ROLE OF EVOH IN BARRIER FLEXIBLE PACKAGING

WORLD PACKAGING CONGRESS

09-10 OCTOBER 2015 ,MUMBAI ,INDIA

CONTENTS

• BRIEF INTRODUCTION OF KURARAY

• INTRODUCTION OF GAS BARRIER RESIN

EVOH

• EVOH PROCESSING TECHNIQUES

• CONVENTIONAL EVOH APPLICATIONS –

GLASS /METAL / AL FOIL REPLACEMENT

• EMERGING EVOH APPLICATIONS

Who is Kuraray?

The world’s largest producer of Vinyl Acetate Monomer derivatives

Kuraray Co. Ltd., founded 1926 in Kurashiki, Japan

World’s largest producer of PVOH (POVAL™) and EVOH (EVAL™) as well as many other specialty polymers, fibres and films

Leader in gas barrier technology and development Head office in Tokyo, Japan. Global sites: 43 sites in 17 countries

Pasadena, Texas

Antwerp, Belgium

Okayama

Tokyo 24,000T

10,000T

▲ ▲

Regional sales office Production site ▲ R&D center

Shanghai

Production capacity of EVOH EVALTM

Singapore

Bangkok

Total Global Capacity = 81,000T

47,000T Deli

Higher density Higher melt point Higher gas barrier

WHAT IS EVOH

24 27 32 35 38 44 48

a semi-crystalline thermoplastic and a random copolymer of

Ethylene and

Vinyl ALcohol

(CH2-CH2)m (CH2-CH)n

OH

More flexible More orientable

Easier to process

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Eth

yle

ne

mo

l %

Polyolefin

Tie

EVAL™

Tie

Polyolefin

EVOH PHYSICAL PROPERTIES

O2 permeability cc.20µm/m2.day.at

m

0.1

0.2

0.4

0.5

0.6

1.5

3.2

Mol% et.

24

27

32

35

38

44

48

g/cc Tm ºC

195

191

183

177

172

165

160

1.22

1.20

1.19

1.18

1.17

1.14

1.12

mol% ethylene

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OXYGEN PERMEABILITY OF POLYMERS

@ 20°C, 65%RH

High Barrier

Medium barrier

Low barrier

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Material cm3.20 μm/m2.day.atm

32 mol% Et. EVOH 0.4

38 mol% Et. EVOH 0.7

PVdC (Polyvinylidine chloride) 2.6

Polyamide (Nylon) 38

PET (Polyester) 54

HDPE (High Density Polyethylene) 2300

PP (Polypropylene) 3000

PC (Polycarbonate) 5000

PS (Polystyrene) 8000

LDPE (Low density Polyethylene) 10000

EVA (Ethylene Vinyl Acetate) 18000

Oil - Fats resistance

Oxygen Barrier

Flavour Barrier

Processability

Recycling

Chemical Resistance

Transparency

Antistatic properties

Printable

Odour Barrier

Ageing resistance

EVOH PROPERTIES

Flex-crack Resistance

LDPE

Monolayer

EVOH

multilayer

Structure

(µm)

LDPE

100

LDPE/ tie/ EVOH/ tie /LDPE

42.5/ 5 / 5 / 5 / 42.5

OTR

(cc/m2,day,atm) 1650 1.6

EVOH PROVIDES EXCELLENT OXYGEN

BARRIER

Condition: 20C-65%RH(out)/65%RH(in)

Monolayer

Polyethylene

CONCEPT OF GAS BARRIER

PACKAGING – MONOLAYER PE BASED

Atmosphere

Content (Food)

Oxygen

Flavor Aromatics

(1) Loss of flavor/Aromas (2) Oxidation of content

Moisture

Atmosphere

Content (Food)

EVOH

Adhesive (Tie)

Inner Layer PE

Outer Layer PE Oxygen

Flavor

Aromatics

Adhesive (Tie)

CONCEPT OF GAS BARRIER PACKAGING –

MULTILAYER EVOH BASED

Moisture

EVOH CONTRIBUTES TO EXTEND SHELF LIFE AND

MAINTAIN EXCELLENT FOOD QUALITY !

