Multi-layer high barrier packaging reduces environmental impact · 2018-10-08 · Traditional...
Transcript of Multi-layer high barrier packaging reduces environmental impact · 2018-10-08 · Traditional...
Multi-layer high barrier packaging reduces environmental impact
AIMCAL Web Coating and Handling Conference 2012 2
The function of packaging
PROTECTION
Containing
Preserving Transporting
Informing
Selling
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Barrier properties
BOPP has exceptional moisture barrier compared to other polymer packaging films…
0
5
10
15
20
25
BOPP HPDE CPP BOPET LDPE
WVT
R (g
/m2 d
)*
Film Type * Refers to 25 µm
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Barrier properties
0
2000
4000
6000
8000
EVOH BOPA BOPET BOPP Cast PP HDPE OPS LDPE
OTR
(cm
3 /m2 d
)*
Film Type
…but the OTR is relatively poor.
* Refers to 25 µm
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Barrier properties
OTR can be improved by metallisation but sometimes a transparent or ultra high barrier film is needed.
0
10
20
30
40
MetallizedBOPET
PVOH-coatedBOPP
MetallizedBOPA
PVdC-coatedBOPET
PVdC-coatedBOPP
PVdC-coatedBOPA
MetallizedBOPP
SealablePVdC-coated
BOPP
OTR
(cm
3 /m
2 d)
Film Type
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Sustainability
Packaging design: • Type of materials • Process • Weight and volume reduction • Environmental impact Prevention includes all measures aimed at reducing environmental impact.
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Potentials to Reduce Environmental Impact Energy saving CO2 reduction
Saving of raw materials
Reusable packaging
Use of recycled materials
Optimisation of logistics
Facilitation of recycling
Simplification of the packaging structures
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Product Range Aesthetical Aspect Thickness (µm) O2TR (cm3/m2 d) Note
MULTILAYER FILMS Single Web Structure and/or Lamination transparent 20/30 ≤ 15 MST = 105°C
transparent 30 ≤ 3 Al replacement
metallised 20/30 ≤ 15 WVTR = 0.30
metallised 30 ≤ 3 WVTR = 0.30
MULTILAYER FILMS Single Web Structure and/or Lamination, White Voided white voided 35 ≤ 15 MST = 105°C
white voided metallised 35 ≤ 15 WVTR = 0.40 MULTILAYER FILMS Flow Wrapper Film – Horizontal, Vertical
transparent 35 ≤ 25 MST = 85°C
transparent 30 ≤ 10 Enhance seal, PE
transparent 30 ≤ 10 Enhance seal, PP MULTILAYER FILMS Tray Lidding
transparent 30 ≤ 10 Heat sealable, PE
transparent 30 ≤ 10 Heat sealable, PP
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Key applications
Lidding Films
Flow Wrap Films
Easy Printing and Lamination
High Barrier Triplex Replacement
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Technology Skin layer
PP Homopolymer
Barrier layer
PP Homopolymer
Skin layer
• OTR: 3 – 15 cm3/m2 d • chlorine free • easy lamination and printing like standard BOPP
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Properties
Outstanding flavour barrier
740
720
670
50
200
260
55
50
1650
450
452.5
50
10
10
10
50
0 200 400 600 800 1000 1200 1400 1600 1800
limonene (lemon)
2-acetylpyridine (bread)
dipropil disulfide (garlic)
4-hydroxy-3-methoxybenzaldehyde
(vanilla)
TR (mg/m2 d)
EXTENDO XTMH 20 µmBOPP 20 µmAcr/PVdC coated BOPP 21 µmAcr/Acr coated BOPP 30 µm
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Properties
OTR after pasteurization of a single, non-laminated film EXTENDO XTMU 30 for 60 minutes at 80 ̊C in an autoclave
Oxygen transmission rates at 23 ̊C, 50 % RH Fraunhofer IVV Freising, September 2011
OTR
(cm
3 /m2 d
)
Before pasteurization OTR = 2,5 cm3/m2 d
4 hours after pasteurization OTR = 5 cm3/m2 d
Time (h)
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Properties
In contrast with coated BOPP films, the OTR is not influenced by scratches, wrinkles or abrasion.
