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Functional barrier films in flexible packaging industry

The document analyzes global trends in high-performance barrier films in flexible packaging, noting significant growth in the market led by convenience foods and evolving consumer demands. Key insights include the projected 4.8% annual growth in barrier film markets across various food applications, particularly in fresh and processed meat packaging. It highlights the shift towards innovative packaging solutions using advanced materials like EVOH and PVDC to improve product preservation and reduce environmental impact.

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TREND PACKAGING & OUTLOOK henkywibawa@yahoo.com Functional BARRIER FILMS in FLEXIBLE PACKAGING
Global Trends Packaging Requirements Packaging and Processing
Source: Standard Chartered
The Middle Class Spending Journey Middle class rise Increase in available consumer credit Small amount to LARGE number LOW income Purchase BIG ticket : Electronic,Furniture, Auto lifestyle Choose where to shop or entertained. Farther home Increase demand for travel and leisure service Greater emphasize for entertainment and leisure Retirement Healthcare Child education Increased demand for financial services
means Modern living FMCG drive the growth Fast growing segment (>15%)
Years ahead : Indonesia retail growth 2nd best after china
Megatrends •Convenient •Healthy •Feel good •Look good
Brand engagement to boost consumption We - commerce
Easy to use packaging
The Business Stuck on the -er words • Bigger • Brighter • Better • Stronger • Faster • Easier • Newer • Cheaper ! imagin
Copyright©2013TheNielsenCompany.Confidentialandproprietary. 31 No differentiation means price
More Convenient Anytime, anywhere HOW YOU CREATE POSSIBLE SURPRISE THAT KIDS AND FAMILY LOVE …
Experience Economy Lets move
The Magic Triangle of Packaging: Customer Packaging Material Packaging Machine Packaging System Functionality compliance
 Globalization  Customer Delivered Value  Networked Technology  Product Life Cycle Compression  Supply Chain Management  Mass Customization  Digital Business
Product value Services value Personnel value Image value Total customer value TCV Monetary cost Time cost Energy cost Psychic cost Total customer cost TCC Customer delivered value CDV  CDV = TCV - TCC  TCV = Bundle of benefits expected from product  TCC = Bundle of costs expected to evaluate, obtain, and use the product
Raw Material Suppliers Converters (at full capacity/overcapacity) Food/Pharma Manufacturers Consumers Converters are squeezed Design Process Packing Process Distribution Process
HIGH-PERFORMANCE BARRIER FILMS: Examining Global Trends from Our Perspective
The global packaging market is huge; offering many opportunities in barrier packaging, led by flexibles. N. America and Europe account for roughly 55% of global packaging value, but growing at slower rates than rapidly developing regions such as Asia Global Packaging Market (value of shipments-all structures) $450 Billion Annual Growth 2-3% (>5% Asia)
High-performance barrier packaging films is specific, as follows. Film structures providing high barrier levels to oxygen, water vapor, aromas/flavors, and/or UV light – A barrier film is usually a coextruded, coated, or metallized substrate – Barrier components include PVdC resin/coating, EVOH, nylon, MET films, or Al2O3 or SiOx – But excludes all structures that use Al foil as the barrier, paper as a structural member, or MET films used only for graphic enhancement Film structures <10 mil (e.g. multilayers of printed layer, barrier & sealant) Includes film structure laminations (with a barrier film), or a coextrusion containing a layer of barrier resin, or a substrate coated with a barrier material that might also function as a sealant A mono-structure of only barrier film is very rare; real value is created when the barrier film is a ‘component’ that enables the final package
The market for H.P. barrier packaging films is positively influenced by many factors. Cost Reduction Rigids to flexible; less R.M. & lower freight Process Improvement CoEx & laminates offset resin cost High growth of Convenience food Home Ready - Ready to Cook Smaller packages More barrier needed, Higher surface-volume ratio Alternative Packaging Smart, security, reclosability, etc. Market forMarket for High PerformanceHigh Performance Barrier PackagingBarrier Packaging FilmsFilms Geo-Cultural & Trade Impacts Our focus is on food packaging, with some comments on medical devices
Business opportunity emanates from the value chain continuum of application, film and structure. Package Structure Markets & Applications Barrier Film Perishable Food -Fresh meat -Prepared food -Processed meat & cheese Dry Food -Confections & snack bars -Pet food -Snacks & baked snacks Medical & others PVdC EVOH Nylon Metallized Specialty oxides CoEx. & laminates Bags Lid stock Stand-up pouches Forming web Wraps Barrier Film Package Structure Markets & Applications Business Opportunity Barrier Film Package Structure Markets & Applications Business Opportunity US H.P. Barrier Film $1.2 BIL We use sophisticated applications model to combine film & package conversion costs, area and package structure to determine various market size relationships
StructureFilmMarkets The overall barrier film market is forecast to grow at a good AAGR of 4.8% over the next five years. 0 1 2 3 4 5 6 7 Overall market, 4.8% Averageannualgrowth,% Perishable food Dry food Fresh meat Processed meat Cheese and dairy Prepared food Total Perishable Food ($950 MIL) Snack food Baked snacks Dry mixes Confections and snack bars Pet food Coffee Total Dry Food ($250 MIL) Largest Share 82% Perishables Smallest 3% of Perishables Largest Share 70% Dry Food Coffee & Pet Small Share <5% of Dry Food
StructureFilmMarkets In perishable food, consumption of barrier films for fresh-meat applications is to grow AAGR of 5.6%. Key Stats: Fresh Red Meat: •$720-740 MIL Film •5.6% Growth/yr •82% of Perishables •67% of Barrier Pkg Examples: •Case-ready red meat focus •Pork & poultry already case-ready & maturing Penetration of case-ready meat to drive growth of barrier films Trend toward the production of more case-ready red-meat products Increase in the use of shrink bags for case-ready and value-added products Refrigerated space allocated for fresh meat expected to decline, as consumers demand convenience products; i.e. need increased O2 barrier & shelf life
StructureFilmMarkets Processed meat, cheese and dairy segments will exhibit more steady growth, at about 3-3.5%. Key Stats: Proc. meats, cheese, dairy: •$100-110 MIL Film •3-3.5% Growth/yr •14% of Perishables •11% of Barrier Pkg Examples: •Deli meat & cheese slices •Natural chunk cheese •Milk, pudding, yogurt The image of processed meats (deli) as unhealthy is changing, with some products now viewed by consumers as convenient sources of protein The use of barrier films to package cheese will continue to increase as consumers’ preference for natural cheese continues to grow at the expense of processed cheese that requires less barrier packaging Consumer demand for smaller, more convenient packages will contribute to the increase in barrier film consumption Cost reduction will continue to drive the trend toward replacement of laminations with coextrusion technology
StructureFilmMarkets In dry-foods, consumption of barrier films for dry-mixes is forecast strong AAGR of 4.2%. Key Stats: Dry mixes: •$25-30 MIL Film •4.2% Growth/yr •12% of Dry Foods •2% of Barrier Pkg Examples: •Cake mixes •Pudding powder •Powder flavoring The dry food category is much smaller than perishables at about $250 MIL, or 20% of barrier film share Dry mixes is a relatively small part of the dry food category, driven by consumer preference for standup pouches and away from rigid packaging To reduce investment risk, many companies are increasing the use of contract packagers as a means of converting to standup pouches Trend toward clear packaging to view contents favors clear barrier film solutions
