Very interesting and thorough presentation by Cascades Sonoco including bright future for water soluble coatings.

1. Paper-based Packaging
Functional and Sustainable Coating
Presented by:
Islem Yezza
Technical Business Development Director

2. Worldwide food loss: 1.3 billion tons/year
 For decades, packaging was seen as nothing but waste,
a nuisance to be avoided
 Packaging waste pales into insignificance compared with
the losses caused by food waste
 One-third of food in developing
countries is destroyed before it ever
reaches the consumer
Source: United Nations Food and Agriculture Organization (FAO)
2

3. Food packaging: Hero or Villain?
Three main messages came across with great importance for
food packaging:
 Packaging prevents food waste and saves
resources
 Packaging is part of the solution for an
overall resource efficient economy
 Packaging
lifestyles
3
facilitates
more
sustainable

4. Finding the balance between under-packaging and
over-packaging is the aim for all of our businesses
Source: Innventia
4

5. AGENDA
1. Paper-based Packaging : Trends and Market
2. Enhancing barrier properties : Why Wax is on the Wane?
3. Extrusion coating:
a) Conventional resin: recyclability and sustainability
b) Renewable and compostable resin (bioplastics)
4. Water-based coating: A bright future
5. Eco-friendly and Innovative Paper-based Packaging
6. Take home…
5

6. Packaging: Sustainability is a Shared Responsibility
 Eco-conscious Consumer demand
Sustainable and Convenient packaging
for
more
 Retailers and manufacturers perceive a marketing
advantage. Eco-friendly, Green, Bio-based,
Compostable & Biodegradable: big selling points
 Legislation & regulations pushing for innovative
eco-friendly packaging
Sustainable packaging: Win-Win-Win for the environment,
for manufacturers and suppliers, and for consumers
6

7. Packaging Industry:
Market and Growth
 Global Packaging Industry expected to reach $820 billion by 2016
 US: largest consumer for packaging in 2010 with a demand of $137 billion
 Paper Packaging Materials to reach 223.9 metric tons by 2015
7
(Source: Pira International, 2012; Global Industry Analysts, 2012)

8. Paper-based Packaging: The Responsible Package
 Provides versatile and responsible packaging solutions for product
manufacturers, retailers, and consumers
 Paper has an excellent image as packaging material (renewable,
recyclable and biodegradable)
 Paper and paperboard account for 29% of the Total
MSW generation in 2010 (Total 250 million tons)
 About 71% of paper and paperboard containers and
packaging was recycled, including 85% of all
corrugated boxes
(Source: EPA, 2010)
8

9. Paper-based Packaging: Barrier Improvement
 Improving paper's barrier properties is seen as a crucial step in
increasing its viability as a packaging material
 The missing performance and barrier properties of paper can be
compensated by:
1. Wax impregnation: curtain, cascaded
2. Extrusion coating: Petro-based resin
and Bioplastics
3. Water-based coating
9

10. Wax-coated Packaging: Wax is on the Wane
 Petroleum-based wax has traditionally
been used as a moisture barrier to
preserve the strength of a corrugated
container holding iced or wet products
 Waxed paper-based packaging are
raising Recyclability, Sustainability and
Renewability Concerns
 Growers and retailers are looking for alternatives to wax
10

11. Wax: Sustainability & Economic Concerns
 Wax-coated packaging are not recyclable:
wax coatings do not dissolve in water, so
they cannot easily be recycled
 Wax-coated packaging are heavy
 Paraffin based wax, a non-renewable
resources is becoming more expensive
 Many leading retailers and grocers, including Wal-Mart and Costco
have been demanding an eco- friendly alternative to wax coated
boxes from their suppliers
11

12. Wax Alternatives: Growing market
 The future is clear – wax replacement
packaging will become a necessity
 Opportunities to sharply reduce their landfill
costs, while boosting their recycling levels
 In 2010, the corrugated industry shipped 6.4
billion square feet of boxes using
recyclable wax alternative coatings. That’s
over 30% more than the 4.9 billion square
feet shipped in 2009 and 385% more than
when first measured in 2002, dramatically
increasing the volume of containers that
could be recycled.
12
(Source: Corrugated Packaging Alliance, 2011)

