application of food films with copa and [email protected] . title: troubleshooting...
TRANSCRIPT
Application of Food Films with
CoPA and TerPOLYAMIDES
Presented by: Carlos Catarozzo UBE Latin America Serviços Ltda
EVOLUTION OF PA FOR FLEXIBLE PACKAGE
SOLUTIONS FOR EXISTING FLEXIBLE PACKAGES
NYLON POLY BAGS
THERMOFORMING
LIQUID PACKAGING
SHRINK BAGS
SOLUTIONS FOR THE FUTURE OF THE PACKAGE
CONCLUSIONS
INDEX
Versatility / Many applications
Mechanical properties
Puncture resistance
Processability & output
WHY PA FOR FLEXIBLE PACKAGING?
PA6
PA6 Specialties
CoPA 6/6.6
CoPA 6/12
CoPA 6/6.6 Specialties
TerPA
6/6.6/12
EVOLUTION OF PA FOR FLEXIBLE PACKAGING
PA with high cristallinity
PA with reduced cristallinity
Chill-roll Water
Air cooling
PA
Medium Barrier
Mechanical properties
EVOH
Transparency
High Barrier
PE
Sealing
Flexibility
Tie
Extrudable
Compatibility
EVOLUTION OF PA FOR FLEXIBLE PACKAGING
EVOLUTION OF PA FOR FLEXIBLE PACKAGING
EVOLUTION OF PA FOR FLEXIBLE PACKAGING
Bags Thermoforming
Flexible bottles
Shrink film
CoPA
Applications
CoPA SOLUTIONS FOR EXISTING FLEXIBLE PACKAGES
Bags
CoPA SOLUTIONS FOR
PROBLEMS / CHALLENGES
Nice aspect
Production speed
Curling
Toughness
Retort
Very good transparency and gloss
CoPA FOR : TRANSPARENCY
Puncture resistance
CoPA FOR : PUNCTURE
ºC Tm (PA) TC (PA) Tm (PE) TC (PE) Tg (PA)
Both polymers
are in molten
status
PA crystallizes
(“solidifies”)
and shrinks.
PE is still
molten, it can
go with the PA
PE crystallizes (“solidifies”)
and shrinks.
PA is solid, it cannot go
anymore with the PE
Stresses are created in the PA
PA6/6.6 and PA6/6.6/12:
- More amorphous
- Lower Tc
Curling reduction
CoPA FOR : CURLING
Measured on 100 microns air blown film: LDPE/Tie/PA (30 % PA)
Curling degree measurement: 100 mm round specimen – final dimensions after cutting (UEP method)
PA 6 PA 6/6.6
15%
PA 6/6.6
20 % PA 6/6.6/12
Curling = 90% Curling = 80% Curling = 45% Curling = 5%
CoPA FOR :CURLING
Melting point range
CoPA FOR : THERMAL RESISTANCE
Autoclave T = 125ºC
50 µm monolayer airblown film
CoPA FOR : RETORT
Thermoforming
PROBLEMS / CHALLENGES
Deeper packages
Functionality
Distribution
CoPA SOLUTIONS FOR
Mould: - 2x2 cavity - 91 mm diameter - variable depth
CoPA FOR : DEEPER PACKAGES
MAX thermoforming DEPTH study
Film: 50 microns monolayer air blown film
CoPA FOR : DEEPER PACKAGES
Max. thermoforming depth (Airblown)
PA6
Heating plate
110ºC 7
0 m
m CoPA
10 % 10%
Heating plate
85ºC
70
mm
CoPA
Heating plate
80ºC
85
mm
TerPA
Heating plate
80ºC
95
mm
LOW CO-MONOMER
% HIGH CO-MONOMER
% THREE
CO-MONOMER
CoPA FOR : DEEPER PACKAGES
Max. thermoforming depth (Airblown)
Heating plate
105ºC
115
mm
TerPA+
Additive
PA6
Heating plate
110ºC
70
mm
CoPA 10 % 10%
Heating plate
85ºC
70
mm
CoPA
Heating plate
80ºC
85
mm
TerPA
Heating plate
80ºC 9
5 m
m
LOW CO-MONOMER
% HIGH CO-MONOMER
% THREE
CO-MONOMER
MODIFICATION
READY-TO-USE
Higher optimum
tempertaure
CoPA FOR : BETTER DISTRIBUTION
Thermoforming THICKNESS DISTRIBUTION
study
Film: 50 microns monolayer air blown film
Mould: - 1X1 cavity - 202 mm diameter - 60 mm depth
CoPA FOR : DEEPER PACKAGES
Thickness distribution at 60 mm depth (Airblown)
--- PA6 --- CoPA (10 %) --- CoPA (20 %) --- TerPA
Thermoforming for respiring cheese with TerPA 6/6.6/12
CoPA FOR : FUNCTIONALLITY
Flexible
bottles
CoPA SOLUTIONS FOR
PROBLEMS / CHALLENGES
Flexcrack
Barrier
Puncture
Flex Crack Resistance
40
20
10105
00
10
20
30
40
50
PA6 CoPA6/6.6
CoPA6/6.6/12
Nu
mb
er
of
ho
les
(0
,04
.m
2)
23 ºC1000 cycles
5 ºC 100 cycles
CoPA FOR : FLEXCRACK
PE PE Tie CoPA EVOH CoPA Tie PE PE
PE PE PE Tie EVOH Tie PE PE PE
Co-ex films (9) = 30 microns / Each layer of CoPA = 2 microns
Puncture Resistance
CoPA FOR : PUNCTURE
