ExxonMobil, partners engineer 67-layer pre-stretch film for high-performance pallet wrapping

USA – ExxonMobil has teamed up with Alliance Films and Cloeren to develop a 67-layer Nano Layer pre-stretch (PPS) film, targeting the packaging sector’s demand for improved stretchability, holding force, puncture resistance and tear-propagation performance.

The multilayer film structure leverages ExxonMobil’s metallocene polyethylene (mPE) portfolio to deliver optimized mechanical strength while enhancing material efficiency.

Central to the design is a nanolayer combination of Exceed m 3518 and Exceed Tough m 3812 mPE grades, engineered to balance toughness with stretchability under high pre-stretch conditions.

The film’s core incorporates Exceed Flow m 1716, also a metallocene PE, to enhance holding force, while Vistamaxx 6000 performance polymer improves tear-propagation resistance.

On the release side, the structure utilizes higher-density Exceed Tough m 4536, while the cling layer features a blend of Exceed Tough m 3812 and Vistamaxx 6102.

According to the partners, most layers in the 67-layer configuration are based on neat polymers rather than blends.

This approach allows Alliance Films to maximize the molecular architecture of the performance PE grades, translating into improved mechanical integrity and consistency across the film structure.

Optimized performance and efficiency

Performance data shared by ExxonMobil indicate high mechanical output across a wide working range. The film delivers ultimate elongation of 490%, force at break of 131 N, and stretch force of 105 N at 250% pre-stretch.

It also achieves a natural draw ratio of 325%, enabling converters to operate at elevated pre-stretch levels while reducing film consumption per pallet.

At 250% pre-stretch, tear break times exceed 25 seconds, and remain above 15 seconds even at 300% pre-stretch, supporting load stability in demanding transport conditions.

The Nano Layer PPS film maintains puncture strength across 200–300% pre-stretch levels, and at 300% pre-stretch can reduce film usage by approximately 10% compared to standard wrapping levels while maintaining strong containment.

The development reflects broader industry efforts to combine downgauging with enhanced performance amid rising sustainability pressures.

Recently, ExxonMobil collaborated on a recyclable mono-PE cheese pouch and introduced foamed products incorporating recycled content. At K 2025 in Germany, the company also showcased its latest recycled film solutions.

As pallet stabilization remains critical across logistics and e-commerce supply chains, high-layer nano structures are increasingly positioned as a route to balancing load security, material reduction and operational efficiency.

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