StructureFilmMarkets Snack-foods & baked-snacks to have respective modest growth, at AAGR of 2.3% & 2% each. Key Stats: Snack food/baked-snacks: •$160-170 MIL Film •2-2.5% Growth/yr •79% of Dry Foods •16% of Barrier Pkg Examples: •Chips, nuts, cookies, dried fruits, raisins, etc •Baked (healthy snacks) – no preservatives One of the biggest trends in snack foods is the move toward products packaged in single servings that are easily portable and consumed on- the-go; we work 24/7, have a family and need convenience The snack food category will continue to move away from rigid containers in favor of flexible packaging (SUP), with new introductions by major suppliers of snack nuts, cookies, and most recently, crackers The use of barrier films in the baked-snack segment is expected to increase overall, driven by consumer desire for healthier products that require more protection from moisture and oxygen to retain freshness
StructureFilmMarkets High-growth expected in perishable foods for EVOH & Al2O3-PET films (8%+); in dry-foods PVdC-PET (9.2%). 0 1 2 3 4 5 6 7 8 9 10 Overall market, 4.8% Averageannualgrowth,% Perishable food Dry food PVdC 45% EVOH 25% Nylon 25% PVdC- coated PET Total Perishable Food ($950 MIL) Al2O3- coated PET MET nylon SiOx- coated PET PVdC- coated PP PVdC- Coated PP 50% MET-PP 35% MET-PET 10% PVdC- coated PET EVOH Total Dry-Food ($250 MIL) MET PETFresh & Processed Meats Fresh Foods, Meats & Tray Lidding Fresh Foods, Meats & Lam-Trays Retort; Japan & Europe interest Retort; Japan & Europe interest High-growth, but small market today Snacks & Baked Snacks & Baked Displacing PVdC SUP Clarity Applications
StructureFilmMarkets Primary converters of shrink bags for fresh & processed meat entrenched in PVdC CoEx-tech. Although PVdC is inherently difficult to process, primary converters of shrink bags for packaging fresh and processed meat (Cryovac, Curwood,and Amcor) are entrenched in PVdC coextrusion technology for narrow web Dow has introduced patented encapsulation technology to blow multilayer film and for producing wider width substrate. Licensing of this technology is likely to spur growth of PVdC resin for blown multilayer film New growth markets for PVdC include lid stock and retort applications for prepared foods, which require moisture stability Despite environmental issues, PVdC is still widely used for shrink bags in Europe, and its use in the U.S. does not appear to be a threatened
StructureFilmMarkets PVdC-coated PET, used as lid-stock & inner ply of clear standup pouches for is growing. Increase in the use of PVdC-coated PET lid stock for packaging prepared foods – MAP, hot-fill and retort The use of PVdC-coated PET in packaging processed meats will decline Lamination and coating processes are being displaced by coextrusions However, PVdC-coated PET, commonly used as the inner ply of standup pouches for snack foods, dry mixes, and pet food, is expect to grow for applications requiring clarity
BARRIER COATED FILMS Barrier Coated Moisture Barrier Films on BOPP, on PET and on NYLON are specially coated films to enhance Moisture Barrier and Oxygen Barrier. There are able to reduce Moisture Barrier and Oxygen Barrier by more than 50 % of uncoated plain films. It is also more cost effective than PVDC and EVOH. The Barrier Coating materials is 100% Waterbased. And this film totally environmentally friendly. It is proven to be more cost effective, when compared to 3 or 4 layers laminating structures without compromising the Moisture/Oxygen Barrier of the Packaging. Most importantly these Films are able to reduce Carbon Footprint in Flexible Packaging by minimum 10%.
MOISTURE / OXYGEN BARRIER OF VARIOUS FILMS & COATINGS * Total Film+ Coating Thickness 25µ gms/sqm gms/100 in² cc/sqm cc/100 in² EVOH* Dry 0.20 0.01 Moist (90%RH) 58.90 3.80 2.70 0.17 HB-PVDC* 0.78 0.05 1.20 0.08 PVDC (15µ BOPET) ∆ 14.00 0.90 6.00 0.40 HDPE 25µ ∆ 9.00 0.30 3,000.00 195.00 LDPE 25µ ∆ 18.00 1.20 8,000.00 519.00 CPP 25µ ∆ 12.00 0.80 4,200.00 272.00 BOPP 20µ ∆ 8.00 0.50 2,500.00 162.00 MYLAR™ BOPET 12µ ∆ 40.00 2.60 140.00 9.00 BOPA 15µ ∆ 250.00 16.20 90.00 5.80 K-BOPET 15µ 5.40 0.35 7.00 0.45 K-NYLON 17µ 4.00 0.25 6.00 0.40 EVAL™ EF-CR 15µ ∆ 142.00 9.20 1.50 0.10 EVAL™ EF-XL 15µ ∆ 29.00 1.90 1.00 0.06 BICOR™ 20MB666 7.00 0.45 1,000.00 65.00 BICOR™ 21MB866 (PVOH) 4.00 0.26 0.70 0.05 Barrier Coated-P20 (BOPP 20µ) 5.00 0.30 1,210.00 79.00 Barrier Coated-P18NS (BOPP 18µ) 6.00 0.40 8.00 0.50 Barrier Coated-P20NS (BOPP 20µ) 5.30 0.35 8.00 0.50 Barrier Coated-T12NS (BOPET 12µ) 14.00 0.90 4.60 0.30 MVTR (24 hrs/38°C/90%RH) OTR (24 hrs/23°C/1 ATM)FILMS * Coated on BOPP 25µ Films BarrierCoated Films Tested by Labthink Instruments Co., Ltd. On Perma W03/030 MVTR Unit (ASTM F1249) & Perma OX2-231 OTR Unit (ASTM D1434) Source *: Current Technologies in Flexible Packaging- STP 912 by Michael L. Troedel Source ∆: Dupont Teijin Film™ Specification Sheet. BICOR™ is a product of ExxonMobile EVAL™ is a product of Kuraray Co., Ltd. MYLAR™ is a product of Dupont Teijin Film™
Polyamide provides  oxygen and aroma barrier  heat resistance  good mechanical properties  thermoformability Polyethylene provides  high water barrier  sealability multilayer film combines properties of multiple components Multi-layer Film 2
 5-layer PE/tie/PA/tie/PE + PA protected from humidity  7-layer PE/tie/PA/tie/PA/tie/PE + split PA - improved thermoformability  7-layer PE/tie/PA/EVOH/PA/tie/PE + very high barrier + good thermoformability ● 9-layer PE/PE/tie/PA/EVOH/PA/tie/PE1/PE2 + sealing PE + antiblock/slip in PE1 + reclosable in PE2 Coextrusion Film: Symmetric Structures 5
+ fast sealing due to heat-resistant PA skin layer - curl ● 3-layer PE/tie/PA ● 5-layer PE1/PE2/PE2/tie/PA + sealing material, antiblock/slip in PE1 + simple polyolefins in PE2 ● 5-layer PE/tie/PA/tie/PA + split PA - improved thermoforming ● 5-layer PE/tie/PA/EVOH/PA ● 7-layer PE/tie/PA/EVOH/PA/tie/PA ● 9-layer PE/tie/PA/EVOH/PA/tie/PE/tie/PA Coextrusion Film: Asymmetric Structures 6
 Double/Triple bubble process o Extrusion (downward/watercool) o Blow-up o Annealing  40-50% shrink  For : o shrink bottom seal bags o shrinkable lidding for rigid tray o shrinkable bottom + lidding film Shrink Bag / Shrink Film 10
StructureFilmMarkets Growth in case-ready MAP for fresh meat will translate into growth for multilayer EVOH film. EVOH coextrusions in packaging processed meats and cheese will continue to displace more expensive PVdC-coated films Trend toward clear EVOH/nylon structures as replacements for MET PET in prepared foods and bag-in-box wines EVOH to continue growing in laminated food trays
StructureFilmMarkets MET PP has all but replaced higher-priced MET PET in the snack foods category. MET PP is the film of choice in packaging candy and snack bars (graphics appeal) Use of MET PET as the inner ply of standup pouches for snack foods, dry mixes, and pet food will continue due to good dimensional stability and heat resistance are critical The use of MET PET bags in foodservice applications, will continue to grow with the trend toward clear barrier films, replacing metal cans
StructureFilmMarkets Barrier packaging films for lid stock & standup pouches in the food sectors forecast to grow at above rates. Lid stock -4 -2 0 2 4 6 8 10 Overall market, 4.8% Averageannualgrowth,% Perishable food Dry food Lid stock Bags Standup pouches Wraps Total perishable food segment Bags Wraps Total dry-food segment Forming web Standup pouches interestAbove average growth Above average growth Above average growth
StructureFilmMarkets Bags continue to be the major flexible barrier packaging structure, growing at average rates. Bags are extensively used in packaging dry foods — most are pillow packs & bag- in-box type, supplied as rollstock to end users to run on form/fill/seal lines Square-bottom bags, used to package coffee, becoming popular for other dry food with improved graphics, reclosability & overall cost reduction vs. bag-in-box Increases in oil prices will continue to fuel growth in 1 gal foodservice bags as replacements for #10 metal cans The use of barrier shrink bags for packaging case-ready & processed meats growing at about 3-4%, led by convenience products - fresh meat & cooked
StructureFilmMarkets Standup pouches are being introduced into every category of dry-foods to differentiate products. Standup pouches with zippers offer reclosability, improved barrier & material savings in a one-component flexible package vs. multi-component rigid containers they are replacing for packaging dry food Rising fuel prices drive the trend toward metal can replacement with standup pouches; one truckload of flat bags/pouches equals 25 truckloads of cans Sales of shelf-stable foods in retort pouches grown 20-30% in recent years, reaching $100 MIL in pouches. Many are foil laminates with clear barrier films Standup pouches are also gaining popularity for packaging processed meats like bacon bits and pre-cooked bacon.
