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Innovative Hochbarrierefolien –Herstellung, Design und neueste Anwendungen

Möhlin- May 17, 2017

Simone HermannProduct Development Manager Pharma

Amcor - introduction

- our approach to Innovation - Manufacturing processes

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Amcor: A leading global packaging supplier

29,000+CO-WORKERS

GLOBALLY

180+ MANUFACTURING

SITES

40+ COUNTRIES WITH

OPERATIONS

US $10 BILLION ANNUAL

SALES

1860’sSTART OF

OPERATIONS

70,000+ SHAREHOLDERS

TOTAL OUTPUT

4,000,000UNITS/MIN

In Flexible Packaging

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Innovation

Amcor is today a US$9.5 billion global business with strong exposure to the emerging markets of Asia, Latin America, Eastern Europe and Africa

Over 95% of annual sales are from consumer staples including food, beverage, healthcare, home and personal care and tobacco products

Emerging markets

32%

North America

32%

Western Europe

31%

AUS,NZ 5%

Food 33%

Beverage 32%

Specialty Folding Cartons

15%

Home and personal care

3%

Healthcare 15%

Other2%Rigid

plastics 36%

Flexibles64%

Portfolio Global Reach Segments

Note: All numbers refer to FY 2016

Amcor today

4

4

1

4

CANADA

SOUTH AFRICA

SOUTH KOREACHINA

INDIA

1

3

1

1

1

1 1

2

1

1

1

11

1

USA

MEXICO

EL SAVADOR

ECUADOR

COLUMBIA

CHILE

PERU

ARGENTINA

BRASIL

TRINADAD & TOBAGO

VENEZUELA

11

29

3

2

3

2

1

11 3

1

1

7

1

1

3

1

DENMARK

NETHERLANDS

BELGUIM

SWITZERLAND

1

4

AUSTRALIA

NEW ZEALAND

7

5

THAILAND

INDONESIA

SINGAPORE

3

1

4

10

1

TURKEY

SPAIN

PORTUGAL

MOROCO

3

1 3

1

11 6

Flexibles Packaging110 Plants33 Countries

Folding Cartons23 Plants20 Countries

Rigid Plastics62 Plants12 Countries

UK

IRELAND

GERMANY

FRANCE

FINLAND

RUSSIA

POLAND

UKRAINEKAZAKHSTAN

3

1CZECH REPUBLIC

ITALY

4

1

2

7

4

1

11

PUERTO RICO

DOMINICAN REPUBLIC1

1

11

6

1

1MALAYSIA

PHILIPPINES

Amcor strategy – global, integrated, relevant

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6© Amcor 2017 Confidential

Amcor has a full range of production technologies

Aluminium rolling SioX-coating Film extrusion (cast/blown) Lacquering Lacquer/adhesive lamination Extrusion coating Extrusion lamination Printing (solvent based, UV-curing, Digital) Slitting Bag making Die cutting

Example: Formpack® – Manufacturing process

7© Amcor 2016 Confidential

The Formpack® innovation is the ability to stretch an aluminium laminate ≥32% in three dimensions to produce small, deep cavities without fractures, guaranteeing the protective barrier properties

oPA 25 µm

PVC 60 µm

Aluminium 45 µmadhesive

adhesiveprimer

Formability

Stiffness

Barrier

Example: Formpack® – Manufacturing process

8© Amcor 2016 Confidential

a) Aluminium – from ingot to foil:

AnnealingMetal temp: 280-350°C(change form hard to

soft temper)

Cold rolling3 single rolling steps,

Last step to 45µm (double rolling)

Separating(separation of double rolled foil, trimming)

AnnealingMetal temp: 280-350°C(change from hard to

soft temper)

Pre-roll stock800-1690mm

Thickness: 700µFoil stock ex Hot Rolling Mill

Packaging

Converting (Lamination)

Hot Rolling

Example: Formpack® – Manufacturing process

9© Amcor 2016 Confidential

Primer on Alu

LaminationoPA/ Alu/ PVC

Curing

Slitting

Packing

LaminationClean Room Class D, ISO 8 conditions

CuringSlittingClean Room Class D, ISO 8 conditions

b) Lamination & Slitting:

Example: Lidding – Manufacturing process

© Amcor 2016 Confidential

Clean Room Class D, ISO 8 conditions

Printing

Trimming

Slitting

Packing

Lacquer mixing

Lacqueringon Alu

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Amcor has an extensive and powerful set of innovation capabilities right across the packaging spectrum

DesignOur creative and technical designs drive consumer appeal. Through innovative design, we help our customer products look amazing, feel great and perform intuitively.

Material scienceUsing our deep understanding of materials, we develop and test packaging to ensure it works the way we intended, from how the product looks, feels, works, and performs.

Manufacturing and processesWe apply advanced manufacturing and engineering to maximise efficiency across the entire supply chain from how materials are sourced, processed, converted, handled, transported and recycled.

