Extrusion coating

1. Confidential
Film extrusion and extrusion coating with
Ecoflex® and Ecovio®
Godrej Consumer Products Limited Seminar
July 20th, 2012
Saurabh Varma, Ashwin Patel

2. Confidential
100% biobased
Partly biobased
Fossil-based
Bio-terms – What do they mean?
PLA
100% biobased
Fossil-based
PE
Bio-PE



3. Confidential
Non-biodegradable Biodegradable
Renewable raw materials
Fossil raw materials
Ecoflex®
Ecoflex®
PLA
Biodegradable polymers
Ecovio®
PE, PA, PP, PVC
Bio-PE, Bio-PA, Bio-PP, Bio-PVC
 Fossil-based and biobased polymers can both be 100% biodegradable.
cf: Hans-Josef Endres, Technische Biopolymere, 2009 (p. 21)

4. Confidential
High
temperatures
End
Aeration
(availability
of oxygen)
Carbon/
nitrogen
ratio
Start
12 weeks according to DIN EN 13432*
Optimal process conditions
* Composting phases can differ according to different technologies and processes
EN 13432
Compostability of biodegradable polymers
in industrial composting sites
Moisture
content

5. Confidential
Key benefits of composting
Compost:
 helps to prevent pollution.
. increases soil workability, water holding capacity
 improves porosity and thus soil structure
 minimizes wind and water erosion.
 helps to maintain a healthy soil pH, so that plants
grow better and lawns stay greener.
 creates enhanced microbial action in the soil, which
creates stable ecosystem
 serves as potential carrier for fertilizers
Compost:
reduces the need for water
 eliminates need of structural soil improvement
 serves as a marketable commodity.
 low cost alternative to standard landfill cover and
artificial soil amendments
 less costly alternative to conventional methods of
remediating.
Environmental Economical
Benefits of composting
 Turn waste into valuable resource.

6. Confidential
The major value proposition of Ecoflex® & Ecovio®
is: 100% Compostability and biodegradability
Biodegradability standard is prerequisite for any substantial business
Ecoflex® fulfills all standards for compostable and biodegradable plastics
Europe
EN 13432
Asia
GreenPla
North America
ASTM 6400

7. Confidential
Film extrusion and extrusion coating with
Ecoflex® and Ecovio®
What is Ecoflex® ?
What is Ecovio® ?
Extrusion Coating with Ecovio® FS Paper
Mineral oil barrier for food protection
Application

8. Confidential
What is Ecoflex® ?
 Ecoflex® is a biodegradable Copolyester based on monomers:
- Terephthalic Acid
- 1,4 Butanediol
- Adipic Acid
 Goals of Development:
 Biodegradability in industrial composting and in soil
 Compatibility to biopolymes from renewable resources
 Film material with good mechanical properties close to LDPE
 Processability on existing production lines

9. Confidential
Compostability is measured using a controlled
composting test
 Ecoflex® yields more than 90% conversion to CO2 after only 80 days.

10. Confidential
Ecoflex® shows no acute and advers toxicity and
is heavy metal free
 Ecoflex® causes no build up of environmentally dangerous compounds during
biodegradation that could have accumulation potential in organisms or the
ecosystem.

11. Confidential
Advantages of Ecoflex® ?
Typical properties
 Worldwide certified
compostability
 High strength and
ultimate elongation
 Processing on existing
production lines
EU - EN 13432 USA: ASTM D 6400-04 Japan: GreenPla

12. Confidential
What is Ecoflex® ?
The biodegradable polyester from BASF -
Compatible to renewable resources
Ecoflex®
Cellulose Lignin
Polylactic Acid PHAs
Starch
Polyhydroxyalkanoat
Polymer of Lactic Acid Storage Polymer of Micro Organisms

13. Confidential
Advantages of Ecovio®
Product name for blends of Ecoflex® and PLA
Typical properties, Potential packaging solutions
Foam Trays Carrier Bags Shrink Film
EU - EN 13432 USA: ASTM D 6400-04 Japan: GreenPla
 World wide certified
Compostability
 Adjustable stiffness
 Excellent draw down,
- Film Thickness > 8 µm

14. Confidential
Film extrusion and extrusion coating with
Ecoflex® and Ecovio®
What is Ecoflex® ?
What is Ecovio® ?
Extrusion Coating with Ecovio® FS Paper
Mineral oil barrier for food protection
Application

15. Confidential
 Terephthalic acid
 1,4 Butane diol
 Adipic acid
Chemical Structure of Ecoflex®
Biodegradable polymer
Ecoflex® is a biodegradable copolyester on the basis of:
Ecovio®
PLA
(stiff)
Ecoflex®
(flexible)
Ecovio®

16. Confidential
Using Ecovio®, Ecoflex® and PLA you can
approach major application segments in
packaging
Ecovio® + Ecoflex®
Flexible Stiff
Ecovio® Ecovio® + PLA
Flexible packaging,
Carrier bags,
Hygiene films
Packaging, pouches
Carrier bags,
Hygiene films
Rigid packaging,
Oriented nets

