Post on 15-May-2020
Unique High Oxygen Barrier Coatings for Food Packaging
Flexible Packaging Conference 2016 October 10, 2016
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Agenda
Two very different oxygen barrier coatings will be presented
– Coatings onto BOPET film– Coatings onto AlOx coated BOPET film
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Coatings onto BOPET Film
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Objective
• Reduce oxygen transmission through thin, transparent packaging film to retard oxidative spoilage and prolong product freshness, extend shelf life
• Demonstrate a very thin layer of coating on film can have a high impact on barrier, without adding significant cost or weight to a package structure.
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In Line Barrier Coating Application
Used in line in the film production process BOPET substrate
Substrate selection is critical, smoother is better
Better properties achieved through the stretching process – e.g. adhesion
Coat weight range 0.04 – 0.07 dry gsm Enhance barrier properties by metalizing on
top of the coating Work done at Bruckner
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Michem® Flex Barrier 3510
• Applied in-line with BOPET line• Applied between machine
direction and transverse stretching
• Used either– As a pre coating prior to
metallization– Or as a transparent barrier for
dry conditions• Applying in-line gives low coat
weight and better properties.
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Gravure Coating Head
Inline Film Coating
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10% solids in water Single component Excellent shelf life No mineral nano-particulate content No chlorine Food compliant Adhesion
To film substrates To vacuum deposited metal, AlOx and SiOx
Promising water resistance >500 g/in metal adhesion between film and metal
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Barrier Coating Characteristics
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12u BOPET film12u BOPET/0.07gsm
MFB3510
12u BOPET/0.07gsm MFB3510/2.7 OD
metallizing
0.1
1
10
100
0.01 0.1 1 10 100 1000
MVT
R g
/m2/
day
@ 3
8C a
nd 9
0% R
H
OTR cc/m2/day @ 0% RH
12uBOPET/0.07gsm MFB3510/adhesive//80uCPP
Michelman In Line Barrier Coating
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12u BOPET/MFB3510@ 0% RH
12u BOPET/ MFB3510/
2.7 OD metallizing @ 0% RH
12u BOPET/MFB3510@ 90% RH
12u BOPET/ MFB3510/
2.7 OD metallizing @ 90% RH
0.1
1
10
100
0.01 0.1 1 10 100 1000
MVT
R g/
m2/
day
Oxygen Barrier cc/m2/day/atm
Barrier Coating - Effect of Humidity
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Chart1
0.620.081.720.04
Oxygen Barrier cc/m2/day/atm
12u BOPET/0.07gsm MBC @ 0% RH
12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 0% RH
12u BOPET/0.07gsm MBC @ 90% RH
12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 90% RH
MVTR g/m2/day
12u BOPET/MFB3510 @ 0% RH
12u BOPET/ MFB3510/ 2.7 OD metallizing @ 0% RH
12u BOPET/MFB3510 @ 90% RH
12u BOPET/ MFB3510/2.7 OD metallizing @ 90% RH
40
3
40
3
Data 1 elevated RH
After converting simulation
Barrier resultsOxygen barrierMVTROxygen barrierMVTR
SubstratesOTR @ 0%RH, cc/m2/dayMVTR @ 38°C 90%RH, g/m2/day0%RH, cc/m2/day38°C 90%RH, g/m2/day
12u BOPET film12840
