporating BOPP as the outer printed layer, or BOPP labels for your product range, our team can specify the right grade and structure for your application and provide a quotation based on your volume and format requirements.

If you are currently using a BOPP-based packaging structure and want to review whether the specification is still the most appropriate — whether for performance, cost or sustainability reasons — we are happy to carry out a technical review and make recommendations.