At PlastIndia 2026 in New Delhi, Luk Plastcon introduced Metallocal, a patent-pending calcium carbonate-based masterbatch developed for multilayer blown film applications, positioning it as a cost-effective alternative to metallocene and LDPE in flexible packaging.
Varun Bajaj, executive director of Luk Plastcon, said the newly developed masterbatch is engineered to enhance key performance parameters in three-layer and multilayer films, particularly those used in milk, noodles, detergent and lamination packaging.
According to Bajaj, Metallocal improves dart impact strength and elongation while maintaining puncture resistance, tear strength, secant modulus, coefficient of friction and seal strength. He highlighted dart impact strength as a critical property for converters, especially in high-speed packaging operations where film durability is essential.
The product is based on a specialized grade of calcium carbonate and is designed to partially replace metallocene linear low-density polyethylene (MLLDPE) and low-density polyethylene (LDPE) in the middle layer of multilayer films. The company has applied for patent protection for Metallocal following the resolution of earlier development and procedural challenges.
Cost pressures remain a major issue for converters, particularly in high-volume segments such as milk packaging, where margins are tight. With metallocene and LDPE prices remaining elevated, raw material substitution has become a priority.
Bajaj said Metallocal can replace 10–20% of these polymers in the middle layer, offering meaningful cost savings. Priced at approximately Rs 75–80 per kg, the masterbatch allows partial substitution of higher-cost resins while retaining essential mechanical properties.
Luk Plastcon is concentrating on expanding the adoption of Metallocal across detergent films, lamination films, milk pouches and noodles packaging applications that rely on multilayer blown film structures. The company is working on further product innovations, including developments in blow moulding, which may be taken forward for patent filing.
On the sector’s outlook, Bajaj expressed confidence in the continued growth of India’s flexible packaging industry, citing rising consumption, population growth and the shift towards organized, branded products. He said items previously sold loose, such as wheat flour, are increasingly moving to three- to five-layer flexible packaging formats, reinforcing long-term demand for advanced film solutions.
He described PlastIndia as a key platform for technology showcase and industry engagement, highlighting improvements in event management and digital navigation tools at this year’s edition.
