Successfully reported this slideshow.
We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime.

Developments in clear high barrier packaging

9,221 views

Published on

Developments in clear high barrier packaging

  1. 1. Developments in Clear High Barrier Packaging Dhuanne Dodrill Flexible Packaging Conference 2004 March 24 - 26, 2004 1Flexible Packaging Conference 2004
  2. 2. Package Clarity • Product Visibility – Consumer appeal – Product Identification – Product Inspection • Visual • Metal Detection • Package Inspection 2Flexible Packaging Conference 2004
  3. 3. The Standard • Aluminum Foil – 1 mil and above considered pinhole free – Virtually impervious to moisture and gas – Well understood with long history – Not clear – Limited formability 3Flexible Packaging Conference 2004
  4. 4. The Standard • Below 1 mil, pinholes impact barrier 0.20 WVTR (g/100 in2-day) 0.15 0.10 0.05 0 0.28 0.30 0.35 0.50 0.70 Foil Thickness (mil) 4 Reference: ASTM B 479Flexible Packaging Conference 2004
  5. 5. Package Requirements • Barrier – Oxygen – Water Vapor – Aroma – Chemical – UV – Microbial 5Flexible Packaging Conference 2004
  6. 6. Package Requirements • Product – Contain Water – Chemically Active – Sharp • Sterilization Method (if applicable) • Formability • Environmental/Disposal Requirements • Cost 6Flexible Packaging Conference 2004
  7. 7. Barrier Choices • Barrier Films – Barrier proportional to the thickness. • Barrier Coatings • Combination of Films/Coatings 7Flexible Packaging Conference 2004
  8. 8. Barrier Properties Common Films 100 O-Nylon Cast Nylon 10 WVTR (g-mil/100 in2-day) PVC LDPE 1 PET OPP HDPE 0.1 35 ga Foil 0.01 50 ga Foil 0.001 0.001 0.01 0.1 8 1 10 100 1000 O2TR (cc-mil/100 in2-day)Flexible Packaging Conference 2004
  9. 9. Barrier Films – EVOH • Ethylene Vinyl Alcohol (EVOH) – Discrete layer in a coextrusion LLDPE Tie EVOH Tie LLDPE 9Flexible Packaging Conference 2004
  10. 10. Barrier Films – EVOH • Excellent Oxygen Barrier – 0.006 - 0.12 cc-mil/100 in2-day – Barrier dependent upon: • Mole percent • Degree of crystallinity • Thickness • Humidity • Temperature 10Flexible Packaging Conference 2004
  11. 11. Barrier Films – EVOH • Effect of humidity on oxygen barrier O2TR (cc-mil/100 in2-day) 1 0.1 0.01 0 20 40 60 80 100 Relative Humidity (%) 11 Tested at 20°CFlexible Packaging Conference 2004
  12. 12. Barrier Films – EVOH • Excellent Oxygen Barrier • Excellent Odor/Aroma Barrier • Thermoformable • Widely used and well understood 12Flexible Packaging Conference 2004
  13. 13. Barrier Films – Barex® • Good Oxygen Barrier – 0.7 g-mil/100in2-day • Thermoformable • Can be used as a sealant 13Flexible Packaging Conference 2004
  14. 14. Barrier Films – COC • Cyclic Olefin Copolymers (COC) – Excellent moisture barrier • Discrete layer in a coextrusion or laminate. • Topas® 8007: 0.071 g-mil/100 in2-day • Topas® 6015: 0.11 g-mil/100 in2-day – Enhance stiffness – Excellent clarity – Thermoformable – Heat Resistant Grades Available 14Flexible Packaging Conference 2004