 Thermoforming – forming (bottom) web – lidding  Bags – tubular bags – side-seal bags  Pouches – VFFS vertical form/fill/seal – HFFS horizontal form/fill/seal  Shrink Bags / Film Barrier Film Applications 7
9 PE/tie/PA 75-150µm Heavy bulk bags (unprinted) CPA//PE 75-150µm Bulk bags BOPA//PE 60-120µm Printed pouches PE/tie/PA/tie/PE 60-100µm Pouches /face-to-back sealing BOPET//PE/tie/PA/EVOH/PA/tie/PE 60-100µm High-barrier pouches (printed) BOPET//Alu//BOPA//PE 90-120µm High-barrier pouches for retort applications Typical Bag/Pouch Film Structures
 PE / tie / PA  CPA // PE  BOPA // PE  BOPET // (PE/tie/PA/EVOH/PA/tie/PE) 70-120µm thickness of lidding film is determined as the residual wall thickness of formed web Typical Structures of Lidding Film 8
Going forward, the outlook for high performance barrier packaging films is very positive. Large and non-cyclical market Sustainable growth drivers – Cost reduction – Convenience-oriented food – Smaller packages – Demand for alternate packaging formats
Product Name Existing Developing Detergent Powder: Philippines, Indonesia. PET (12µ)/Print/ LLDPE (45µ) OTR: 200gm/m²/24hr MVTR: 7.0gm/m²/24hr • 2 Ply Laminate Structure Barrier Coated-P35NS/Print /LTS2502, LTS2502H OTR: 5.0gm/m²/24hr MVTR: 2.0gm/m²/24hr • 1 Layer Structure •Coated-P35NS: BOPP35µ Global Customer Move Pattern Coat, 3 gsm for Sealing Purpose: Reduce Plastics Consuming from 2 Layers to 1 Layer.
Product Name Existing Developing Snacks/Chips: Indonesia, South Africa- NAMPAK Flexible Packaging. • PET/Print/MPET/LLDPE OTR: 1.20gm/m²/24hr MVTR: 0.90gm/m²/24hr • PET/Print/PE/MPET/LLDPE OTR: 1.0gm/m²/24hr MVTR: 0.75gm/m²/24hr Barrier Coated-P18NS/Print/ VMCPP OTR: 0.15gm/m²/24hr MVTR: 0.80gm/m²/24hr or Barrier Coated-T12NS/Print/ VMCPP OTR: 0.07gm/m²/24hr MVTR: 0.90gm/m²/24hr • 2 Layers •Coated-P18NS: BOPP18µ •Coated-T12NS: BOPET12µ Global Customer Move Purpose: Reduce Plastics Consuming from 3-4 Layers to 2 Layers.
Product Name Existing Developing Instant Noodle: Malaysia,Indonesia Salad/Vegetables: Australia BOPP/Print/PP OTR: 1100gm/m²/24hr MVTR: 5.0gm/m²/24hr BOPP/Print/PE OTR: 1300gm/m²/24hr MVTR: 5.0gm/m²/24hr PET/PRINT/LLDPE OTR: 200gm/m²/24hr MVTR: 7.0gm/m²/24hr •2 Ply Laminate Structure BARCO-P35NS/Print/ LTS2502, LTS2502H OTR: 5.0gm/m²/24hr MVTR: 2.0gm/m²/24hr • 1 Ply Laminate Structure •BARCO-P35NS : BOPP 35µ Global Customer Move Pattern Coat, 3 g. for Sealing Purpose: Reduce Plastics Consuming from 2 Layers to 1 Layer.
Cost Competitive Study Product Name Existing Structures Laminating Structures using Barrier Coated Films Instant Coffee: Indonesia A)PET/Print/Al/LLDPE OTR: 0.20gm/m²/24hr MVTR: 0.30gm/m²/24hr Cost/100sqm: USD 42.00 B)PET/PRINT/VMPET/LLDPE OTR: 1.20gm/m²/24hr MVTR: 0.90gm/m²/24hr Cost/100sqm: USD 37.00 C)PET/PRINT/VMPET/CPP OTR: 1.60gm/m²/24hr MVTR: 0.80gm/m²/24hr Cost/100sqm: USD 26.50 •3-Ply laminate Structures Barrier Coated-P18NS/Print/ VMCPP OTR: 0.15gm/m²/24hr MVTR: 0.80gm/m²/24hr Cost/100sqm: USD 26.50 • 2-Ply Laminate Structures. • Coated-P18NS: BOPP18µ •58% lower cost with Coated 2-Ply > (A). •39% lower cost with Coated 2-Ply > (B). Reduction of laminating structures from 3 Layers to 2 Layer.
