Enhancing Polyolefin Films for Retort Applications Using Cyclic Olefin Copolymers
1. Polyolefin Film Enhancement Using
Cyclic Olefin Copolymers
For Retort Applications
Paul D. Tatarka
SPE Polyolefins & FlexPack Conference
February 25-27, 2008
SPE Polyolefins & FlexPackCon www.topas.com
2. Project Objectives
Desired Enhancements for Commercial Retort Films
TOPAS COC Value Proposition
COC Test Film Structures:
▶ Monolayer Cast Films (4)
▶ Multilayer Blown FIlms (2)
▶ Multilayer Cast Films with PP Skin Layers (5)
Retort Pouch Preparation
Understand How COC Responds Under Retort Conditions
▶ Appearance, Burst Strength, Gelbo Flex and Barrier
▶ Identify Most Promising COC Film Structures
Conclusions and Recommendations for Future Study
SPE Polyolefins & FlexPackCon www.topas.com
3. Desired Enhancements for Retort
Extend Product Shelf Life From 3 To 5 Years
Eliminate Foil To Offer Package Clarity
Increase Barrier:
▶OTR
▶MVTR
Increase Retort Temperature & Reduce Cycle Time
Enhance Package Durability To Prevent Loss of Barrier
Increase Package Stiffness For Pouches & Rigid Containers
Commercial Retort (4.58 mil)
PET / adh / Foil / adh / Nylon / adh / cast PP
0.48 mil 0.50 mil 0.60 mil 3.00 mil
SPE Polyolefins & FlexPackCon www.topas.com
4. What Are Cyclic Olefin Copolymers (COC)?
The cyclic olefin copolymer (COC) molecule is a
linear chain of small CH2-CH2 links randomly
interspersed with large bridged ring elements
It cannot fold up to make a regular structure, i.e., a
crystallite
NB NB NB NB
COC has no crystalline melting point, but only a
glass transition temperature, Tg , at which the
polymer goes from “glassy” to “rubbery” behavior
SPE Polyolefins & FlexPackCon www.topas.com
10. Tensile Strength At Yield (ASTM D882)
MD TD
6000
5000
Tensile Yield Strength (psi)
4000
3000
2000
1000
0
T5: PP / T1: TOPAS 6013 T7: T8: T12: 36% T16: 36% T14: 21% T18: 21%
LLDPE+LDPE / / LLDPE 4.0 mil 6013+LLDPE & 6013+LLDPE & TOPAS 6015 PP TOPAS 5013 PP TOPAS 6015 PP TOPAS 5013 PP
PP 6.0 mil 6013+HDPE 4.5 6013+HDPE 3.0 Coex Coex Coex Coex
mil mil
COC Improves Film Yield Strength By 50 – 200%
Good Balance Between Machine and Transverse Directions (20 IPM)
SPE Polyolefins & FlexPackCon www.topas.com
11. Impact Resistance
Film Slow Puncture Slow Puncture Fast Puncture
Gauge TOPAS® Break Force Energy to Fast Puncture Total Energy (ft-
Film Description (mil) COC (%) (lb) Break (lbf-in) Peak Force (lb) lb)
Test Method ASTM F1306-90 ASTM F1306-90 ISO 7765-2 ISO 7765-2
T5: PP / LLDPE+LDPE / PP 6.0 0 9.7 6.9 32.4 1.6
T1: TOPAS 6013 / LLDPE 4.0 70 10.2 1.8 11.8 0.1
T7: 5-Layer 6013 / LLDPE & 6013 / HDPE Blends 4.5 20 5.4 3.1 17.8 0.6
T8: 5-Layer 6013 / LLDPE & 6013 / HDPE Blends 3.0 20 3.8 1.5 9.4 0.4
T12: 36% TOPAS 6015 PP Coex 6.0 36 16.9 6.3 25.2 0.8
T16:36% TOPAS 5013 PP Coex 6.0 36 5.1 2.2 26.5 0.3
T14: 21% TOPAS 6015 PP Coex 6.0 21 13.0 6.4 40.5 1.7
T18: 21% TOPAS 5013 PP Coex 6.0 21 11.4 5.4 28.3 0.7
Puncture Resistance Can Be Enhanced By TOPAS COC; Depends On Content & Molecular Weight