13. Extrusion Coating:
PE, PP and HDPE
 Extrusion coating allows processing a variety of polymers and board
 Paper and paperboard (SBS, CCNB, CRB, Bending Chipboard, Liner)
 LDPE - most widely used material for extrusion coating applications:
easy to process, provides adequate moisture barrier, has excellent
sealing properties, grease resistance and lamination layer and cost
competitive

13
PP and HDPE

14. Extrusion Coating: Hygroscopic Resin
 Hygroscopic resin consume more torque than the
standard olefin resin: Low shear (low speed),
high torque
 PET coated paperboard: Thermoformed paperbased trays, Ovenable/Microwavable paper-based
trays/folding carton
 Nylon coated paperboard: Corrugated box (pass
through the corrugators)
 PLA coated paperboard: Compostable Paperbased bags, Take-out box…
14

15. Bioplastic: Sustainable and Functional
 The bioplastic Market in 2010 was 771 million pounds. This is expected
to reach nearly 932 million pounds in 2011 and then further increase to
2.5 billion pounds in 2016, at a CAGR of 22% for the 5-year period
 Biopolastcis can be
used as barrier coatings
15
(Source: BBC Research 2011)

16. Bioplastic: Confusion in terminology
 Biopolymers are plastics that are
biodegradable/ compostable and/or
have bio-based content
 Biomass based plastics are not always
biodegradable
 Biodegradable plastics are not always
biomass-based
16

17. Biodegradable/Compostable/Biobased
 Distinctions are subtle but significant
 All biodegradable material are not compostable
 Biobased not necessarily compostable
 Biobased: Focus is on the “origin of life” or
where did the carbon come from (ASTM D6866).
Uses C14 content measurement
 Compostable: Focus is on “end of life or
disposal”. Independent of carbon source standards
(EN13432 and ASTM D6400)
17

18. Bioplastics: Challenges & Hurdles
1)
Confusion in terminology: Biodegradable, Oxo,
Biobased, Compostable? Education is needed to
clarify in the minds of consumers and clients, the
environmental benefits of these new materials
2)
End of life hurdles: the puzzle? Consumers are
3)
Carbon footprint: bioplastics not necessarily
greener than oil based relatives? Skeptics about
confused when it comes to separating biodegradable,
compostable and recyclable plastics. Information about
how to best dispose of it, is necessary
LCA studies: data may not be accurate or complete and
system boundaries are not easily defined
18

19. Bioplastics: Challenges & Hurdles
4)
Price: Current prices for bioplastics are significantly
higher than the cost of PE. People are environmentally
conscious when it’s convenient and affordable. Higher oil
prices are lowering the gap in prices of bioplastics and
conventional plastics
5)
Weak barrier properties: MVTR, OTR, heat
resistance, microwavable…? Barrier and physical
properties may limit applications - Blends and compounding
6)
Value
proposition:
Promoting
Biobased,
Biodegradable or Compostable? Is not yet clear in the
minds of most consumers and clients
19

20. Bio-resin extrusion coating: Challenges
Bio-resin could not be processed at existing PE screw: Stability is
poor, melt temperature are too high, and the available torque is inadequate
1. Bio-resins consume more torque than the
standard olefin resin: Low shear (low speed),
high torque → New screw
2. Bio-resins are very hygroscopic. Hygroscopic
materials absorb water, even from the air: Inline drying is essential → Dryers
20

21. Bio-resin extrusion coating: Market education
1. Biopolymer-coating: sustainable and functional barrier
2. Bio-resin extrusion coating: dedicated screw and dryers
3. Trends: volatile oil prices; energy security concerns; environmental
benefits; favourable regulatory initiatives; and the improving
performance and competitiveness
4. The distinctions are subtle but significant: not all bioplastics are
created equal and there are a lot of misleading claims out there
5. Education: has to be a combined effort from resin makers,
converters and the companies that will be selling these products to
the consumer
21