In pharmaceuticals, flexible H.P. barrier packaging is insignificant; growth of unit-dose blister packs The pharmaceutical segment is comprised of prescription drugs, medications, and dietary supplements sold over-the-counter (OTC) World demand for pharma packaging to reach $24 BIL in 2009, increasing 4-5% annually. 80% of demand from the US, Japan, China, Germany, France, UK, Italy, & Switzerland. The US will remain the largest consumer driven by aging baby boomers Blister packaging is the fastest-growing segment of the pharma market. Worldwide demand expected to grow 7% AAGR, reaching $5.6 BIL by 2009, driven by unit dose & sterile applications It is estimated that less than 1% of all pharmaceuticals are packaged in barrier films, as defined by our definition and therefore not a significant consuming segment of barrier films However, future barrier may be needed to maintain drug potency or inhibit degradation. A moisture barrier is critical for gels or liquids, sensitive to moisture loss. Foil used for UV barrier In addition to unit-dose blister packs, companies are converting to flexible pouches Unit doses maintain the ‘five rights’ of medicine monitoring: Right patient, right drug, right dose, right time, and right route of administration. Thus safer & tamper resistant New delivery systems, nasal, transdermal and parenterals in home-care and self-care applications also growing - not having to visit a doctor’s office cuts costs and saves time Key trend is aging population - 75% of pharma consumers are senior citizens – Healthy lifestyle & fitness craze has fuel popularity of vitamins and dietary supplements – The market for cosmeceuticals also experiencing rapid growth - aged refuse to look old – Opportunities exist for the growth of barrier films in alternative pharma delivery. The use of Al2O3- and SiOx-coated films are expected to grow in niche applications
Packaging opportunities gleaned from other regions. Drivers Western Europe China & Japan Consumer Preference Traditional frequent trips to market Few long lunches at home; grab-n-go Higher income – spend more at stores Rapid lunches-aesthetics outweigh costs Local shops provide flexible single serve Refrigerator limitations (small or none) Low birth-rate More singles & elderly Displaced families - move to coastal cities Environmental directives affect plastics use Space and waste reduction, recycling Energy from incineration Eye-catching aesthetics important Environmental awareness Want more efficient products, i.e. reduce package size - easy to store/use Packagers switch to new materials Less concern on amortizing investments Using new barrier films for perishable food Japanese resin innovation, e.g. Mitsui Demographics Smaller families – singles,working women Growth in aged and non-married women Small apartments, urban pop. density Smaller package – growth of single-serve Environment European Union packaging directive Space and waste reduction, recycling Promotion Marketing Package catches the consumer’s eye Brand owner marketing influence Brand owner environmental awareness Perception that less is more; buy efficient products, e.g. dry detergent; smaller size Innovation Technology New solutions – quick digital printing, e.g. – team logo on package, quick to shelf Use of alternative substrates, e.g. barrier New resin technology drives innovation –- e.g. Topas COC, new metallocenes
Europe & Asia markets have similarities and yet differences vs. the US; but, flexibles are favored. Europe – Improved package shelf-life; high-quality techno-product needs; new advances in flexible aseptic dairy packaging - flexibles environment & disposal convenience – Bundle brand recognition and functionality with new flexible designs – Coffee in single portion flexibles to increase convenience; coffee in regular size flex packs increase product quality, brand differentiation – Growth in frozen food flexible packaging market due to stronger brand development and increased popularity of prepared foods Asia – Improved aesthetics via flexible constructions; improve recloseability and dispensing systems, less freight for flexibles (China is key) – Japan leads in different MAP balances for different products; create new aseptic flexible packaging designs; unique combination of materials for new function – Flexible structures to withstand pasteurization at 116 degrees C - crucial in the sterilization of low-acid foods like milk, meat and vegetables. – Need shelf-life with no significant difference in taste, compared to glass – Compared to Japan, the rest of Asia is less advanced in packaging. Many rely on innovations from Japan and West; advances from S. Korea, Singapore & Taiwan – Packaging materials in Japan, Singapore, Korea are influenced by disposability recycling laws; incineration laws ban PVC; China’s new 5-year plan pro-environment
To summarize, opportunities are created when your solution meets the unmet needs of end users. Adhesive & Ink Producers Specialty Film Producers Resin Producers Converters Increasing difficulty of communication Packagers/ Brand Owners/ Retailers Packagers/ Brand Owners/ Retailers Materials Suppliers Technologies: Lamination Coextrusion Adhesion Printing Conversion Materials/ Resin Influencers Materials: PET EVOH Nylon Polyolefins Captured value Needs-based analysis is difficult due to communication / business-related industry barriers… Technology Influencers
Protection and integrity Quality and safety Shelf-life Environmental respect Supply Chain handling and identification On-Shelf/ Off-Shelf needs Image and appearance Aesthetic and appeal Brand awareness Visual Communication Display needs Cost competitiveness Manufacturing and supply chain performance Machinability Specifications Modularity and flexibility Emotion / satisfaction Consumer benefits Differentiation Information Ergonomic Convenience Easiness and comfort Any package is a Combination of three Core Requirements influenced by four main Factors
Worldwide Regulatory Compliance All information available required by the FDA guideline “Container Closure Systems for Packaging Human Drugs and Biologics”. All information available required by the EU guideline EMEA “Plastic Immediate Packaging Materials” (May 05). An up to date DMF type III is on file at the FDA and reviewed in conjunction with NDA’s on a regular basis All production facilities are ISO9001 certified All production facilities work under cGMP standards. Goal: trouble free global submissions of new products in USA, Europe and Japan:
Packaging Center New: camera inspection system operational Position on the reel Type of defect, Size of defect,
AFAP Product Safety System Description - DocumentsProduct Safety Policy Statement Product Safety Policy Raw Material Approval • Questionnaires for suppliers • Procedure Product Development •Questionnaire for customers •Documents of Compliance templates • Procedure (PSCS) Documented Change Control •Procedure and standard •Template for temporary deviation to commercial spec Product Safety Excellence Base (PSEB) audit document Product Safety Alert • Procedure • Template

• higher level of convenience & functionality easy opening dispensing systems reclose options valves design • product differentiation Add-on features and design
Proprietary & Confidential©2014 Printpack, Inc. All rights reserved.
100% Degradable applications Stretch Wrap Carrier Bags Food Packing Trays Garbage bags Health care Bubble Wrap Label & tapes Stretch Films Cutlery and Cups Slider Zip lock Bags Flower wraps Bread Bags
Process Product Material
• Flavored carbonated softdrinks, such as colas, are micro-biologically stable, i.e. “not sensitive” • Micro-organism can’tgrow in the beverages, due to: • Very low pH • High CO2 level • No fruit juicecontent
Definition • Package is sterilized and beverage is bottled in a cold asepticenvironment • Milk, juice, tea, and isotonicsare possible candidates foraseptic filling 5-Jul- 12 10 3
• Commercial sterility is “the absenceof microorganismscapableof reproduction in the food under normal conditionsof storageand distribution” • not necessarily kill thegerms, but make sure they cannot multiply • Inhibit the process • “Commercial sterility” and “sterility” are two different concepts 56
• Carbonation orsugarcontent • Preservatives • Hot Filling • Aseptic Filling • In bottle sterilization • Pasteurization • Retort • Selection of filling methodsdepend upon: • Product • Cost • Brand image • Shelf lifeexpectation 57
Technique Strength Weakness PeroxyaceticAcid (PAA) Well established Cold Sterilant Needs rinsing Strong Smell Wet Environment Long Treatment Hydrogen Peroxide Well established for Peroxide residues high cartons temperature requirement Ozonized Water Unknown Efficiency Level UV Irradiation Simple, no residues Shadow Effect Gamma Irradiation Well established in medical application Expensive Batch Process Heat (Steam, air) Used widely for machine sterilization Not possible for heat sensitive plastics
Aseptic Filling Line Sources: Krones 24-Mar-14 110
henkywibawa@yahoo.com YOUR FUTURE PRODUCT DEVELOPMENT DETERMINE OURS !

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Functional barrier films in flexible packaging industry

  • 1.
    TREND PACKAGING &OUTLOOK henkywibawa@yahoo.com Functional BARRIER FILMS in FLEXIBLE PACKAGING
  • 2.