Blown film

Cast film

Sheet & Thermoforming Coex Tube / Pipe

Co-extrusion process applicable for EVOH

EVOH PROCESSING ON CONVENTIONAL EXTRUDER IS POSSIBLE

Screw type ： FULL FLIGHT

L/D ： 24- 26 ( DEPENDING UPON THE GRADE )

NYLON / SCREW WITH MIXING HEAD GENERALLY

NOT RECOMMENDED

120～150°

TYPICAL EXTRUDER FOR EVOH PROCESSING

L/D Feed Compression Metering

28 8D 10D 10D

26 8D 9D 9D

24 8D 8D 8D

TYPICAL TEMPERATURE PROFILE FOR EVOH

J171

GENERAL PROPERTIES OF EVOH

EVOH IS EASILY PROCESSED ON CONVENTIONAL EXTRUDERS

BUT EVOH IS LESS THERMALLY STABLE THAN POLYOLEFINS

EVOH DOES NOT HAVE COMPATIBILITY WITH POLYOLEFINS HENCE NEED FOR TIE RESINS

HYGROSCOPIC IN NATURE

STRONG REACTIVITY WITH PA HENCE CAREFUL HANDLING REQUIRED WHEN PROCESSING PA/EVOH BASED STRUCTURE

EVOH FOR VARIOUS APPLICATIONS

Lid for barrier cup & tray

EVOH FOR FLEXIBLE APPLICATIONS

Ham & sausage Bag In Box

UHT-milk

Meat (MAP)

EVOH TRENDS IN WORLD

REPLACEMENT OF TRADITIONAL PACKAGING

PACKAGING REASON FOR REPLACEMENT

GLASS LIGHT WEIGHT , EASY TO

HANDLE

CAN TRANSPARENT , DESIGN

FLEXIBILITY

AL FOIL METAL DETECTABLE , FLEX

CRACK

PVdC ENVIROMENTAL FRIENDLY

GROWING NEED FOR BARRIER PACKAGING

USING EVOH

• IMPROVEMENT IN LIVING STANDARDS OF CONSUMER

•GROWTH OF CONVENIENCE STORES / MEGAMARKETS

•PUSH FOR HIGHER BARRIER PACKAGING

•FOOD FACTORY EXPORT TO DEVELOPED WORLD

•LOCAL PUSH TO REPLACE IMPORTED BARRIER

PACKAGING FOR THE EXPORTED FOOD

NEW STYLE OF PACKAGING USING EVOH

• UHT MILK IN FLEXIBLE POUCH

•FLEXIBLE POUCH FOR SAUCES

•BAG IN BOX ( BIB)