22. Water-based coatings: Repulpability, an
Important Route to Sustainability
 With the push towards sustainability, repulpability and
recyclability, water-based technologies are gaining acceptance
 The packaging combines the best aspects of two materials:
environmentally friendly paperboard and good barrier properties of
water-based coatings
 Coatings can be recycled, repulped and/or
composted
 Alternative
solution to current wax, PE
extrusion coating and film lamination
22

23. Water-based Coatings : Basic Formulation






Latex (as binder, other polymer can also be used)
Pigment s
Fillers
Dispersant
Defoamer
pH control agent
Mica
Talc
23

24. Water-based Coatings: SEM Image
(Source: Claude Tremblay, Cascades)
24

25. Water-based coatings: Tailored solutions
Water-based coatings can be custom-formulated to meet the
packaging requirements of a wide range of products
1. Barrier properties : Moisture - Oil and grease barrier
2. Physical & Chemical properties : Scuff resistance, anti-slip,
non-abrasive, corrosion inhibitor, conductive & anti-static
3. Aesthetic & decorative : color coatings
25

26. Water-based Barrier: A Balancing Act
There are always exceptions, but …
 Greater heat sealability = more blocking
 Higher coating water retention = poorer water barrier effectiveness
 Higher water barrier = poorer cold glueability
 Higher oil resistance = poorer hot melt adhesion
 Higher effectiveness = higher cost
26

27. To-Go containers: Grease and Moisture Barrier
 Replace not easily Recyclable and Non Renewable EPS containers
 About 61% of consumers say that they are willing to pay more for
takeout packaging made with sustainable materials. (Source: Technomic 2012)
Packaging Requirements: Moisture & grease
barrier, heat resistance, microwavable, Gluable. FDA
compliant, Compostable/recyclable/Repulpable
27

28. Corrugated Boxes : Produce, Meat, Poultry and Fish
 Replace not easily recyclable EPS Boxes, waxed boxes and Petroplastic film laminated board
 Eliminates costs linked to disposal at landfills
Packaging Requirements: Avoid water wicking inside
28
the linerboard, Endure both packing house and transport
conditions, withstands Corrugating process heat up to 375°F,
FDA compliant, Recyclable/Repulpable

29. Folding Boxes: Dry and fatty Goods
 Replace not easily recyclable Petro-plastic film laminated board
Packaging Requirements: Prevent Caking and moisture
picking, Grease-resistant, Holds up to hot-melt glue and cold set
adhesives, FDA compliant, Recyclable and Repulpable
29

30. Food waste bags: Compostable
 Replace Petro-plastic film laminated paper and plastic bags
Packaging Requirements: Leak proof, Grease
barrier, Sealable, Compostable
30

31. Thermoformed trays: Functional and sustainable
 Alternative to the traditional Styrofoam trays, PET microwavable trays
and others plastic trays and plates
Packaging Requirements: Leak proof, Grease
barrier, Dual Ovenable, FDA compliant,
Repulpable and/or Compostable
31
Recyclable,

32. Wrap-up…: Keep the Molecule in Play
 Major companies are beginning to take note and a few have stepped
forward to lead the “Sustainable Packaging Revolution”
 Market drivers: Increased focus on recyclability and Increased
demand for sustainability
 Divert from landfill is sustainable, but we must keep in mind the
packaging basic functions: Protect – Inform – Contain – Transport
 Both the packaging industry and consumers need to work together to
develop a unified set of standards that will end confusion and
maintain transparency in the rapidly growing sustainability sector
 Functional an Sustainable coatings: Developments of speciality
paperboard through innovation
32

33. Thank you
PRESENTED BY
Islem Yezza
Technical Business Development Director
Email: Islem_yezza@cascades.com