  • 4.
  • 5.
    The Middle ClassSpending Journey Middle class rise Increase in available consumer credit Small amount to LARGE number LOW income Purchase BIG ticket : Electronic,Furniture, Auto lifestyle Choose where to shop or entertained. Farther home Increase demand for travel and leisure service Greater emphasize for entertainment and leisure Retirement Healthcare Child education Increased demand for financial services
  • 6.
    means Modern livingFMCG drive the growth Fast growing segment (>15%)
  • 7.
    Years ahead : Indonesiaretail growth 2nd best after china
  • 8.
  • 9.
    Brand engagement toboost consumption We - commerce
  • 10.
    Easy to usepackaging
  • 11.
    The Business Stuck onthe -er words • Bigger • Brighter • Better • Stronger • Faster • Easier • Newer • Cheaper ! imagin
  • 12.
  • 13.
    More Convenient Anytime, anywhere HOWYOU CREATE POSSIBLE SURPRISE THAT KIDS AND FAMILY LOVE …
  • 14.
  • 16.
    The Magic Triangleof Packaging: Customer Packaging Material Packaging Machine Packaging System Functionality compliance
  • 17.
     Globalization  CustomerDelivered Value  Networked Technology  Product Life Cycle Compression  Supply Chain Management  Mass Customization  Digital Business
  • 18.
    Product value Services value Personnel value Image value Total customer value TCV Monetary cost Time cost Energy cost Psychic cost Totalcustomer cost TCC Customer delivered value CDV  CDV = TCV - TCC  TCV = Bundle of benefits expected from product  TCC = Bundle of costs expected to evaluate, obtain, and use the product
  • 19.
    Raw Material Suppliers Converters(at full capacity/overcapacity) Food/Pharma Manufacturers Consumers Converters are squeezed Design Process Packing Process Distribution Process
  • 20.
    HIGH-PERFORMANCE BARRIER FILMS: ExaminingGlobal Trends from Our Perspective
  • 21.
    The global packagingmarket is huge; offering many opportunities in barrier packaging, led by flexibles. N. America and Europe account for roughly 55% of global packaging value, but growing at slower rates than rapidly developing regions such as Asia Global Packaging Market (value of shipments-all structures) $450 Billion Annual Growth 2-3% (>5% Asia)
  • 22.
    High-performance barrier packagingfilms is specific, as follows. Film structures providing high barrier levels to oxygen, water vapor, aromas/flavors, and/or UV light – A barrier film is usually a coextruded, coated, or metallized substrate – Barrier components include PVdC resin/coating, EVOH, nylon, MET films, or Al2O3 or SiOx – But excludes all structures that use Al foil as the barrier, paper as a structural member, or MET films used only for graphic enhancement Film structures <10 mil (e.g. multilayers of printed layer, barrier & sealant) Includes film structure laminations (with a barrier film), or a coextrusion containing a layer of barrier resin, or a substrate coated with a barrier material that might also function as a sealant A mono-structure of only barrier film is very rare; real value is created when the barrier film is a ‘component’ that enables the final package
  • 23.
    The market forH.P. barrier packaging films is positively influenced by many factors. Cost Reduction Rigids to flexible; less R.M. & lower freight Process Improvement CoEx & laminates offset resin cost High growth of Convenience food Home Ready - Ready to Cook Smaller packages More barrier needed, Higher surface-volume ratio Alternative Packaging Smart, security, reclosability, etc. Market forMarket for High PerformanceHigh Performance Barrier PackagingBarrier Packaging FilmsFilms Geo-Cultural & Trade Impacts Our focus is on food packaging, with some comments on medical devices
  • 24.
    Business opportunity emanatesfrom the value chain continuum of application, film and structure. Package Structure Markets & Applications Barrier Film Perishable Food -Fresh meat -Prepared food -Processed meat & cheese Dry Food -Confections & snack bars -Pet food -Snacks & baked snacks Medical & others PVdC EVOH Nylon Metallized Specialty oxides CoEx. & laminates Bags Lid stock Stand-up pouches Forming web Wraps Barrier Film Package Structure Markets & Applications Business Opportunity Barrier Film Package Structure Markets & Applications Business Opportunity US H.P. Barrier Film $1.2 BIL We use sophisticated applications model to combine film & package conversion costs, area and package structure to determine various market size relationships
  • 25.
    StructureFilmMarkets The overall barrierfilm market is forecast to grow at a good AAGR of 4.8% over the next five years. 0 1 2 3 4 5 6 7 Overall market, 4.8% Averageannualgrowth,% Perishable food Dry food Fresh meat Processed meat Cheese and dairy Prepared food Total Perishable Food ($950 MIL) Snack food Baked snacks Dry mixes Confections and snack bars Pet food Coffee Total Dry Food ($250 MIL) Largest Share 82% Perishables Smallest 3% of Perishables Largest Share 70% Dry Food Coffee & Pet Small Share <5% of Dry Food
  • 26.
    StructureFilmMarkets In perishable food,consumption of barrier films for fresh-meat applications is to grow AAGR of 5.6%. Key Stats: Fresh Red Meat: •$720-740 MIL Film •5.6% Growth/yr •82% of Perishables •67% of Barrier Pkg Examples: •Case-ready red meat focus •Pork & poultry already case-ready & maturing Penetration of case-ready meat to drive growth of barrier films Trend toward the production of more case-ready red-meat products Increase in the use of shrink bags for case-ready and value-added products Refrigerated space allocated for fresh meat expected to decline, as consumers demand convenience products; i.e. need increased O2 barrier & shelf life
  • 27.
    StructureFilmMarkets Processed meat, cheeseand dairy segments will exhibit more steady growth, at about 3-3.5%. Key Stats: Proc. meats, cheese, dairy: •$100-110 MIL Film •3-3.5% Growth/yr •14% of Perishables •11% of Barrier Pkg Examples: •Deli meat & cheese slices •Natural chunk cheese •Milk, pudding, yogurt The image of processed meats (deli) as unhealthy is changing, with some products now viewed by consumers as convenient sources of protein The use of barrier films to package cheese will continue to increase as consumers’ preference for natural cheese continues to grow at the expense of processed cheese that requires less barrier packaging Consumer demand for smaller, more convenient packages will contribute to the increase in barrier film consumption Cost reduction will continue to drive the trend toward replacement of laminations with coextrusion technology
  • 28.
    StructureFilmMarkets In dry-foods, consumptionof barrier films for dry-mixes is forecast strong AAGR of 4.2%. Key Stats: Dry mixes: •$25-30 MIL Film •4.2% Growth/yr •12% of Dry Foods •2% of Barrier Pkg Examples: •Cake mixes •Pudding powder •Powder flavoring The dry food category is much smaller than perishables at about $250 MIL, or 20% of barrier film share Dry mixes is a relatively small part of the dry food category, driven by consumer preference for standup pouches and away from rigid packaging To reduce investment risk, many companies are increasing the use of contract packagers as a means of converting to standup pouches Trend toward clear packaging to view contents favors clear barrier film solutions
  • 29.
    StructureFilmMarkets Snack-foods & baked-snacksto have respective modest growth, at AAGR of 2.3% & 2% each. Key Stats: Snack food/baked-snacks: •$160-170 MIL Film •2-2.5% Growth/yr •79% of Dry Foods •16% of Barrier Pkg Examples: •Chips, nuts, cookies, dried fruits, raisins, etc •Baked (healthy snacks) – no preservatives One of the biggest trends in snack foods is the move toward products packaged in single servings that are easily portable and consumed on- the-go; we work 24/7, have a family and need convenience The snack food category will continue to move away from rigid containers in favor of flexible packaging (SUP), with new introductions by major suppliers of snack nuts, cookies, and most recently, crackers The use of barrier films in the baked-snack segment is expected to increase overall, driven by consumer desire for healthier products that require more protection from moisture and oxygen to retain freshness
  • 30.
