Heavy Duty Sack Film

5-layer Heavy Duty Sack (HDS) film inline printed and gusseted

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Your benefits at a glance

Heavy Duty Sack film

Why choose this film:

  • Excellent sealing/ hot tack properties
  • Strong impact resistance
  • High package integrity and load stability
  • Excellent toughness/stiffness


Why choose this W&H machine:

  • Superior line output
  • Excellent film tolerances and roll quality
  • Easy operation and well integrated processes

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All about HDS film

All about HDS film with SABIC® SUPEER™ metallocene

The film demonstrated on the EXPO features the newly introduced SABIC® SUPEER™ metallocene, which together with the high molecular weight PE-HD succeeds in fulfilling the current film requirements defined by SABIC®. The 110 µm film produced has passed the critical test of creep resistance as well as extensive drop tests.

This recipe is produced on the OPTIMEX FFS line at a groundbreaking production output with excellent film tolerances and roll quality. The film meets the requirements of all downstream processes from inline printing, side gusseting and embossing to filling and stacking of the finished bags.

With the newly introduced SUPEER™ resins, FFS film produced on an OPTIMEX FFS blown film line fulfills the demanding film specifications defined by Sabic in 110 µm thickness. The 5-layer structure consists of a blend of metallocene and PE-HD types. These resins are typically difficult to process – with W&H machinery and Sabic performance resins this is no longer the case. The 5-layer structure provides more flexibility for recipe development while maintaining ground-breaking output levels.

HDS film with ExxonMobil Exceed XP

We demonstrate a PE-HD rich 100 µm film that meets the challenging requirements of the creep test, with no compromise on toughness and dart impact resistance. This balance of properties was made possible by the ExxonMobil high performance polyethylene, Exceed XP, produced with the proprietary catalyst technology that also ensured an excellent processability even at limits of machine output.

The result is a 100-micron, 5-layer POD FFS bag film, including Exceed™ XP performance PE polymers, and ExxonMobil HDPE offer extreme toughness and stiffness so it can endure dynamic and impact loadings which may cause stress and ruptures during filling, transportation, storage and use. The bags are capable of withstanding rough handling and storage conditions in various environments and climates. The creep resistance and bag drop performance of the bags provide optimum stability even when stacked or left on pallets for long periods of time, helping to prevent toppling and improve safety. By providing a sound water vapor barrier, the product contents of the bags are kept dry and protected. The extreme toughness and stiffness of the bags provides opportunities for step-change downgauging. High melt strength delivers improved bubble stability for optimized converter performance.

Our Partner

SABIC© is a global leader in diversified chemicals headquartered in Riyadh, Saudi Arabia. SABIC© manufactures on a global scale, making distinctly different kinds of products: chemicals, commodity and high performance plastics, agri-nutrients and metals.

SABIC© supports customers by identifying and developing opportunities in key end markets such as construction, medical devices, packaging, agri-nutrients, electrical and electronics, transportation and clean energy.

SABIC© has more than 33,000 employees worldwide and operates in around 50 countries. Fostering innovation and a spirit of ingenuity, SABIC© has 11,738 global patent filings, and have significant research resources with innovation hubs in five key geographies – USA, Europe, Middle East, South Asia and North Asia.

SABIC© is the first in the industry to scale-up innovative chemical recycling process to return mixed plastic waste back to the original polymer for high quality applications, thereby enabling circular reuse of the planet’s natural resources. While recycling by mechanical methods makes a contribution towards circularity, the rates at which it can economically recycle plastic packaging waste are limited. SABIC’s certified circular polymer process, however, enables the creation of brand new polymers, offering a real alternative to mechanical methods and closing the recycling ‘loop’.

Brand owners want to make sure that their products are being protected, from the instant Form Fill and Seal (FFS) bags are being filled to the moment they are being used.

As part of its commitment to helping customers create differentiated solutions that add value, ExxonMobil wanted to develop a five-layer POD FFS bag film solution that offered extreme performance for brand owners and was easy to process for converters.

Continuing their almost 20 years of collaboration, ExxonMobil and Windmöller & Hölscher have developed an FFS bag film solution that includes Exceed™ XP performance PE polymers.


The OPTIMEX FFS has been optimized to overcome the three main factors limiting the line output of the most commonly used recipes. The bubble stability has been significantly improved with the introduction of a high performance package, allowing for an additional 15-20% output increase.

A secondary cooling ring below the flattening unit has been introduced to prevent blocking of the collapsed tube. When used in combination with the new cooling ring concept, it enables our customers to unlock the full potential of the line output. The products featured at K 2019 show are produced at highest output and without any anti-block additives. The 5-layer system provides a highly flexible platform for recipe design at a groundbreaking output level.

Key features

  • Easy operation and well-integrated processes
  • 3-5 layer films e.g. for petrochemicals
  • Up to 6-colour inline printing including the gusset area
  • Micro-perforation for powdery products available

Technical key features

  • 5-layer die designed for reduced melt pressure
  • High performance package to maximize bubble stability and output
  • Secondary air ring to prevent tube blocking
  • Inline printing unit with gusset printing


You can see our machines live at our Technology Center in Lengerich. Please contact your sales representative if you are interested in a live demonstration.

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Optimized for superior line output and easy operation. Learn more about the OPTIMEX FFS.

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