0.0
2.0
4.0
6.0
8.0
10.0
Intact Wrinkled
OTR
(cm
3 /m2 d
)
HIGHER
PROTECTION +
= SUSTAINABLE
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Properties
In comparison with other high gas barrier films, the unit weight of the packaging can be decreased.
PROTECTION
+
= SUSTAINABLE
Unit weight (g/m2)
18,2
19,8
19,5
17,1
22,8
22,8 33.0
21.0
28.0
0.1
7.0
15.0
0 10 20 30 40
PA cast 20 μm
BOPA 20 μm
BOPA 15 μm
EVOH coated BOPET 14 μm
PVdC coated BOPET 14 μm
EXTENDO XTMH 20 μm
OTR (cm3/m2 d)
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Properties
In contrast with other high gas barrier films, the thickness of the film does not have influence on the gas barrier properties.
15.0 15.0 15.0
35.0
28.0
21.0
17.0
33.0
22.0
16.0 13.0
0
5
10
15
20
25
30
35
40
0 5 10 15 20 25 30 35 40 45 50 55
OTR
(cm
3 /m2 d
)
Thickness (µm)
EXTENDO XTMH
BOPA
PA cast
PROTECTION
+
= SUSTAINABLE
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Properties • Cardboard packaging is usually made of recycled paper (mostly newspaper)
that contains mineral oil residues from printing inks. • Mineral oil residues can migrate from cardboard into food. • Most of the plastic linings (PP or PE) in the bag-in-box systems in use today
do not provide sufficient protection. • PET and PLA have „natural barrier“ • EVOH has an excellent barrier against mineral oils Film type Breakthrough period on 23°C LDPE 100 μm < 10 hours
BOPP 30 μm < 2,1 days
EXTENDO XTMH 30 μm > 2,5 years
PET > 3 years
Al foil > 3 years
BOPLA 20 μm > 3 years
HIGHER
PROTECTION +
= SUSTAINABLE
Source: BASF measurements and results from Grob,K et al, Kantonales Labor Zürich, April 2011
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Properties – horizontal flow wrapping
0.00
1.00
2.00
3.00
4.00
5.00
6.00
80 85 90 95 100 105 110 115 120 125 130 135 140
F max
(N)
Temperature (°C)
EXTENDO XFWL
EXTENDO XTMH
0.00
1.00
2.00
3.00
4.00
5.00
6.00
80 85 90 95 100 105 110 115 120 125 130 135 140
F max
(N)
Temperature (°C)
EXTENDO XFWL
EXTENDO XTMH
HOT - TACK
SEAL STRENGTH
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Properties – tray lidding
• Film for thermoforming, PE/APET: 270 µm • Film for lid, PVdC coated PET/PE: 70 µm
3900 4228
0
500
1000
1500
2000
2500
3000
3500
4000
4500
EXTENDO XLDM 30 µm Film for lid 70 µm
Seal
str
engt
h (g
/25
mm
) PROTECTION
+
= SUSTAINABLE
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Case study: fresh pasta packaging – VFFS
PA 15 µm PP Cast 75 µm
Traditional structure
EXTENDO XTMH 20 µm PP Cast 70 µm
New structure
+
= SUSTAINABLE
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Case study: walnuts
BOPP 30 µm PE//EVOH 60 µm
Traditional structure
EXTENDO XTMH 20 µm PP Cast 60 µm
New structure
PROTECTION
+
= SUSTAINABLE
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Case studies: biscuits
BOPP matt 20 µm EXTENDO XTMH 20 µm
PP Cast peelable PROTECTION
+
= SUSTAINABLE
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General information
The O2TR and WVTR measurements shown in this presentation are all carried out under the below conditions:
• O2TR • Unit: cm³/m² d • Test Conditions: 23°C – 0% RH • Method: ASTM D 3985
• WVTR • Unit: g/m² d • Test Condition: 38°C – 90% RH • Method: ASTM F 1249