  15. 15. Barrier Films – LCP • Liquid Crystal Polymers (LCPs) – Typically used as a 0.08 - 0.2 mil layer in a coextrusion – Excellent barrier properties • Vectran V200P: O2TR: 0.04 cc-mil/100 in2-day WVTR: 0.015 g-mil/100 in2-day – Thermally stable – Inert – Chemical resistance – Thermoformable 15Flexible Packaging Conference 2004
  16. 16. Films – CTFE • Chlorotrifluoroethylene (CTFE) – Excellent Moisture Barrier • Aclar 22C: 0.026 g-mil/100 in2-day • Aclar UltRx, SupRx: 0.016 g-mil/100 in2-day – Inert – Excellent Clarity – Thermoformable 16Flexible Packaging Conference 2004
  17. 17. Films – Nanocomposites • Nanocomposites – Polymer structures containing fillers in the nanometer range. – The fillers separate into tiny platelets that disperse into a matrix of layers – Increased oxygen and gas barrier – Increased strength and puncture resistance 17Flexible Packaging Conference 2004
  18. 18. Barrier Properties Barrier Films 100 O-Nylon Cast Nylon 10 WVTR (g-mil/100 in2-day) Polyacrylonitrile PVC LDPE 1 PET OPP HDPE 0.1 Topas® 6015 Topas® 8007 35 ga Foil Aclar UltRx Aclar 22C 0.01 50 ga Foil 0.001 0.001 0.01 0.1 18 1 10 100 1000 O2TR (cc-mil/100 in2-day)Flexible Packaging Conference 2004
  19. 19. Coatings – PVdC • Polyvinylidine chloride (PVdC) – Good oxygen and moisture barrier O2TR WVTR Material (cc/100 in2-day) (g/100 in2-day) PVdC-coated PET 0.5 0.5 PVdC-coated OPP 1.3 0.3 PVdC-coated Nylon 6 0.7 0.65 19Flexible Packaging Conference 2004
  20. 20. Coatings – PVdC • Good Barrier – Barrier dependent upon coating thickness • Good aroma/flavor barrier • Widely used and well understood • Contains chlorine – Specialized equipment to apply – Incineration issues 20Flexible Packaging Conference 2004
  21. 21. Coatings – PVOH • Polyvinyl alcohol (PVOH) – Excellent oxygen barrier • PVOH-coated PET: 0.2 cc/100 in2-day • PVOH-acrylic-coated OPP: 0.02 cc/100 in2-day – Barrier dependent upon coating thickness – Moisture sensitive 21Flexible Packaging Conference 2004
  22. 22. Coatings – SiOx • Silicon Oxide (SiOx) O2TR WVTR Material (cc/100 in2-day) (g/100 in2-day) ClearFoil®A 0.04 0.04 ClearFoil®F* <0.003 0.02 *Excellent flex-crack resistance 22Flexible Packaging Conference 2004
  23. 23. Coatings – SiOx • Flex/Pinhole Resistance Flat O2TR Flexed O2TR Material (cc/100 in2-day) (cc/100 in2-day) 48 ga oPET/35 ga Foil/ 2mil LLDPE 0.03 3.2 48 ga oPET/Met/ 2mil LLDPE 0.1 0.7 48 ga oPET/ClearFoil® A/ 2mil LLDPE 0.04 0.5 48 ga oPET/ClearFoil® F/ 2mil LLDPE <0.003 <0.003 23Flexible Packaging Conference 2004
  24. 24. Coatings – Al2O3 • Aluminum Oxide (Al2O3) O2TR WVTR Material (cc/100 in2-day) (g/100 in2-day) ClearFoil®P 0.2 0.2 ClearFoil®M 0.045 0.03 ClearFoil®M2 0.04 0.3 ClearFoil®X 0.005 0.002 24Flexible Packaging Conference 2004