UFLEX BOPET F-PLX22Commercial high barrier films
Camvac 300931.5
dai Nippon IB-PET-P22
Aryalox AQ41145
Aryalox AB41011
Mitsubishi Techbarrier TX0.50.5
Mitsui Maxbarrier0.80.3
Reiko Fine barrier AT-R1.51
Toppan GL -RD0.10.2
Toray Barriarlox 1011HG-CX1.51.5
Toray Barrierlox 1011SB-R20.10.3
Trias Sentosa AZB1.51.5
Ultimet CeramAlox 1561.51
12u BOPET/AlOx1.150.7515.65.82
12u BOPET/0.07gsm MBC @ 0% RH0.6240Our coating constructions
12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 0% RH0.083
12u BOPET/0.07gsm MBC @ 90% RH1.7240
12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 90% RH0.043
Besela PET0.720Competative coating constructions
Kurarister PET0.320
PVDC coated PET10.93.9
12u BOPET/0.07 gsm MBC//CPP0.20.6
12 micron film, in line coated
MILBC = Michelman Barrier Coating
Data 1 elevated RH
Oxygen Barrier cc/m2/day/atm
12u BOPET film
12u BOPET/0.07gsm MBC @ 0% RH
12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 0% RH
12u BOPET/0.07gsm MBC @ 90% RH
12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 90% RH
MVTR g/m2/day
12u BOPET/0.07gsm MILBC/2.7 OD metallizing @ 0% RH
Data 1
After converting simulation
Barrier resultsOxygen barrierMVTROxygen barrierMVTR
SubstratesOTR @ 0%RH, cc/m2/dayMVTR @ 38°C 90%RH, g/m2/day0%RH, cc/m2/day38°C 90%RH, g/m2/day
12u BOPET film12840
UFLEX BOPET F-PLX22Commercial high barrier films
Camvac 300931.5
dai Nippon IB-PET-P22
Aryalox AQ41145
Aryalox AB41011
Mitsubishi Techbarrier TX0.50.5
Mitsui Maxbarrier0.80.3
Reiko Fine barrier AT-R1.51
Toppan GL -RD0.10.2
Toray Barriarlox 1011HG-CX1.51.5
Toray Barrierlox 1011SB-R20.10.3
Trias Sentosa AZB1.51.5
Ultimet CeramAlox 1561.51
12u BOPET/AlOx1.150.7515.65.82
12u BOPET/0.07gsm MILBC0.6240Our coating constructions
12u BOPET/0.07gsm MILBC/2.7 OD metallizing0.083
Besela PET0.720Competative coating constructions
Kurarister PET0.320
PVDC coated PET10.93.9
12u BOPET/0.07 gsm MILBC//CPP0.20.6
12 micron film, in line coated
MILBC = Michelman in line Barrier Coating
Data 1
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Oxygen Barrier cc/m2/day/atm
12u BOPET film
12u BOPET/0.07gsm MILBC
12u BOPET/0.07gsm MILBC/2.7 OD metallizing
Besela PET
Kurarister PET
PVDC coated PET
12u BOPET/AlOx
12u BOPET/0.07 gsm MILBC//CPP
MVTR g/m2/day
Performance sheet
After converting simulation
Barrier resultsOxygen barrierMVTROxygen barrierMVTR
Substrates0%RH, cc/m2/day38°C 90%RH, g/m2/day0%RH, cc/m2/day38°C 90%RH, g/m2/day
BOPET film12840
UFLEX BOPET F-PLX22Commercial high barrier films
Camvac 300931.5
dai Nippon IB-PET-P22
Aryalox AQ41145
Aryalox AB41011
Mitsubishi Techbarrier TX0.50.5
Mitsui Maxbarrier0.80.3
Reiko Fine barrier AT-R1.51
Toppan GL -RD0.10.2
Toray Barriarlox 1011HG-CX1.51.5
Toray Barrierlox 1011SB-R20.10.3
Trias Sentosa AZB1.51.5
Ultimet CeramAlox 1561.51
BOPET plus barrier precoat1.150.7515.65.82
BOPET with Michelman product in line0.6240Our coating constructions
BOPET with michelman product applied in line and then metallised0.083
BOPET with michelman topcoat over barrier precoat0.0010.470.030.44
BOPET with EKF1402 primer under Alox with a further topcoatingTBDTBD
BOPET :AlOx: MC95 acrylic1.630.961.830.96
BOPET with EXP0915.E over ALOx0.630.50.420.52
Besela PET0.720Competative coating constructions
Kurarister PET0.320
PVDC coated PET10.93.9
Actual commercial lamination using Michelman coating0.20.6