    StructureFilmMarkets High-growth expected inperishable foods for EVOH & Al2O3-PET films (8%+); in dry-foods PVdC-PET (9.2%). 0 1 2 3 4 5 6 7 8 9 10 Overall market, 4.8% Averageannualgrowth,% Perishable food Dry food PVdC 45% EVOH 25% Nylon 25% PVdC- coated PET Total Perishable Food ($950 MIL) Al2O3- coated PET MET nylon SiOx- coated PET PVdC- coated PP PVdC- Coated PP 50% MET-PP 35% MET-PET 10% PVdC- coated PET EVOH Total Dry-Food ($250 MIL) MET PETFresh & Processed Meats Fresh Foods, Meats & Tray Lidding Fresh Foods, Meats & Lam-Trays Retort; Japan & Europe interest Retort; Japan & Europe interest High-growth, but small market today Snacks & Baked Snacks & Baked Displacing PVdC SUP Clarity Applications
  • 31.
    StructureFilmMarkets Primary converters ofshrink bags for fresh & processed meat entrenched in PVdC CoEx-tech. Although PVdC is inherently difficult to process, primary converters of shrink bags for packaging fresh and processed meat (Cryovac, Curwood,and Amcor) are entrenched in PVdC coextrusion technology for narrow web Dow has introduced patented encapsulation technology to blow multilayer film and for producing wider width substrate. Licensing of this technology is likely to spur growth of PVdC resin for blown multilayer film New growth markets for PVdC include lid stock and retort applications for prepared foods, which require moisture stability Despite environmental issues, PVdC is still widely used for shrink bags in Europe, and its use in the U.S. does not appear to be a threatened
  • 32.
    StructureFilmMarkets PVdC-coated PET, usedas lid-stock & inner ply of clear standup pouches for is growing. Increase in the use of PVdC-coated PET lid stock for packaging prepared foods – MAP, hot-fill and retort The use of PVdC-coated PET in packaging processed meats will decline Lamination and coating processes are being displaced by coextrusions However, PVdC-coated PET, commonly used as the inner ply of standup pouches for snack foods, dry mixes, and pet food, is expect to grow for applications requiring clarity
  • 33.
    BARRIER COATED FILMS BarrierCoated Moisture Barrier Films on BOPP, on PET and on NYLON are specially coated films to enhance Moisture Barrier and Oxygen Barrier. There are able to reduce Moisture Barrier and Oxygen Barrier by more than 50 % of uncoated plain films. It is also more cost effective than PVDC and EVOH. The Barrier Coating materials is 100% Waterbased. And this film totally environmentally friendly. It is proven to be more cost effective, when compared to 3 or 4 layers laminating structures without compromising the Moisture/Oxygen Barrier of the Packaging. Most importantly these Films are able to reduce Carbon Footprint in Flexible Packaging by minimum 10%.
  • 34.
    MOISTURE / OXYGENBARRIER OF VARIOUS FILMS & COATINGS * Total Film+ Coating Thickness 25µ gms/sqm gms/100 in² cc/sqm cc/100 in² EVOH* Dry 0.20 0.01 Moist (90%RH) 58.90 3.80 2.70 0.17 HB-PVDC* 0.78 0.05 1.20 0.08 PVDC (15µ BOPET) ∆ 14.00 0.90 6.00 0.40 HDPE 25µ ∆ 9.00 0.30 3,000.00 195.00 LDPE 25µ ∆ 18.00 1.20 8,000.00 519.00 CPP 25µ ∆ 12.00 0.80 4,200.00 272.00 BOPP 20µ ∆ 8.00 0.50 2,500.00 162.00 MYLAR™ BOPET 12µ ∆ 40.00 2.60 140.00 9.00 BOPA 15µ ∆ 250.00 16.20 90.00 5.80 K-BOPET 15µ 5.40 0.35 7.00 0.45 K-NYLON 17µ 4.00 0.25 6.00 0.40 EVAL™ EF-CR 15µ ∆ 142.00 9.20 1.50 0.10 EVAL™ EF-XL 15µ ∆ 29.00 1.90 1.00 0.06 BICOR™ 20MB666 7.00 0.45 1,000.00 65.00 BICOR™ 21MB866 (PVOH) 4.00 0.26 0.70 0.05 Barrier Coated-P20 (BOPP 20µ) 5.00 0.30 1,210.00 79.00 Barrier Coated-P18NS (BOPP 18µ) 6.00 0.40 8.00 0.50 Barrier Coated-P20NS (BOPP 20µ) 5.30 0.35 8.00 0.50 Barrier Coated-T12NS (BOPET 12µ) 14.00 0.90 4.60 0.30 MVTR (24 hrs/38°C/90%RH) OTR (24 hrs/23°C/1 ATM)FILMS * Coated on BOPP 25µ Films BarrierCoated Films Tested by Labthink Instruments Co., Ltd. On Perma W03/030 MVTR Unit (ASTM F1249) & Perma OX2-231 OTR Unit (ASTM D1434) Source *: Current Technologies in Flexible Packaging- STP 912 by Michael L. Troedel Source ∆: Dupont Teijin Film™ Specification Sheet. BICOR™ is a product of ExxonMobile EVAL™ is a product of Kuraray Co., Ltd. MYLAR™ is a product of Dupont Teijin Film™
  • 35.
    Polyamide provides  oxygenand aroma barrier  heat resistance  good mechanical properties  thermoformability Polyethylene provides  high water barrier  sealability multilayer film combines properties of multiple components Multi-layer Film 2
  • 36.
     5-layer PE/tie/PA/tie/PE +PA protected from humidity  7-layer PE/tie/PA/tie/PA/tie/PE + split PA - improved thermoformability  7-layer PE/tie/PA/EVOH/PA/tie/PE + very high barrier + good thermoformability ● 9-layer PE/PE/tie/PA/EVOH/PA/tie/PE1/PE2 + sealing PE + antiblock/slip in PE1 + reclosable in PE2 Coextrusion Film: Symmetric Structures 5
  • 37.
    + fast sealingdue to heat-resistant PA skin layer - curl ● 3-layer PE/tie/PA ● 5-layer PE1/PE2/PE2/tie/PA + sealing material, antiblock/slip in PE1 + simple polyolefins in PE2 ● 5-layer PE/tie/PA/tie/PA + split PA - improved thermoforming ● 5-layer PE/tie/PA/EVOH/PA ● 7-layer PE/tie/PA/EVOH/PA/tie/PA ● 9-layer PE/tie/PA/EVOH/PA/tie/PE/tie/PA Coextrusion Film: Asymmetric Structures 6
  • 38.
     Double/Triple bubbleprocess o Extrusion (downward/watercool) o Blow-up o Annealing  40-50% shrink  For : o shrink bottom seal bags o shrinkable lidding for rigid tray o shrinkable bottom + lidding film Shrink Bag / Shrink Film 10
  • 39.
    StructureFilmMarkets Growth in case-readyMAP for fresh meat will translate into growth for multilayer EVOH film. EVOH coextrusions in packaging processed meats and cheese will continue to displace more expensive PVdC-coated films Trend toward clear EVOH/nylon structures as replacements for MET PET in prepared foods and bag-in-box wines EVOH to continue growing in laminated food trays
  • 40.
