Introduction to Packaging Laminates. How it performs the 6 functions of packaging

1. Packaging Laminates
Shakti Nadar
30th April 2020

2. Definition of Packaging
 Art, Science & Technology of enclosing Products for
Distribution

3. Functions of Packaging
 Contain
 Protect
 Preserve
 Identify
 Educate
 Dispense

4. Packaging Materials
 Glass
 Metals
 Paper & Paper boards
 Wood
 Plastic
 Aluminium
 Tin
 Rigid
 Semi-Rigid
 Flexible

5. Plastic Film
 A very thin layer of polymeric material is called
film.
 Plastic Polymer can be
 PET, HDPE, LDPE, PP, PVC,
etc
 It can be Natural or Coloured
using masterbatch
 Plastic Film is tightly wound
on Plastic or Paper Board
Core

6. Extrusion

7. Cast Film

8. Blown Film

9. Difference between Cast & Blown film
Home Work!!!

10. Co-Extrusion

11. Basic Pouch/Sachet types
Side Seal Pouch Center Seal Pouch

12. Types of Center Seal

13. Heat Sealing
 It’s the process of sealing one thermoplastic to
similar or another thermoplastic using Heat &
Pressure.
 Heat is applied with hot metal bars
 Key Factors:
 Temperature
 Pressure
 Dwell Time

14. Heat Sealing
 Heat melts the polymer
 Molten polymers create a bond with each other due
to pressure applied by metal bars
 This creates a hermetic seal
 Key aspects to check:
 Seal Strength
 Seal Integrity
 Drop

15. Catch 22
 To get a good seal, we have to optimize :
 Temperature
 Pressure
 Dwell time
 How do we improve production speed?
 Reduce Dwell Time
 Hence, Increase temperature
 Increase in Temperature causes:
 Polymer charring!
 Charred polymer resides on sealing bars
 This causes improper seal

16. Catch 22
 To clean the sealing bar, one has to stop the
machine
 This cause production loss
 How do we address this??
 Add a layer which melts at a higher temp. on the outer
side

17. Lamination
 It is the process of bonding two or more films
together with the help of an Adhesive
 The resultant is called Laminate
 Key aspects to check:
 Bond Strength
Adhesive

18. Types of Lamination
 Solvent based Adhesive
Lamination
 Solvent less Adhesive Lamination
 Hot Melt Adhesive Lamination
 Extrusion Lamination
 Water
 Chemical
 Mono
 Tandem
For more info on Laminating adhesives click below link:
www.slideshare.net/ashrikant58/07lamination-
adhesives

19. Laminate development process
 Brief understanding
 Product understanding
 Benchmarking of competition
 Suppliers for PM
 Test Samples
 Suggest options
 Conduct Factory Trials / Machine Trials
 Shelf Life Testing
 Validation
 Specification

20. Shelf Life - Product
 Initial Moisture Content
 Final Moisture Content
 Critical Moisture Content
 Impact of Oxygen – oxidation
 WVTR or MVTR & OTR of Laminate

21. Printing Process
 Gravure
 Flexo
 Digital

22. Flow of Work - Aesthetics
 Brief
 Key Line drawing / Engg. Drawing
 Creative / Design development
 Artwork development
 Proofing
 Commercial Printing
 LSD / Shade Card

23. Dispensation
 Easy opening of sachet
depends on multiple factors:
 Tear property of Polymer
 Film or Laminate Thickness
 Other ways to improve pouch
opening:
 Serration in horizontal seal
 V-Notch

24. Dispensation
 Consumer convenience can be improved by:
 Spout
 Zipper
 Making it Functional
 Innovate
www.nichrome.com/blog/nichrome-brings-easysnap-to-india/
www.ecolean.com/lightweight-packages/snapquick/
www.youtube.com/watch?v=Dwh0oPPPj_k

25. We did not discuss…
 Use of Aluminium or/and Paper in laminates
 Metalizing of films & use in Laminate
 Advantages of one lamination process over the other
 Additives in lamination
 Laminates for Retort technology
 Laminates for Vacuum packaging
 Relation between Filling Machines & Laminates
(COF)
 Impact of Printing ink on Bond strength (reverse
printing)
 Seal Failure, Bond Failure

26. Thanks for Listening!
Any Questions?