12 micron film
Performance sheet
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Oxygen Barrier cc/m2/day/atm
BOPET film
BOPET with Michelman product in line
BOPET with michelman product applied in line and then metallised
BOPET with michelman topcoat over barrier precoat
Besela PET
Kurarister PET
PVDC coated PET
BOPET plus barrier precoat
Actual commercial lamination using Michelman coating
Costing sheet
Barrier resultsOxygen barrierMVTRPrecoat weight (gsm)Topcoat weight (gsm)Typical cost addition of coatingManufacturing cost
Substrates0%RH, cc/m2/day38°C 90%RH, g/m2/day$ per square metre (based on base price)$ per square metre
BOPET with EKF1402 in line4400.040.002592
BOPET with EKF1402 in line and metallised0.0830.0400.002592
BOPET with EKF1402 primer under ALOx0.081.500.50.00324
BOPET with EKF1402 topcoat over ALOx0.0010.4700.50.00324
BOPET with EKF1402 primer under Alox with a further topcoatingTBDTBD0.040.50.0034992
BOPET with MC95 over AlOx1.630.9400.64
BOPET with polyester over AlOx0.630.501
BOPET with AlOx only1.150.75
BOPET film
Metallized BOPET Film0.0896
AlOx coated film1.51.50.0973
SiOx coated film0.60.60.1883
Prices usedBase pricevolume price based on 250tpa
EKF14026.48 USD/Kg
MC95
Polyester
1 m2 = 1550 in2
0.0016722581$/msi @0.04 dry gsm
$0.0045/m2, 0.0029/msi @0.07 gsm
MVTR 38°c, 90%RH(g/m2/day)
AlOx and EKF1402 interaction
AlOx and EKF1402 interaction
Experimental set upOxygen transmission (cc/m2/day)Comments
Oxygen sideSubstrateStructureCarrier gas at humidty0%RH90%RH
at 0%RH
12µm PETPET/AlOx2.662.46bobst sample
23µm PETPET/EKF14020.2436.3without alox - pilot coated
12µm PETPET/AlOx/EKF14020.10.24With MF crosslinker- overcoated bobst sample
12µm PETPET/AlOx/MFP8880.140.12Without MF crosslinker- overcoated bobst sample
12µm PETPET/AlOx/ME90508P0.20.08Conventional PVOH
Tg
sampleCure temp (°C)Tg (°C)Comment
G-Polymer plus adhesion enhancer125°c69.2No cure
G-Polymer plus adhesion enhancerplus Xlinking package125°C72.9Incomplete cure
G-Polymer plus adhesion enhancerplus Xlinking package140°C78.4Incomplete cure
G-Polymer plus adhesion enhancerplus Xlinking package160°C82.3Incomplete cure
G-Polymer plus adhesion enhancerplus Xlinking package170°C90.4Complete cure
Barrier with humidity
Sample PreperationPrimermetallisation?Oxygen barrier (cc/m2/day/atm)
0%RH90%RH
Pet- offllineG-Polymer plus adhesion enhancerNo0.419
PET-offlineG-Polymer plus adhesion enhancerplus Xlinking packageNo0.44.5
PET- onlineG-Polymer plus adhesion enhancerplus Xlinking packageNo0.61.7
PET- onlineG-Polymer plus adhesion enhancerplus Xlinking packageYes0.080.04
Sample PreperationPrimermetallisation?Oxygen barrier (cc/m2/day/atm)Dry coat weight/gsm
0%RH90%RH
PET-offlineEKF1402.ENo0.44.50.3
PET- onlineEKF1402.ENo0.61.70.07
PET- onlineEKF1402.EYes0.080.040.07
0.3 - 0.5 dry gsm
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Summary: Coating for BOPET
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TransparentOxygen Barrier
Primer for Metallization
Functional Inline PET
Coating
Aqueous0.05 – 0.10 micronsRecyclableSustainableStrong O2 BarrierEasy to coat – one componentFood Compliant Excellent adhesionConverter FriendlyMetalizable
Multi-functional
New Building Block Structure for higher performance and/or
lower cost
Can we eliminate lamination?