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Design & Services

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Packaging Simulation (Pharma)

13© Amcor 2016 Confidential

Simulation & Analysis

Prediction• Coldform cavity size• Tooling material selection• Forming forces• Thermoforming thickness

distribution• WVTR calculation• …

Physicalmodelling

• Springback and relatedstresses

• Material behaviour modelling• Heat transfer during sealing• Process simulation• Impact test (crash type)• …

Validation

• Material testing (stress-strain)• Forming strain measurement• Inverse calculations• Formability tests• Friction measurement

Packaging Simulation (Pharma)

14© Amcor 2016 Confidential

• Black Box Thermorforming Simulation

Thickness distribution

Permeability

Packaging Simulation (Pharma)

15© Amcor 2016 Confidential

• FORSIS Cold forming Simulation for Tool design

Customers’Tablet Geometry

FORSISForming Simulation

CADTool drawing

Technical application support

Analytical labPilot line & Technikum

Testing on blister line, development of test methods, prototyping

Evaluation of extractables& other analytical tests

Phi-Check (analysis of strain distribution and tool alignment)

Cross Diffusion Simulation

Calculation of permeation intoFormpack ® blister through the seal area

Cross Diffusion Simulation

17© Amcor 2016 Confidential

Sealing LayerLid foil

Cross diffusion

Base foil

Top layer

AluminumHeat seal lacquer

Main polymer

Aluminum

Bottom layer

Adhesive

Relevant layers for cross diffusion

Lid

Base

Diffusion distance

Permeation = solubility x diffusivity

Material properties:• Density• Diffusivity• Solubility

18© Amcor 2016 Confidential

FORMPACK® blister

Corner cavity,no perforation

Mid-strip cavity,perforated

Mid-strip cavity,no perforation

Mid-strip cavity,perforated & lateral offset 1.5 mm

Humidity flow

Cross Diffusion Case Study

Case study results:

Corner cavity shows 30% more cross diffusion than mid strip cavity

Perforation increases cross diffusion by 6 times for a mid strip cavity

When the sealing width changes due to variations in production process (e.g.. misalignment), it is more than 7 times worse

Cross diffusion into standard Formpack® blister is more than two decades betterthan into high barrier thermoform film (e.g. PVC/Aclar Ultrx4000)

Cross Diffusion Simulation

Innovative Solutions in Pharma

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Our Pharma flexibles product range

Ready-to-Use Formpack® Blister

• Materials feature special sealing properties with both a tightseal and easy peel (frangible seal) to allow a controlled mixingof the different components, means “on-the-spot mixing”.

• Allowing highly moisture-sensitive drugs to be instantlymixed before usage, thus enhancing drug stability and simplifying supply chain (e.g. eliminating necessity of cool storage).

• New laminates (bottom and lid foil) create a high barrier cold formed blister pack, a perfect solution for unstable and water/vapor-sensitive drugs .

Option with 2 components

TDSP0506-E & TDSP0507-E

straw

Technical description:

awarded with

22© Amcor 2016 Confidential

• Significantly increases protection against cross diffusion,extends pharmaceutical and medical product shelf life

• Dries tablet humidity and headspace thanks to the extra capacity available

• Water absorption capacity (guaranteed): 3.6 g/m2

DessiflexTM Blister & Sachet System- a new dimension in protection

Formpack DessiflexTM Blister System

DessiflexTM Sachet System

Formpack® Dessiflex Blister System

23© Amcor 2016 Confidential

• Forming like Formpack® with PVC (Teflon plugs!); FORSIS to design optimal cavity & tooling

• Lid foil with PE based coating needed (lower seal temperature than for PVC-based blister needed)

• Reels packed in Alu/plastic pouches (under vacuum)• No capacity reduction during processing on blister line (unwinding

to sealing); Processing of a reel within 120h recommended

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Cost SavingsUp to 40% less film than

4-side sealed sachets

Single-serve pack solution

Key Benefits for Customer

Key Benefits for Patient

On-the-go ConvenienceLightweight and easy to open

thanks to an easy opening system

Easy DispensingEasy dispensing directly from the pack,

avoids product waste keeps hands clean

Product DosingSingle-portion packs and controlled

dosing means no measuring is required

Brand PositioningEntire printing surface and high quality

image for premium look and increased brand recognition

Examples of Material Structure

Standard spec would be PET/Alu/PE

- PET

- Alu

- PE

Other specs available, depending on application

Single-serve pack with PolyInert

Example of Material Structure

High resistance to aggressive substances.

Low scalping & chemical interaction for Dermal or liquids where the API suffer absorption into the sealant layer.

Replacement / alternative to discontinued Barex.

Polyinert sealant layerPolyinert sealant layer

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Easy-openingEasy-opening

Pharma Segment Drivers impacting Flexible Packaging

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Amcor Key Innovation AreasMacro Trends Implications for Packaging

Changing demographics:Aging population; rapid growth of middle classes in emerging regions; global mobility

Uncertain Future:Increasing cost pressure on healthcare systems

Personal Wellbeing:Higher expecations on health, safety and efficacy of drugs

Education:Increased understanding of health issues; readiness to seek treatment

Increase usage of multi-dose drugs for aging patients

Convenient packaging for mobile patients

Packaging must be cost-effective

Sustainable and recyclable materials

Packaging used as a differentiator to appeal to patients as consumers

Ease of opening for seniors; protection for children

Increased focus on supply chain security (illegal reimports, counterfeits)

Climate Challenge:Increased interest in environmental sustainability;

Personal Economics:Variable access to health insurance; wide differences in ability to pay for medicines

PATIENT SAFETYAnti-counterfeit measures, improved Child-Resistant/Senior-Friendly packs; focus on Patient Adherence

TOTAL COST OF OWNERSHIPSmaller packs; higher operational output; reduced complexity

SUSTAINABLE PACKAGINGReduced size and weight; sustainable materials; recyclability

DIFFERENTIATIONDrug Delivery Systems; easy open packs; extended shelf life

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