    StructureFilmMarkets MET PP hasall but replaced higher-priced MET PET in the snack foods category. MET PP is the film of choice in packaging candy and snack bars (graphics appeal) Use of MET PET as the inner ply of standup pouches for snack foods, dry mixes, and pet food will continue due to good dimensional stability and heat resistance are critical The use of MET PET bags in foodservice applications, will continue to grow with the trend toward clear barrier films, replacing metal cans
  • 41.
    StructureFilmMarkets Barrier packaging filmsfor lid stock & standup pouches in the food sectors forecast to grow at above rates. Lid stock -4 -2 0 2 4 6 8 10 Overall market, 4.8% Averageannualgrowth,% Perishable food Dry food Lid stock Bags Standup pouches Wraps Total perishable food segment Bags Wraps Total dry-food segment Forming web Standup pouches interestAbove average growth Above average growth Above average growth
  • 42.
    StructureFilmMarkets Bags continue tobe the major flexible barrier packaging structure, growing at average rates. Bags are extensively used in packaging dry foods — most are pillow packs & bag- in-box type, supplied as rollstock to end users to run on form/fill/seal lines Square-bottom bags, used to package coffee, becoming popular for other dry food with improved graphics, reclosability & overall cost reduction vs. bag-in-box Increases in oil prices will continue to fuel growth in 1 gal foodservice bags as replacements for #10 metal cans The use of barrier shrink bags for packaging case-ready & processed meats growing at about 3-4%, led by convenience products - fresh meat & cooked
  • 43.
    StructureFilmMarkets Standup pouches arebeing introduced into every category of dry-foods to differentiate products. Standup pouches with zippers offer reclosability, improved barrier & material savings in a one-component flexible package vs. multi-component rigid containers they are replacing for packaging dry food Rising fuel prices drive the trend toward metal can replacement with standup pouches; one truckload of flat bags/pouches equals 25 truckloads of cans Sales of shelf-stable foods in retort pouches grown 20-30% in recent years, reaching $100 MIL in pouches. Many are foil laminates with clear barrier films Standup pouches are also gaining popularity for packaging processed meats like bacon bits and pre-cooked bacon.
  • 44.
     Thermoforming – forming(bottom) web – lidding  Bags – tubular bags – side-seal bags  Pouches – VFFS vertical form/fill/seal – HFFS horizontal form/fill/seal  Shrink Bags / Film Barrier Film Applications 7
  • 45.
    9 PE/tie/PA 75-150µm Heavybulk bags (unprinted) CPA//PE 75-150µm Bulk bags BOPA//PE 60-120µm Printed pouches PE/tie/PA/tie/PE 60-100µm Pouches /face-to-back sealing BOPET//PE/tie/PA/EVOH/PA/tie/PE 60-100µm High-barrier pouches (printed) BOPET//Alu//BOPA//PE 90-120µm High-barrier pouches for retort applications Typical Bag/Pouch Film Structures
  • 46.
     PE /tie / PA  CPA // PE  BOPA // PE  BOPET // (PE/tie/PA/EVOH/PA/tie/PE) 70-120µm thickness of lidding film is determined as the residual wall thickness of formed web Typical Structures of Lidding Film 8
  • 47.
    Going forward, theoutlook for high performance barrier packaging films is very positive. Large and non-cyclical market Sustainable growth drivers – Cost reduction – Convenience-oriented food – Smaller packages – Demand for alternate packaging formats
  • 48.
    Product Name ExistingDeveloping Detergent Powder: Philippines, Indonesia. PET (12µ)/Print/ LLDPE (45µ) OTR: 200gm/m²/24hr MVTR: 7.0gm/m²/24hr • 2 Ply Laminate Structure Barrier Coated-P35NS/Print /LTS2502, LTS2502H OTR: 5.0gm/m²/24hr MVTR: 2.0gm/m²/24hr • 1 Layer Structure •Coated-P35NS: BOPP35µ Global Customer Move Pattern Coat, 3 gsm for Sealing Purpose: Reduce Plastics Consuming from 2 Layers to 1 Layer.
  • 49.
    Product Name Existing Developing Snacks/Chips: Indonesia, South Africa- NAMPAKFlexible Packaging. • PET/Print/MPET/LLDPE OTR: 1.20gm/m²/24hr MVTR: 0.90gm/m²/24hr • PET/Print/PE/MPET/LLDPE OTR: 1.0gm/m²/24hr MVTR: 0.75gm/m²/24hr Barrier Coated-P18NS/Print/ VMCPP OTR: 0.15gm/m²/24hr MVTR: 0.80gm/m²/24hr or Barrier Coated-T12NS/Print/ VMCPP OTR: 0.07gm/m²/24hr MVTR: 0.90gm/m²/24hr • 2 Layers •Coated-P18NS: BOPP18µ •Coated-T12NS: BOPET12µ Global Customer Move Purpose: Reduce Plastics Consuming from 3-4 Layers to 2 Layers.
  • 50.
    Product Name ExistingDeveloping Instant Noodle: Malaysia,Indonesia Salad/Vegetables: Australia BOPP/Print/PP OTR: 1100gm/m²/24hr MVTR: 5.0gm/m²/24hr BOPP/Print/PE OTR: 1300gm/m²/24hr MVTR: 5.0gm/m²/24hr PET/PRINT/LLDPE OTR: 200gm/m²/24hr MVTR: 7.0gm/m²/24hr •2 Ply Laminate Structure BARCO-P35NS/Print/ LTS2502, LTS2502H OTR: 5.0gm/m²/24hr MVTR: 2.0gm/m²/24hr • 1 Ply Laminate Structure •BARCO-P35NS : BOPP 35µ Global Customer Move Pattern Coat, 3 g. for Sealing Purpose: Reduce Plastics Consuming from 2 Layers to 1 Layer.
  • 51.
    Cost Competitive Study Product Name ExistingStructures Laminating Structures using Barrier Coated Films Instant Coffee: Indonesia A)PET/Print/Al/LLDPE OTR: 0.20gm/m²/24hr MVTR: 0.30gm/m²/24hr Cost/100sqm: USD 42.00 B)PET/PRINT/VMPET/LLDPE OTR: 1.20gm/m²/24hr MVTR: 0.90gm/m²/24hr Cost/100sqm: USD 37.00 C)PET/PRINT/VMPET/CPP OTR: 1.60gm/m²/24hr MVTR: 0.80gm/m²/24hr Cost/100sqm: USD 26.50 •3-Ply laminate Structures Barrier Coated-P18NS/Print/ VMCPP OTR: 0.15gm/m²/24hr MVTR: 0.80gm/m²/24hr Cost/100sqm: USD 26.50 • 2-Ply Laminate Structures. • Coated-P18NS: BOPP18µ •58% lower cost with Coated 2-Ply > (A). •39% lower cost with Coated 2-Ply > (B). Reduction of laminating structures from 3 Layers to 2 Layer.
  • 52.