17. Confidential
Film extrusion and extrusion coating with
Ecoflex® and Ecovio®
What is Ecoflex® ?
What is Ecovio® ?
Extrusion Coating with Ecovio® FS Paper
Mineral oil barrier for food protection
Application

18. Confidential
■ Technology: Extrusion coating of Ecovio FS Paper on paper or board for
flexible or rigid packaging
Slit die extrusion at 150 to 600 m/min
Extrusion coating technology
Ecovio® FS Paper coating technology (2)
Extrusion coating

19. Confidential
Ecovio® FS Paper
Combining complementary functionalities
Ecovio®
FS Paper
Paper

20. Confidential
■ Value and benefits
a) For converter:
 Glossy coating without adhesion to chill roll
 Excellent adhesion to paper and board using flame treatment
 Coating weights of 12 to 30 g/m² depending on application and equipment
 Stable at high line speed of 600 m/min. – 800 m/min. feasible on pilot line
 Runs full speed on fastest cup making line with a coating weight of 20 g/m²
and 330 cups/min.
 Energy saving => Melt temperature 40 to 100 °C lower than LDPE
 Energy saving => Heat seal strength at PE level at 30° C lower temperatures
 Good printability (water / alcohol based colors)
 Repulpable under alkaline conditions
Ecovio® FS Paper coating technology (3)
Extrusion coating

21. Confidential
■ Value and benefits
b) For end user e.g. brand owners, fast-food chains and coffee shops:
 Grade for biodegradable coating with a renewable carbon content of 75 %
according to ASTM D 6866
 Barrier to oil, fat, liquids, aroma and mineral oil
 Scratch resistance
 Food contact approval in Europe and in North America (FCN, type C)
 Compostability according to EN 13432 in Europe, to ASTM D 6400 in North
America
Ecovio® FS Paper coating technology (4)
Extrusion coating

22. Confidential
Trial conditions:
Starting temperature 40°C
Consistency 4%
NaOH for pH adjustment
Repulping time 15, 30, 60 min
100% Fresh fiber board
Paper recycling - Fate of paper
Repulping trials in a professional Voith Lab Pulper

23. Confidential
■ Cup grade
■ Coated cup
grade
■ pH 10
■ pH 11
■ pH 12
Paper recycling - Fate of paper
Repulping Trials with Ecovio FS Paper – Results
15 Min, 30 Min. 60 Min.

24. Confidential
Film extrusion and extrusion coating with
Ecoflex® and Ecovio®
What is Ecoflex® ?
What is Ecovio® ?
Extrusion Coating with Ecovio® FS Paper
Mineral oil barrier for food protection
Application

25. Confidential
Barrier properties of samples coated with
Ecovio FS Paper against mineral oil
Substrate Ecovio® FS Paper Break Through @ 22 °C
Fresh Fiber Board, 210g/m² 16 g/m² (12.8 µm) > 9 years
Transparent Paper, 92 g/m² 16 g/m² (12.8 µm) > 9 years
Recycled Board, 290 g/m² 29 g/m² (23.2 µm) > 6.8 years
LDPE-Film, 100 µm (92 g/m²) - < 10 h
 Mineral oil migration lag time measured in days at 60°C using
Gravex 913 (75% MOSH, 25% MOAH)
 Lag time at 60 °C recalculated in time unit at 22°C
Source: BASF SE, Ludwigshafen based on results of Grob, K. Kantonales Labor Zürich, April 2011

26. Confidential
Film extrusion and extrusion coating with
Ecoflex® and Ecovio®
What is Ecoflex® ?
What is Ecovio® ?
Extrusion Coating with Ecovio® FS Paper
Mineral oil barrier for food protection
Application

27. Confidential
Potential applications for Godrej Consumer
Products Limited - 1
 Soap Wrappers
Today: Non-biodegradable plastic laminate – not
eco-friendly
BASF Proposal:
Outer Base Material: Box – Paper board
Inner Base Material: Kraft Paper
Sealant: Ecovio® FS Paper
Certification according to standards for
biodegradability - EN 13432 - ASTM D 6400
Differentiation from competition by logos

28. Confidential
Potential applications for Godrej Consumer
Products Limited - 2
 Small Sachets
Today: Non-biodegradable plastic laminate – not eco-
friendly
BASF Proposal:
Base Material: Paper
Adhesive: Epotal P100 Eco
O2, H2O-Barrier, metCellophane
Oil and Aroma Barrier
Sealant Ecovio® FS Paper
Certification according to standards for
biodegradability - EN 13432 - ASTM D 6400
Differentiation from competition by logos

29. Confidential
 Soft Drink and Coffee Cups Packaging for Frozen Food
 - Coffee cups, + 90 °C - Packaging for frozen food, -18 °C
 Extrusion coated paper cups Extrusion coated boxes, Freezer bags

Potential applications for Godrej Consumer
Products Limited - Others

30. Confidential
Biodegradable packaging as a complete
solution for closed systems
 Food Service Restaurants
 Sport Arenas (Cricket)
 Festivals etc.
Food Waste
+ Food Serviceware
=> Compost

31. Confidential