  25. 25. Barrier Properties Barrier Coatings 100 O-Nylon Cast Nylon 10 WVTR (g-mil/100 in2-day) PVOH PET PVC 1 PET LDPE PVdC PET PVdC Nylon OPP PVOH OPP CF P PVdC OPP HDPE 0.1 35 ga Foil CF A CF M CF F 0.01 50 ga Foil CF X 0.001 0.001 0.01 0.1 25 1 10 100 1000 O2TR (cc-mil/100 in2-day)Flexible Packaging Conference 2004
  26. 26. Active Packaging • Oxygen Scavengers – Reduce oxygen level in the package 20 Percent Oxygen 15 10 5 0 5 10 15 20 25 Time (hours) 26Flexible Packaging Conference 2004
  27. 27. Active Packaging • Oxygen Scavengers – Use with a passive barrier – Separated from the product with a functional barrier Passive Barrier Oxygen Scavenger Sealant 27Flexible Packaging Conference 2004
  28. 28. Active Packaging • Oxygen Scavengers – Ferric compositions • Moisture activated (>40% RH) • Must store at low RH – OSP • Oxidizable polymer / transition metal catalyst / photoinitiator • UV to trigger oxidation mechanism • No degradation products 28Flexible Packaging Conference 2004
  29. 29. Active Packaging • Antimicrobial – Inhibit or retard growth of microorganisms – Many options • Organic acids & anhydrides • Inorganic gases • Silver salts • Fungicides • Bacteriocins • Enzymes • Chelating agents • Spices • Essential oils 29 • ParabensFlexible Packaging Conference 2004
  30. 30. Barrier Properties 100 O-Nylon Cast Nylon 10 WVTR (g-mil/100 in2-day) EVOH PVOH PET Polyacrylonitrile PVC 1 PET LDPE PVdC PET PVdC Nylon OPP PVOH OPP CF P PVdC OPP HDPE 0.1 Topas® 6015 CF A Topas® 8007 35 ga Foil CF M CF F LCP Aclar 22C 0.01 Aclar UltRx 50 ga Foil CF X 0.001 0.001 0.01 0.1 30 1 10 100 1000 O2TR (cc-mil/100 in2-day)Flexible Packaging Conference 2004
  31. 31. Barrier Properties Summary Thickness MVTR O2TR Autoclaveable/ Category Material Trade Name Thermoformable (mil) (g/100in2-day) (cc/100in2-day) Retortable Films oPET 1 1.5 4.5 No Yes Oriented Nylon 1 26.5 3 No Yes** Cast Nylon 1 19 3.5 Yes Yes OPP 1 0.33 150 No No LDPE 1 0.9 NA Yes No HDPE 1 0.37 NA Yes Marginal PVC 1 2.3 11 Yes No Barrier Films Polyacrylonitrile Barex 1 4.5 0.7 Yes No EVOH 1 1.4 - 8.0 0.0006 - 0.12 Yes Yes** COC Topas 8007 1 0.071 NA Yes No COC Topas 6015 1 0.11 NA Yes Yes LCP Vectran V200P 1 0.015 0.04 Yes Yes CTFE Aclar 22C 1 0.026 15 Yes Yes CTFE Aclar UltRx/SupRx 1 0.016 7 Yes Yes Barrier Coatings PVdC-coated PET * 0.5 0.5 No No PVdC-coated OPP * 0.3 1.3 No No PVdC-coated Nylon * 0.65 0.7 No No PVOH-coated PET * 4 0.2 No No PVOH-acrylic-coated PET * 0.37 0.02 No No SiOx-coated PET ClearFoil A * 0.04 0.04 No Yes SiOx-coated PET ClearFoil F * 0.02 <0.003 No No Al2O3-coated PET ClearFoil P * 0.2 0.2 No No Al2O3-coated PET ClearFoil M * 0.03 0.045 No No Al2O3-coated PET ClearFoil M2 * 0.3 0.04 No Yes Al2O3-coated PET ClearFoil X * 0.002 0.005 No No Metallized PET * 0.05 0.1 No No Opaque Barrier Aluminum Foil (flat) 0.35 0.02 0.03 No Yes Aluminum Foil (flat) 0.5 0.01 0.02 No Yes Aluminum Foil (flat) 1 <0.00 <0.000 Yes Yes .ssenkciht etartsbus nopu tnedneped ton si dna gnitaoc eht ot eud si slairetam eseht rof reirrab ehT * .noitcurtsnoc etisopmoc eht nopu tnednepeD** 31Flexible Packaging Conference 2004

×