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© 2018 – Fabio Vincenzi – Nordmeccanica Spa

IMAGE TO PRINT

20th September 2018

High barrier through metallization

Barrier improvement of vacuum coated films


Barrier improvement through vacuum coating

BIF : Barrier Improvement Factor for metallizedfilm ranging from 10 to 100 depending on material. © 2018 – Fabio Vincenzi – Nordmeccanica Spa

Aluminium Metallized BOPPOUR PARTENERS :• MANUCOR Italy = The largest single factory in Europe of

Bopp film • SRF India = one of the leading company in Bopet and Bopp

field• FLEX India & Egypt = one of the largest worldwide films

producer

MOTIVATION & OBJECTIVES

• Increasing metallizingproduction efficiency : regular commodity film running speed over 1000 m/min at 2 OD 10000 Tons/yr

• Minimizing Material waste• Increasing barrier

properties© 2018 – Fabio Vincenzi – Nordmeccanica Spa

• Bi-Oriented PolyPropylene is the most used polymerfilm for Flexible packaging approx 60% of all plasticfilms.

• Bi-Oriented PolyPropylene has a very high moisturebarrier and a medium level oxygen barrier.

• Bi-Oriented PolyPropylene is produced in multiplecomposition and functionality. Barrier properties forplain and metallized film reflect the base film variability.

• Increasing Metallized BOPP barrier properties(especially O2TR) represents a general industry trends.

Aluminium Metallized BOPP


0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0 10 20 30 40 50 60 70 80 90 100

WV

TR

O2TR

BARRIER PROPERTIES (examples from major manufacturers)

commodity bopp

High Barrier Bopp

** source: Published data from web site and brochures.

High Performance Vacuum Coating


Factors for Barrier improvement:

• Base Polymer Film

• Aluminium collecting film special skin

• Plasma (in vacuum) pre-treatment

• Machine design and ProcessParameters

Core PP

Metallizable outerlayer (corona treated)

12

3

1: Heat sealableinner layer

2:

3:

Al

High Performance Vacuum Coating


• Barrier properties improve whenthe barrier layer combines with an organic coating

Gas and Vapor transmission throughcoated polymer

• Barrier properties often improvewhen the polymer surface is treatedand seem to be linked to surfacecleanliness and adhesionproperties

• Barrier films are often brittle (especiallymetal-oxide clear coating) and properties can be affected by mechanical /Thermal stress . Protection(Coating, Lamination etc.) is sometimemandatory

**Synergic effect : organic coatings

contribute to decreasingpermeability sometimes

much more than theirintrinsic barrier


As second step we already achieved

• 1200mt/min production speed with 2.5 OD• Very high Alu bond level ( less than 5N/15mm )• 7 minutes machine start including vacuum• High Barrier Level on BOPP with Oxygen Tramission close

to 10


How do we reach such high level of barrier ?!

• Investing our time in a constant R&D

• Listening our customersneeds

• Being curious

• Creating our personal development called

BARRIERMET© 2018 – Fabio Vincenzi – Nordmeccanica Spa

1 - Film (Corona treatedBopp)

2 – «Tie» Layer

1

2

3

3 – Aluminium layer

BARRIERMET (AB)a single-step multi-layer concept

� High bond with polymer surface(adhesion promotion)

� Polymer surfacemodification(Planarization,seedingetc.)

Substrate, mechanicalstrength

Functional : barrier, glossetc.


Gas

BERRIERMET (AB)a single-step multi-layer concept

Conceptualdwg

� A «primer» layergeneration within a conventionalaluminiummetallization process

� An accuratelycontrolled gas distribution for tie-layer uniformity and thickness

� Complemented by plasma treatment


BARRIERMET (AB)typical metal adhesion


BARRIERMET (AB)/PLASMApositive effects on barrier properties

Combination of Plasma treatment («PL») and «Tie» layer (AB) leads to more than 4-times improvement of the Oxygen barrier of this particular BOPP designedfor high barrier metallization.


• The plasma contribution to barrier changes dependingon film type.

• This project confirms the common wisdom that the filmcharacteristics determine the barrier properties … but itshows a general positive effect of plasma treatment onO2TR & WVTR.

• An adhesion promoting layer in film blend has a visibleeffect on improving barriers, too.

• BARRIERMET+PLASMA is for sure the latest innovationfor all the substrates in the PET/BOPP and also CPPmarket


Don’t forget the Aluminium Oxide (AlOx) clear barrier films PET

Objective : Designing optimized process to provide End Users both machine and sound process support for clear barrier film industrial production Method : Running tests at factory-floor conditions, on a sequential three phases approach – Only “commodity” grade film considered

Test equipment: MetallizerNM-12 Width 1200 mmProcess : Reactive evaporationfrom Aluminium evaporators


All thin films can be cracked or damaged by handling and Oxidecoatings are more brittle than metallicones possibly leading to barrier lossduring converting

Pet 12 mic + AloX1% Strain O2TR : +20%; WVTR : +35%

An example

IMPORTANT PHASE : Creating a stress resistantclear barrier film that can be used

Conventional Wisdom :

Three strategies available to improvecoating durability :

AlOx Clear barrier Film


• Top Coating• Lamination

• Air coating• Vacuum coating

• Energy curedpolymer deposition

• Melamine• Others

• DEPOSITING

a more

«flexible»

coating

AlOx Clear barrier Film needs protection


• Provides a permanent protection for mechanically sensitive barrier coating

• Properly designed and set-up laminatorsrepresent a safe step for vacuumdeposited thin films

• In general, lamination increases the vacuumcoated film barrier properties

• Nordmeccanica and its adhesive producingpartners are in the best position to recommend integrated solution tailored to different materials and applications

AlOx Clear barrier Film in the lamination


In LinePattern Metallizing (ILPM)

Packaging

Security

Others


Evaporation zone 5 × 10-4 mbar

Winding zone

Unwind

Process Drum

Rewind

Anilox Roller

and Oil Boiler Print Roller



Width : up to 1650 mm

Roll Diameter: max.800 mm

Typical web speed: 400-600 m/min

Minimized «maskingoil» utilization



Evaporation zone 5 × 10-4 mbar

Winding zone

Process Drum

Print Sleeve

*one line sold to italian gov. mill

In Line Pattern Metallizing(ILPM) with register control system


HIGH TECH“Simplicity is the ultimate

sophistication.”Leonardo da Vinci

AND IT IS NOT OVER…STAY TUNED……

TO ALL, FROM NORDMECCANICA, OUR GREAT…..

THANK YOU

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