Packaging is at the centre of a sustainability reckoning. With plastic waste under the spotlight, consumers calling for more recyclable options and policymakers introducing tougher requirements, the food sector faces mounting pressure to deliver packaging solutions that work for both people and the planet.
As brands and converters seek alternatives to multi-material packaging structures that are difficult to recycle, machine direction orientation (MDO) is emerging as an important enabler of mono-material polyethylene solutions. By enabling the production of high-performance films, MDO helps manufacturers achieve the performance required for demanding applications.
However, embracing the MDO process is not without its challenges. While the technology is creating new opportunities for circular packaging design, it also introduces production complexities that manufacturers must carefully manage, particularly around contamination control and static management, making these important topics for industry discussion.
How does MDO work?
The process works by stretching film in the machine direction through a series of carefully controlled stages: Preheating, stretching, annealing (heating) and then cooling slowly.
The resulting film offers a combination of properties that make it highly attractive for packaging applications. Enhanced mechanical strength, improved barrier performance, and superior surface finish can all be achieved, while increased stiffness can support downgauging strategies that reduce overall material consumption. The sustainability potential is clear.
Yet the very characteristics that make MDO films attractive can also create new manufacturing challenges, particularly where contamination is concerned.
Keeping contamination under control
Meech has worked closely with packaging film manufacturers and machinery manufacturers experiencing contamination issues on MDO lines, including the build-up of white flakes and other contaminants. When these reach heated MDO rollers, contamination can accumulate over time before eventually transferring defects onto the film surface, forcing production stoppages for cleaning and maintenance.
Of course, the sources of contamination can vary widely. Carbonised particles, unmelted gels, airborne dust and the accumulation of processing additives such as slip agents can all contribute to roller build-up and quality issues, meaning the challenge can extend beyond effective roller cleaning. To maximise production efficiency, manufacturers must focus on preventing contaminants from reaching critical process areas in the first place.
Silencing the interruptions
Preventative contamination control is therefore increasingly becoming a key part of successful MDO operations.
By integrating in-line web cleaning and ionisation systems ahead of the MDO section, manufacturers can remove particles and neutralise static charges before contamination accumulates on downstream equipment.
Meech’s VacClean system combines ionisation, brush technology and vacuum extraction to clean the film surface while reducing static-related attraction of contaminants. The goal is simple: minimise the amount of contamination entering the MDO process, reduce roller build-up, and help manufacturers achieve longer production runs, improved yields and reduced maintenance interruptions.
Turning MDO Potential into Production Reality
These topics will be explored in Understanding MDO: Challenges, Opportunities and Best Practices, a free webinar hosted by ProFood World and sponsored by Meech.
During the session, Ian Atkinson and Vic Klashorst from Meech International will examine the opportunities created by MDO, the practical production challenges manufacturers encounter, and the role of preventative contamination and static control in supporting more efficient operations.
For manufacturers evaluating MDO technologies, or looking to optimise existing operations, the session offers practical insight into how production challenges can be addressed before they impact quality, productivity and profitability, and the webinar will also explore global adoption trends, different MDO applications, best practices for roller cleaning, and the experiences of film producers that have implemented preventative in-line cleaning systems.
Register for the webinar here: https://events.profoodworld.com/understanding-mdo-challenges-opportunities-and-best-practices/register