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Presentacion SPE Polyolefins_2014_jlfeijoo
Dr. José Luis Feijoo-Gómez presented at the SPE Polyolefins Conference in February 2014 in Houston. He discussed OPTUM®, an innovative masterbatch technology from Ferro that uses non-nanosized lamellar clays to reduce the water vapor transmission rate of polypropylene-based materials used in food packaging. This allows for reduced EVOH content while maintaining barrier performance, even after thermal processing like sterilization. OPTUM® was shown to decrease the water uptake of PP films by over 50% compared to unmodified PP, protecting the barrier properties of EVOH layers during packaging shelf life.
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Presentacion SPE Polyolefins_2014_jlfeijoo
- 1. Dr. José LuisFeijoo-Gómez SPE Polyolefins Conference2014 23-26 February Houston OPTUM® Technology an innovative barrier solution for polypropylene-based materials in food packaging applications
- 2. A global producerof performance materials. Dr. José Luis Feijoo-Gómez SPE Polyolefins Conference 2014 23-26 February Houston
- 3. • Founded in1919, Ferro is a leading, global producer of performance materials sold to manufacturers worldwide • Our customers represent more than 30 industries and span 100-plus countries • We have manufacturing facilities in the Americas, Europe and Asia-Pacific • Ferro has more than 5,200 employees working at sites in 23 countries Dr. José Luis Feijoo-Gómez SPE Polyolefins Conference2014 23-26 February Houston
- 4. Founded in 1919 (Mayfield Heights, Ohio) 4,600 employees worldwide 23 countries $1.8 billion sales2012 THE PERFORMANCE MATERIALS COMPANY
- 5. 5 Engineered PolymerMaterials Polymer Additives Performance Coatings (Tile Coating Systems, Porcelain Enamel) Pharmaceuticals Polymer and Ceramic Engineered Materials Group
- 6. Engineered Polymer MaterialsOperations Stryker, (NW) OH 72 Employees Operating since 1980 Castellón, Spain 100 Employees Operating since 1959 PLASTICS CONFIDENTIAL
- 7. 7 Carpentersville, IL 35 employees Operatingsince 1987 Belongs to Ferro since 1999 Plymouth, In Gelcoat plant 32 employees Operating since 1968 Engineered Polymer Materials Operations
- 8. 8 Engineered Polymer MaterialsOperations Evansville, In Filled and Reinforced Plastics 71 employees on site Started as Complas in 1973 Belongs to Ferro since 1979
- 9. Master Batch Technology Dr.José Luis Feijoo-Gómez SPE Polyolefins Conference2014 23-26 February Houston
- 10. OPTUM® BARRIER DESCRIPTION • MBbased on based on a passive non-nanosized technology for food packaging in ready meals and some hot beverages in which a heat treatment is necessary and for this polypropylene is extensively used • Our proposal is to reduce the EVOH content in the final packaging by reducing water vapor transmission rate (WVTR) in PP during the thermal treatment
- 11. OPTUM® BARRIER THERMAL TREATMENTS •Sterilization Destroy all microorganisms 110 – 130°C for 15 – 3 min Packaging traditionally uses aluminum but also retort pouches and multilayered PP-based trays • Pasteurization Destroy viable pathogens (needs refrigeration) About 71°C for 20 sec Packaging is very diverse
- 12. Layer structure Applications PolypropyleneFor products with high fat content and lids PP/EVOH/PP Additionally contains interior EVOH layer as high extra oxygen and aroma barrier which allows for very long shelf-life packaging for trays especially developed for MAP and fresh products This requires adhesive as sealing interlayers OPTUM® BARRIER MARKET OF PP TRAYS • Yearly, around 3.3 billion of multilayered PP trays for ready meals in Europe are processed by sterilization • About 5% of the pasteurization market is also based on this type of trays (5 billion trays / year)
- 13. The presence ofEVOH in the multilayer structure is key to food quality and safety because it reduces the ingress of oxygen and the loss of aroma components during extended package shelf life When this is subjected to steam during pasteurization or sterilization, water passing through the protective hydrophobic water-barrier PP layer is thought to be sorbed on the EVOH layer Sorption of water is known to have a severe plasticizing effect on the properties of EVOH and leads to deterioration of the oxygen barrier performance and delamination Since rate of water release through the outer PP layer becomes very slow on cooling, the oxygen permeability can remain elevated for many weeks • Currently, to reduce this effect during the thermal treatment, industry increases thickness of PP or EVOH layers or uses special EVOHs… OPTUM® BARRIER TECHNICAL OVERVIEW
- 14. • WVTR isreduced by tortuosity effect when dispersing low amounts of lamellar clays with high aspect ratio: 100 – 300 m2/g • Such ultrathin reinforced polyolefins also promotes a higher thermal and mechanical performance maintaining transparence and natural color • The clays exfoliation into the polyolefin matrix is the key to success PP matrix Clay H2O OPTUM® BARRIER BARRIER PERFORMANCE
- 15. • PP /Adhesive / EVOH / Adhesive / PP OPTUM® BARRIER PP-BASED MULTILAYER STRUCTURE
- 16. PP / Adhesive/ EVOH / Adhesive / PP OPTUM® BARRIER PP-BASED MULTILAYER STRUCTURE Figure 1. Film extrusion of the composites
- 17. OPTUM® BARRIER PP-BASED MULTILAYERSTRUCTURE Figure 2. SEM images of the unfilled polypropylene and the OPTUM® composite films.
- 18. OPTUM® BARRIER PP-BASED MULTILAYERSTRUCTURE Figure 3. DSC curves of unfilled PP (black) and OPTUM® composite (grey) films.
- 19. OPTUM® BARRIER PP-BASED MULTILAYERSTRUCTURE Figure 4. Box plot of the water uptake on the films.
- 20. OPTUM® BARRIER PP-BASED MULTILAYERSTRUCTURE Films Water Uptake (g/m2µm) Reduction (%) Unfilled PP 1,219 ± 151 - MMT 1,020 ± 204 16.3 Bentonite 906 ± 185 25.7 OM bentonite 828 ± 236 32.1 OPTUM® 525 ± 84 56.9 Table 1. Average values of water uptake of the PP films.
- 21. CONCLUSIONS • Permeation studyduring the steam treatment showed that the incorporation of OPTUM® generates a significant effect on the barrier properties of polypropylene. • The morphology results showed that the incorporated functional fillers in the masterbatch were properly dispersed in a polymer matrix, obtaining a highly exfoliated-structure composite. • Since the crystallinity of the composite is in the order of polypropylene, the decreased of water vapor permeability can be attributable solely to the incorporation of the functional fillers. Dr. José Luis Feijoo-Gómez SPE Polyolefins Conference2014 23-26 February Houston
- 22. THANK YOU FORYOUR ATTENTION jose.feijooj@ferro.com Dr. José Luis Feijoo-Gómez SPE Polyolefins Conference2014 23-26 February Houston