A system and method to predict and assess immunogenicity, especially prior to on-set of immunogenic conditions. A method can include providing two plates, such as a die plate with a scoring rule thereon and a counter plate with an aligned corresponding recess with a knife edge positioned therein and protruding toward the scoring rule. The chopper can have one or any combination of the improvements. The thermoplastic foam composite can be utilized as an article, such as a packaging, wiper, towel, or insulation product, or can be incorporated as a component into a variety of other articles, including personal care articles, healthmedical articles, and householdindustrial articles, for example. These improvements are achieved by incorporating into the thermoplastic film structures a polymeric nanocomposite comprising a polymer and nanosize particles of a modified clay.