Layfield's LAYFLEX® Application

Low density poly taken to the extreme! For more than 25 years, Layfield has worked directly with our customers to find better solutions to deal with various packaging requests. Layfield is proud to present LAYFLEX® as its newest solution to common packaging requests for strength and cost savings.

Background

LAYFLEX® is produced using our technologically advanced three-layer co-extrusion line, combined with three proprietary specialty co-polymers and LLDPE blend layers that have resulted in the development of a superior packaging product for the mattress and furniture industry. These synthetic co-polymer resins in combination with our prime performance packaging polymers have resulted in a synergistic effect that yields superior physical properties.

So what does this all mean? It means that our LAYFLEX® film structure will typically outperform a mono-layer film, as used in the furniture industry, by a factor of 2 to 1 (based on physical properties tested using standard ASTM testing methods). The mattress and furniture industry that have been using thicker gauged products (i.e. – ranging from 4 mil to over 9 mil) to protect their products so that it gets from the factory floor to the final consumer. With the advancements in both film resins and extrusion technology, Layfield is able to supply it’s specialty formulated LAYFLEX® product line, which allows the mattress and furniture industry the ability to use a thinner gauged product that has similar or greater physical properties than most of these thicker gauged products. With a down-gauged product, those that switch to LAYFLEX® will see immediate cost savings.

Layfield’s co-extrusion line produces film to +/- 3% gauge tolerance as compared to typical industry values of +/- 10-12%. Most packaging films are sold to the industry on a per pound basis, and because product performance requirements are only as good as the weakest point, our competitors often produce a heavier gauge product (i.e. 5.0 mil film specification is produced as a 5.5 mil product), resulting in a lower yield per roll. Film yield is especially critical to those within the mattress and furniture industry that use automated packaging machinery, as the greater the yield you get from the film used the more cost effective you become.

Yield Comparison 

The following is a comparison of a 3 mil LAYFLEX ® product to a typical 4-mil, 5-mil & 6-mil x 110” mattress sheeting product. The cost for the 4-mil, 5-mil & 6-mil is depicted at $0.80/lb.

* Savings shown do not take into account  the additional benefits associated with yield factors or roll changes. It should also be noted, that the industry average gauge figures do not take into account the industry average gauge variance of 10%, thus the approximate lineal footage per roll received would typically be lower than values stated here.

Physical Properties

(1) Typical values represent average laboratory values and are intended as guides only, not as specifications.
(2) Film properties are typical of blown film extruded at approximately a 3:1 blowup ratio.
(3) Properties designated have been determined in accordance with the current issues of the specified test methods.

Quality Control 

Layfield Poly Films quality assurance program has been certified and accredited to the ISO 9001:2008 standard. ISO (International Organization for Standardization) is an organization that is recognized as a worldwide authority in setting quality standards. Layfield only ships product that meets or exceeds the published specifications for our products. We test at every step of along the manufacturing process for conformance, from raw materials to finished product. Every individual LAYFLEX® production run, be it rolls of sheeting or bags, is assigned a separate job number, thus if required we are able to back-track production and test data specific to any job run produced at our plant.

Benefits of LAYFLEX®

When superior product protection is a must, LAYFLEX® is the solution. When cost savings are a must, Layfield can deliver.

• Lower Per Package Unit Cost. A switch to a lighter gauged LAYFLEX® will provide immediate cost savings versus thicker gauged products.
• Fewer Roll Changes. Your staff isn’t change rolls as frequently thus your machinery is not sitting idle as long - you equipment becomes more efficient.
• Higher Yield. Layfield produces our sheeting to ±3% gauge tolerance versus typical industry standard of ±10% - higher yield translates into more product being packaged.
• Consistent Processing and Sealing. Tighter gauge tolerance along with uniform tension and superior roll geometry ensures consistent processing and sealing – thus less repacking due to poor seals reduces costs and saves time.
• Environmentally Friendly. Reducing the overall amount of packaging means less environmental impact – our product can be recycled where municipal programs exist.
• Reduce shipping costs. Less packaging weight saves on overall shipping costs.
• Printing Available. Package can be printed with you message or logo - a great marketing tool to get your name out to the marketplace.