Can we eliminate PVDC?
Where are alu foil structures over-
engineered?
Improving AlOx Coatings
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Experiment
• In cooperation with BOBST• Objective - Improve the performance of
AlOx coating especially in durability and retention of barrier properties through converting operations
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Ceramic Clear Barrier Coatings
Advantages over polymer based transparent barrier films (PVDC, EVOH) No barrier loss at high relative humidity Thickness in nanometer range – other technologies in the
micron range Economical raw materials consumption and cost Chlorine free
Advantages of metalized polymer films Product Visibility Microwavable Suitable for met detection
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Barrier Retention
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AlOx Coated PET-Vacuum Metallization
• Bobst K5000 Vacuum Metallizer
• AlOx deposition (10nm) onto
12µm BOPET film
• Speed 720m/min
• Widths 1250mm to 3650mm
• OTR
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Topcoating – AlOx Coated PET Film
Experimental• Bobst CL 850D coater/laminator
- modified for AlOx suitability • 12 micron AlOx coated BOPET• 10 nm AlOx coating• Rotogravure coating application• Coating speed 250 m/min
• Water based topcoats• Coat weights between 0.5 to 1.5
grams/m2 DRY • Three different coating chemistries
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RESULTS• Topcoats successfully applied
without damaging AlOₓ• Barrier performance post-
topcoating depends on topcoat chemistry
• Barrier topcoat C improves OTR and WVTR significantly
• Barrier properties of topcoat material are important for barrier enhancement
Topcoating – AlOₓ coated PETBobst – CL 850D
0
0.5
1
1.5
0.0 0.5 1.0 1.5 2.0 2.5
WVT
R**
[g/(m
² d)]
OTR* [cm³/(m² d)]
AlOₓ PET + Topcoat A
AlOₓ PET + Topcoat B
AlOₓ PET + Topcoat C
AlOₓ PET (no topcoat)
*OTR 23 °C, 50 % RH**WVTR 37.8 °C, 90 % RH
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0.5-0.7 gsm dry
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Barrier Through Converting Processes
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OTR WVTR Conversion Process Structure cm3/(m2 d) g/(m2 d)
AlOx coatings PET/AlOx 1.0 -1.5
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Gelbo Test Results
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
0 5 10 15 20 25
Tran
smis
sion
(eith
er O
TR o
r WVT
R)
Gelbo Flex Number
Coating B OTRCoating C OTRCoating B WVTRCoating C WVTR
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Acknowledgments
• To BOBST– Nick Copeland – R&D Director– Dr. Carolin Struller – Research Associate
• To Michelman– Robin Cooper – Strategic Program
Manager
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Next Steps – Whole ProgramBOPET Coatings and AlOx Coatings
• Build Prototypes – film/convert/fill/shelf life• Offline comparison to inline coating• Work with BOPP film • Retort Testing
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THANK YOU! Vince ZabrockiGroup Marketing Manager Printing & PackagingVinceZabrocki@michelman.com
Slide Number 1AgendaSlide Number 3ObjectiveSlide Number 5Michem® Flex Barrier 3510Slide Number 7Barrier Coating CharacteristicsSlide Number 9Slide Number 10Slide Number 11Slide Number 12ExperimentCeramic Clear Barrier CoatingsSlide Number 15Barrier RetentionAlOx Coated PET-Vacuum MetallizationTopcoating – AlOx Coated PET FilmSlide Number 19Barrier Through Converting ProcessesGelbo Test ResultsAcknowledgments Next Steps – Whole Program�BOPET Coatings and AlOx CoatingsSlide Number 24