PE PE Tie CoPA EVOH CoPA Tie PE PE
PE PE PE Tie EVOH Tie PE PE PE
Co-ex films (9) = 30 microns / Each layer of CoPA = 2 microns
Mechanical properties
CoPA FOR : STRENGTH
Shrink film
CoPA SOLUTIONS FOR
PROBLEMS / CHALLENGES
Shrinkage
Environment
Puncture
Very good shrinkability
CoPA FOR : SHIRNKAGE
Excellent puncture; bone-in
CoPA FOR : PUNCTURE
Request for
PVC and PVDC free solutions
Market feeling
PVC - PVDC :
Environmental concerns
Market is growing
“Pellicola senza PVC”
“PVC free film”
CoPA FOR : ENVIROMENT/LEGISLATION
Film structure
Thickness
PE/EVA/PVDC/EVA/PE
Total : 80 µm (PVDC : 10%)
PA/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 40%)
PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 20%)
PVDC based
7 layers 9 layers
CoPA/EVOH/CoPA based
0
50
100
150
200
PVDC based PA/EVOH/PA based7 layers
PA/EVOH/PA based9 layers
80
130
95
150 140 155
Tensile properties at break (MD)
Strength (MPa) Elongation (%)
0
25
50
75
100
PVDC based PA/EVOH/PA based7 layers
PA/EVOH/PA based9 layers
9 11 9
48
83
48
Puncture resistance
Deformation (mm) Energy (mJ)
CoPA FOR : CHLORINE-FREE ALTERNATIVE
Barrier package + Single hole = Barrier loss = Waste of money !
Puncture risk during shrinkage process (sharp shapes, bone-in)
Puncture risk when handling the packed goods (machine, supermarket)
CoPA FOR : CHLORINE-FREE ALTERNATIVE
Film structure
Thickness
PE/EVA/PVDC/EVA/PE
Total : 80 µm (PVDC : 10%)
PA/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 40%)
PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 20%)
PVDC based
7 layers 9 layers
PA/EVOH/PA based
0
5
10
15
20
PVDC based PA/EVOH/PAbased
7 layers
PA/EVOH/PAbased
9 layers
16
7
13
Haze (%)
0
25
50
75
100
125
150
PVDC based PA/EVOH/PAbased
7 layers
PA/EVOH/PAbased
9 layers
97 121
102
Gloss (%) Angle : 60º
CoPA FOR : CHLORINE-FREE ALTERNATIVE
CoPA FOR : CHLORINE-FREE ALTERNATIVE
Film structure
Thicknesses
PE/EVA/PVDC/EVA/PE
Total : 80 µm (PVDC : 10%)
PA/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 40%)
PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 20%)
PVDC based
7 layers 9 layers
PA/EVOH/PA based
0
10
20
30
40
50
PVDC based PA/EVOH/PAbased
7 layers
PA/EVOH/PAbased
9 layers
10 4,5
15,5
OTR (cc/m2.day)
CoPA FOR : CHLORINE-FREE ALTERNATIVE
Film structure
Thickness
PE/EVA/PVDC/EVA/PE
Total : 80 µm (PVDC : 10%)
PA/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 40%)
PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 20%)
PVDC based
7 layers 9 layers
PA/EVOH/PA based
0
10
20
30
40
50
60
PVDC based PA/EVOH/PA based7 layers
PA/EVOH/PA based9 layers
50
37
48 48
39
54
Thermal shrinkage (%) Soaked @ 90ºC
MD TD
CoPA FOR : CHLORINE-FREE ALTERNATIVE
Film structure
Thickness
PE/EVA/PVDC/EVA/PE
Total : 80 µm (PVDC : 10%)
PA/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 40%)
PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE
Total : 50 µm (PA : 20%)
PVDC based
7 layers 9 layers
PA/EVOH/PA based
Tensile (MD/TD)
Strength (MPa)
Elongation (%)
Puncture Force (N)
Deformation (mm)
Energy (mJ)
80 / 70
150 / 210
13,5
9
48
130 / 135
140 / 125
20,5
11
83
95 / 105
155 / 120
13,5
9
48
Haze (%)
Gloss (%), 60º
16
97
7
121
13
102
OTR (cc/m2.day) 10,0 4,5 15,5
Shrinkage (%) MD
TD
50
48
37
39
48
54
CoPA FOR : CHLORINE-FREE ALTERNATIVE
SOLUTIONS FOR THE OF THE PACKAGE
GLASS/CAN PLASTIC
RIGID PLASTIC FLEXIBLE
Less space
Less weight
Less CO2
SOLUTIONS FOR THE OF THE PACKAGE
SOLUTIONS FOR THE OF THE PACKAGE
New Polymers
New applications
New functionallity
New technology
More combinations
Higher efficiency
SOLUTIONS FOR THE OF THE PACKAGE
CoPA
TerPA
Physical properties
High stretching
& shrinkage
Thermal stability
Design freedom
Cost reduction
Sustain-ability
CONCLUSIONS