Lower Percentage Of Higher Molecular Weight COC Improves Puncture Resistance
SPE Polyolefins & FlexPackCon www.topas.com
12. Tensile Modulus (ASTM D882)
MD TD
200,000
180,000
160,000
140,000
odulus (psi)
120,000
100,000
Tensile M
80,000
60,000
40,000
20,000
0
T5: PP / T1: TOPAS 6013 / T7: 6013+LLDPE & T8: 6013+LLDPE & T12: 36% TOPAS T16: 36% TOPAS T14: 21% TOPAS T18: 21% TOPAS
LLDPE+LDPE / PP LLDPE 4.0 mil 6013+HDPE 4.5 6013+HDPE 3.0 6015 PP Coex 5013 PP Coex 6015 PP Coex 5013 PP Coex
6.0 mil mil mil
COC Improves Film Stiffness By 50 – 200%
Good Balance Between Machine and Transverse Directions (20 IPM)
SPE Polyolefins & FlexPackCon www.topas.com
13. Tear Resistance (ASTM D1922)
MD TD
3500
3000
2500
T a R s ta c (g m )
e r e is n e ra s
2000
1500
1000
500
0
T5: PP / T1: TOPAS 6013 T7: T8: T12: 36% T16: 36% T14: 21% T18: 21%
LLDPE+LDPE / / LLDPE 4.0 mil 6013+LLDPE & 6013+LLDPE & TOPAS 6015 PP TOPAS 5013 PP TOPAS 6015 PP TOPAS 5013 PP
PP 6.0 mil 6013+HDPE 4.5 6013+HDPE 3.0 Coex Coex Coex Coex
mil mil
Ordered Alignment Of COC Domains In Films Reduces Tear Resistance
Low Tear Resistance Does Not Imply Poor Durability
SPE Polyolefins & FlexPackCon www.topas.com
15. Pouch Preparation
Lamination
▶ Faustel Pilot Size Laminator
▶ 50 FPM Line Speed
▶ 48 Gauge Corona Treated PET
Film Applied to All Untreated Test
Films
▶ Retortable Henkel Adhesive (3.0
– 4.0 lb/ream Basis Weight)
▶ Dryer: 150ºF
▶ Nip: 160ºF
SPE Polyolefins & FlexPackCon www.topas.com
16. Pouch Preparation
Pouch Fabrication
▶ Pouch Machine: Shanghi
Gaoqin Packaging Machinery
FSD-600SZ
▶ 100 – 125 4-Side Seal Pouches
per Test Film
▶ Size: 5.0 x 7.5 Inches
▶ Bottom Seal: ½-inch
▶ Side Seals: 3/16-inch
▶ Top Seal: 3/8-inch
SPE Polyolefins & FlexPackCon www.topas.com
17. Pouch Preparation
Pouch Filling and Sealing
▶ Pouch Filling Machine: Toyo
Jidoki Model PMS
▶ Filled With 8 oz Of Water
▶ Pouches Sealed At 140ºC.
▶ PET Removed Prior To Retort
SPE Polyolefins & FlexPackCon www.topas.com
41. TOPAS® COC – Conclusions & Benefits
TOPAS COC Enhances Stiffness, Dimensional Stability &
Package Integrity At Retort Temperatures
TOPAS COC Enables Use Of PE, Especially LLDPE, In
Retort Applications
TOPAS COC Improves Moisture And Oxygen Barrier
Properties Of Polyolefins
COC Coextruded Structures With PP Are Most Effective
TOPAS 6015 (Higher Molecular Weight and Tg) Is More
Effective Than TOPAS 5013 For Property Enhancement.
TOPAS 6017, Tg = 180ºC, Should Be Included In Future
Development Programs
SPE Polyolefins & FlexPackCon www.topas.com
42. Acknowledgments
TOPAS® Retort Team:
Adam Barton, Wolfram Goerlitz, Randy Jester,
Tim Kneale, Robert Roschen, Bernd Sparenberg
CEFPACK Consortium, Clemson University:
Dr. Duncan Darby, Dr. Scott Whiteside &
Ms. Pat Marcondes
TOPAS® Cyclic Olefin Copolymer (COC)
Your Clear Advantage in Retort.
Any questions?
SPE Polyolefins & FlexPackCon www.topas.com
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