    In pharmaceuticals, flexibleH.P. barrier packaging is insignificant; growth of unit-dose blister packs The pharmaceutical segment is comprised of prescription drugs, medications, and dietary supplements sold over-the-counter (OTC) World demand for pharma packaging to reach $24 BIL in 2009, increasing 4-5% annually. 80% of demand from the US, Japan, China, Germany, France, UK, Italy, & Switzerland. The US will remain the largest consumer driven by aging baby boomers Blister packaging is the fastest-growing segment of the pharma market. Worldwide demand expected to grow 7% AAGR, reaching $5.6 BIL by 2009, driven by unit dose & sterile applications It is estimated that less than 1% of all pharmaceuticals are packaged in barrier films, as defined by our definition and therefore not a significant consuming segment of barrier films However, future barrier may be needed to maintain drug potency or inhibit degradation. A moisture barrier is critical for gels or liquids, sensitive to moisture loss. Foil used for UV barrier In addition to unit-dose blister packs, companies are converting to flexible pouches Unit doses maintain the ‘five rights’ of medicine monitoring: Right patient, right drug, right dose, right time, and right route of administration. Thus safer & tamper resistant New delivery systems, nasal, transdermal and parenterals in home-care and self-care applications also growing - not having to visit a doctor’s office cuts costs and saves time Key trend is aging population - 75% of pharma consumers are senior citizens – Healthy lifestyle & fitness craze has fuel popularity of vitamins and dietary supplements – The market for cosmeceuticals also experiencing rapid growth - aged refuse to look old – Opportunities exist for the growth of barrier films in alternative pharma delivery. The use of Al2O3- and SiOx-coated films are expected to grow in niche applications
  • 53.
    Packaging opportunities gleanedfrom other regions. Drivers Western Europe China & Japan Consumer Preference Traditional frequent trips to market Few long lunches at home; grab-n-go Higher income – spend more at stores Rapid lunches-aesthetics outweigh costs Local shops provide flexible single serve Refrigerator limitations (small or none) Low birth-rate More singles & elderly Displaced families - move to coastal cities Environmental directives affect plastics use Space and waste reduction, recycling Energy from incineration Eye-catching aesthetics important Environmental awareness Want more efficient products, i.e. reduce package size - easy to store/use Packagers switch to new materials Less concern on amortizing investments Using new barrier films for perishable food Japanese resin innovation, e.g. Mitsui Demographics Smaller families – singles,working women Growth in aged and non-married women Small apartments, urban pop. density Smaller package – growth of single-serve Environment European Union packaging directive Space and waste reduction, recycling Promotion Marketing Package catches the consumer’s eye Brand owner marketing influence Brand owner environmental awareness Perception that less is more; buy efficient products, e.g. dry detergent; smaller size Innovation Technology New solutions – quick digital printing, e.g. – team logo on package, quick to shelf Use of alternative substrates, e.g. barrier New resin technology drives innovation –- e.g. Topas COC, new metallocenes
  • 54.
    Europe & Asiamarkets have similarities and yet differences vs. the US; but, flexibles are favored. Europe – Improved package shelf-life; high-quality techno-product needs; new advances in flexible aseptic dairy packaging - flexibles environment & disposal convenience – Bundle brand recognition and functionality with new flexible designs – Coffee in single portion flexibles to increase convenience; coffee in regular size flex packs increase product quality, brand differentiation – Growth in frozen food flexible packaging market due to stronger brand development and increased popularity of prepared foods Asia – Improved aesthetics via flexible constructions; improve recloseability and dispensing systems, less freight for flexibles (China is key) – Japan leads in different MAP balances for different products; create new aseptic flexible packaging designs; unique combination of materials for new function – Flexible structures to withstand pasteurization at 116 degrees C - crucial in the sterilization of low-acid foods like milk, meat and vegetables. – Need shelf-life with no significant difference in taste, compared to glass – Compared to Japan, the rest of Asia is less advanced in packaging. Many rely on innovations from Japan and West; advances from S. Korea, Singapore & Taiwan – Packaging materials in Japan, Singapore, Korea are influenced by disposability recycling laws; incineration laws ban PVC; China’s new 5-year plan pro-environment
  • 55.
    To summarize, opportunitiesare created when your solution meets the unmet needs of end users. Adhesive & Ink Producers Specialty Film Producers Resin Producers Converters Increasing difficulty of communication Packagers/ Brand Owners/ Retailers Packagers/ Brand Owners/ Retailers Materials Suppliers Technologies: Lamination Coextrusion Adhesion Printing Conversion Materials/ Resin Influencers Materials: PET EVOH Nylon Polyolefins Captured value Needs-based analysis is difficult due to communication / business-related industry barriers… Technology Influencers
  • 56.
    Protection and integrity Qualityand safety Shelf-life Environmental respect Supply Chain handling and identification On-Shelf/ Off-Shelf needs Image and appearance Aesthetic and appeal Brand awareness Visual Communication Display needs Cost competitiveness Manufacturing and supply chain performance Machinability Specifications Modularity and flexibility Emotion / satisfaction Consumer benefits Differentiation Information Ergonomic Convenience Easiness and comfort Any package is a Combination of three Core Requirements influenced by four main Factors
  • 58.
    Worldwide Regulatory Compliance Allinformation available required by the FDA guideline “Container Closure Systems for Packaging Human Drugs and Biologics”. All information available required by the EU guideline EMEA “Plastic Immediate Packaging Materials” (May 05). An up to date DMF type III is on file at the FDA and reviewed in conjunction with NDA’s on a regular basis All production facilities are ISO9001 certified All production facilities work under cGMP standards. Goal: trouble free global submissions of new products in USA, Europe and Japan:
  • 59.
    Packaging Center New: camerainspection system operational Position on the reel Type of defect, Size of defect,
  • 60.
    AFAP Product SafetySystem Description - DocumentsProduct Safety Policy Statement Product Safety Policy Raw Material Approval • Questionnaires for suppliers • Procedure Product Development •Questionnaire for customers •Documents of Compliance templates • Procedure (PSCS) Documented Change Control •Procedure and standard •Template for temporary deviation to commercial spec Product Safety Excellence Base (PSEB) audit document Product Safety Alert • Procedure • Template
  • 63.
  • 66.
    • higher levelof convenience & functionality easy opening dispensing systems reclose options valves design • product differentiation Add-on features and design
  • 67.
  • 68.
    100% Degradable applications StretchWrap Carrier Bags Food Packing Trays Garbage bags Health care Bubble Wrap Label & tapes Stretch Films Cutlery and Cups Slider Zip lock Bags Flower wraps Bread Bags
  • 69.
  • 71.
    • Flavored carbonatedsoftdrinks, such as colas, are micro-biologically stable, i.e. “not sensitive” • Micro-organism can’tgrow in the beverages, due to: • Very low pH • High CO2 level • No fruit juicecontent
  • 72.
    Definition • Package issterilized and beverage is bottled in a cold asepticenvironment • Milk, juice, tea, and isotonicsare possible candidates foraseptic filling 5-Jul- 12 10 3
  • 73.
    • Commercial sterilityis “the absenceof microorganismscapableof reproduction in the food under normal conditionsof storageand distribution” • not necessarily kill thegerms, but make sure they cannot multiply • Inhibit the process • “Commercial sterility” and “sterility” are two different concepts 56
  • 74.
    • Carbonation orsugarcontent •Preservatives • Hot Filling • Aseptic Filling • In bottle sterilization • Pasteurization • Retort • Selection of filling methodsdepend upon: • Product • Cost • Brand image • Shelf lifeexpectation 57
  • 75.
    Technique Strength Weakness PeroxyaceticAcid(PAA) Well established Cold Sterilant Needs rinsing Strong Smell Wet Environment Long Treatment Hydrogen Peroxide Well established for Peroxide residues high cartons temperature requirement Ozonized Water Unknown Efficiency Level UV Irradiation Simple, no residues Shadow Effect Gamma Irradiation Well established in medical application Expensive Batch Process Heat (Steam, air) Used widely for machine sterilization Not possible for heat sensitive plastics
  • 76.
    Aseptic Filling Line Sources:Krones 24-Mar-14 110
  • 77.