polyethylene & polypropylene in flexible barrier · pdf filepolyethylene &...
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2009 Consumer Packaging Solutions for Barrier Performance Course
Polyethylene & Polypropylene in Flexible
Barrier Packaging
Presented by:Kelly R. FreyExtrusion Coating – Technical ServiceChevron Phillips Chemical Company, LP
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Learning OutcomesHow polyethylene & polypropylene is used in barrier packaging. Barrier properties of PE & PP. Properties of PE which affect barrier performance.How film & coating processing influences barrier performance.
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How does PE & PP fit into flexible barrier packaging?
By itself (monolayer)…
Combined (coex or lamination)…
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How Does PE & PP Provide Barrier?
Polyethylene is used by itself or combined with other materials to create a torturous path to create a barrier. Polyethylene and polypropylene can have good-moderate moisture barrier properties. HDPE MVTR grades are higher in density and can provide improved moisture barrier over LDPE and PP. Good moisture barrier can be achieved with monolayer HDPE MVTR grades.
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How Does PE & PP Provide Barrier? Fair moisture barrier can be achieved with monolayer LDPE grades. Polyethylene and polypropylene have poor oxygen (gas) barrier but good-moderate moisture barrier properties.
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PE & PP MVTR Properties
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PE & PP OTR Properties
0.1
1
10
100
1000
cc-m
il/10
0in2 /d
ay
Foil
PVdC or metP
ET
PVdC or metO
PP
Cello
OPETNylo
n 66
OPPHDPE PPLDPEPap
erNon
-Wov
en
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0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5
Gauge (mils)
g/10
0in2 /d
ay
HDPE MVTR
HDPE MVTR Grade Blown Film
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Using PE & PP for BarrierPE & PP can be combined (blended, coexed, or laminated) with other materials for exceptional MVTR & OTR.
PE & PP properties and processing methods influence barrier properties.
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H H
H
C C
H
ETHYLENEETHYLENE
Colorless GasOdor = Slightly SweetOrigins = Refinery Gas &Liquefied Petroleum GasesMol. Wt. = 28
World Capacity*128 Million Tons. (2005 est.)
* World Petrochemical Review (Oct 2005)
Colorless GasOdor = Slightly SweetOrigins = Refinery Gas &Liquefied Petroleum GasesMol. Wt. = 28
World Capacity*128 Million Tons. (2005 est.)
* World Petrochemical Review (Oct 2005)
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H H
H
C C
H
Catalyst/InitiatorTemperature
Pressure
Catalyst/InitiatorTemperature
PressureH H
H
C C
H
H H
H
C C
H
H H
H
C C
H
Polyethylene Reaction
H H
H
C C
H
H H
H
C C
H
H H
H
C C
H
H H
H
C C
H
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HDPEHDPE
LDPELDPE
LLDPELLDPE
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MOLECULAR WEIGHT
DISTRIBUTION (MWD) HDPE
MOLECULAR WEIGHT
DISTRIBUTION (MWD)
COMONOMBER TYPE (SCB)LLDPE
MOLECULAR WEIGHT
DISTRIBUTION (MWD)
LONG CHAIN BRANCHING (LCB)
CRYSTALLINITY
CRYSTALLINITY
CRYSTALLINITY
LDPE
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Critical Polyethylene Properties
Melt Index / Mol. Wt. Density / Crystallinity
Morphology (shape, size & distribution of the PE molecules & crystals)
Molecular Weight Dist.Long Chain BranchingRheology
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DensityDensity is a measure of the crystallinity of the polymer.Higher density polymers have more closely packed molecules and are more stiff in nature.Lower density polymers have loosely packed molecules and are more flexible.Density is measured as the weight of material occupying a specific volume (g/cc).
No Branching – High Density
Short Chain Branching –Med Density
Short & Long Chain Branching –Low Density
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CrystallineRegions
AmorphousRegions
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Density Test
Density is an indirect measure ofthe crystallinity of a polymer.
Standard Procedure : ASTM D1505Units = g/cc
Calibrated Density Standards
Sample
Controlled TemperatureGradient Column
Other accepted techniques for measuring density include ultrasonic velocity and buoyancy (densimeter).
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As Crystallinity IncreasesThese Properties
Increase
DensityStiffnessTensile StrengthSoftening PointDead FoldCurl
Chemical ResistanceHeat ResistanceWrinkling TendencySeal Initiation Temp.Barrier (Moisture, Light, & Grease)
Decrease
MD Tear StrengthImpact
Puncture ResistanceCOF
Optics (Clarity)
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Crystallinity
For polyethylene, the degree of crystallinity has the largest influence on barrier properties.
Randomly oriented, large crystals, create the most tortuous path.
% crystallinity can be measured and is influenced primarily by polymer type, but also by processing.
LDPE/LLDPE ~ 30% - 55% crystallinityHDPE up to 85% crystallinity
In addition to % crystallinity, morphology (alignment, shape & dimensions of crystals), also affects barrier performance. Processing methods also influence the degree of crystallinity and polymer morphology, which will also directly affect barrier properties. Types of processing methods….
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Produces high barrier structures by coextruding PE & PP with high barrier
materials, predominantly nylon and EVOH.
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Produces high barrier structures by coextruding PE & PP with high barrier
materials, predominantly nylon and EVOH. Also produces good moisture barrier monolayer films using HDPE
MVTR grades.
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Capital CostOutputGauge ControlOptical PropertiesRetrofit to CoexAdditive LoadingFilm StrengthBiax OrientationMVTR Barrier
CAST FILM BLOWN FILM
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Processing Conditions Affecting Barrier
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0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5
Gauge (mils)
g/10
0in2 /d
ay
HDPE MVTR
HDPE MVTR Grade Blow Film
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0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
1.25 1.75 2.25 2.75 3.25
Gauge (mils)
g/10
0in2 /d
ay
HDPE MVTR
HDPE MVTR Grade Blow Film
BUR = 1.5
BUR = 2.5
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Extrusion Coating Process
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Barrier Considerations in Extrusion Coating
HDPE must be blended or coextruded with LDPE for processability in extrusion coating.Blending with highly branched LDPE extrusion coating grades disrupts crystallinity and reduces barrier. Most orientation is in machine direction (similar to cast film). Lack of biax orientation reduces barrier compared to MVTR blown film.Properties dependent on level of comonomerSome applications only require “moderate” barrier and LDPE or HDPE in extrusion coating can work (e.g. sugar pouch).
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Extrusion Coating MVTR
HDPE
00.5
11.5
22.5
0 20 40 60 80% HDPE
g-m
il/10
0in2 /d
ay
BlendCoex
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How to Destroy Barrier in
Extrusion Coating
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SummaryPE & PP are used directly or indirectly in flexible barrier packaging. To achieve oxygen (gas) barrier, PE & PP are typically coextruded or laminated with other materials. HDPE MVTR grades provide good moisture barrier properties.Manufacturing methods and process conditions influence barrier properties.
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PRESENTED BY
Kelly R. FreyExtrusion Coating – Technical ServiceChevron Phillips Chemical Company, LP
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