•LAMINATED OR COEXTRUDED TUBES

•METALIZED EVOH BARRIER FOR SNACK FOOD

•AGRICULTURAL FILMS

•EVOH FOR FOOD SAFETY

BENEFITS OF UHT POUCH WITH EVOH

6 grams IS THE WEIGHT OF A 1 LITER

POUCH USING EVOH BARRIER

LESS PRODUCT WASTE AS DESIGN

FLEXIBILITY POSSIBILE WITH EVOH

BASED MULTILAYER POUCH

BARRIER POUCH IS ALL PLASTIC BASED

HENCE TOTALLY RECYCLABLE

NO NEED FOR COLD CHAIN TO

MAINTAIN 100 % STERILITY IN THE

PRODUCT

BENEFITS OF UHT POUCH WITH EVOH

A FEW MICRONS OF EVOH ARE

SUFFICIENT TO PROVIDE THE DESIRED

AND FUNCTIONAL BARRIER OF UHT

MILK POUCH

SPOILAGE OF THE PRODUCT IS AVOIDED

AND ALSO PROTECTION TO VALUABLE

VITAMIN CONTENT

EVOH ACTS AS FLAVOUR BARRIER AS

WELL AS WELL AS KEEPING THE

OUTSIDE ODOUR AWAY

BESIDES MILK OTHER PRODUCTS

PACKED ARE FLAVOURED MILK , LASSI ,

YOGHURT AND FRUIT JUICES

EVOH UHT POUCH VERSUS AL FOIL /PAPER CARTON

EVOH UHT POUCH VERSUS AL FOIL /PAPER CARTON

Outside

Inside

Outside

Inside

PE + Slip agent PE + White Masterbatch

LLDPE tie

EVAL™ H171B LLDPE tie

LLDPE tie + Black Masterbatch LLDPE + mLLDPE

PE + White Masterbatch + Slip agent

LLDPE tie

EVAL™ H171B

LLDPE tie + Black Masterbatch

LLDPE + mLLDPE

TYPICAL EVAL BARRIER POUCH BASED

ON 5 AND 7 LAYER STRUCTURE

UHT milk pouch in oversea

India / Sri Lanka/Indonesia

India

Sri Lanka

Indonesia

UHT milk pouch in oversea

Latin America

METAL CAN REPLACEMENT

Lighter weight (reduce energy during transportation) Transparent Metal detector available Convenient (Easy/safe to open)

EVOH POUCHES FOR SAUCES PACKAGING

Storage condition: 40degC

Benefit of EVOH - Ketchup/sauces - Lower weight than tin can and glass

Convenience (easy open)

Safety (transparency, metal detectable)

Less preservative due to high O2 barrier

Better brand image

PP/EVOH/PP

EVOH FOR BIB APPLICATIONS

Carbon dioxide emission per 100 gallons wine

Reduced ecological footprint: boxed wines contribute fewer carbon emissions to the atmosphere than traditional glass bottles during making and shipping process.

Glass

BIB

PE/tie/EVOH/tie/PE

EVOH FOR LAMINATED TUBES

Aluminum foil Plastic with EVOH

Prevent oxydation of valuable ingredients Excellent aroma barrier Excellent oil and grease barrier Longer formula preservation

Laminate tube (toothpaste, cosmetic)

Typical structure, manufacturing method

(1) Co-extrusion, PE/tie/EVOH/tie/PE 5-layer

(2) Blown film and lamination

PE film/ PE/tie/EVOH/tie/PE (co-ex blown) / PE film

(3) Extrusion coating

PE film/LD/ tie/EVOH/tie (Co-ex coating) / PE film

EVOH FOR LAMINATED OR COEXTRUDED TUBE

Co-extrusion

Film lamination

METALIZED EVOH BARRIER FOR SNACK FOOD PACKAGING

Lamination

Current structure Proposed structure

Film (micron) OTR*1 WVTR*2

PET (12) 85 55

VM-PET (12) 0.5-1.0 0.5-1.0

BOPP (18) 2300 8

VM-BOPP (18) 20 1

VM-EVOH-BOPP (18) ~0.2 ~0.4

VM-CPP (30) 20 1

VM-EVOH-CPP (30) ~0.1 ~ 0.3

*1: 20degC-65%RH, *2: 40degC-90%RH

1. Structure - Metalized “EVOH/tie/homo-PP/ter-PP (Co-ex) ” - BOPP and CPP types are available 2. Benefits of met-EVOH-PP (1) Higher barrier than met-PET and met-BOPP (2) High bonding strength b/w AL and EVOH (EVOH high surface energy, ~50dyne/cm) (3) Cost down from 3ply to 2 ply (Heat seal ability by ter-PP layer) * Heat seal strength: TBC for each application

VMPET(12)

LLDPE or CPP(30)

PET(12) or OPP(20)

EVOH

PET(12) or OPP(20)

Tie

h-PP Co-Ex

Metalized

ter-PP

EVOH FOR AGRICULTURAL APPLICATIONS

r

EVOH FOR HERMETIC BAGS

EVOH FOR TIF ( FUMIGATION

FILM )

EVOH FOR BULK SILO BAGS

HERMETIC BAG

EVOH FOR HERMETIC BAG

• Post harvest problem: Moisture, molds, insects • Living organism’s respiration makes high CO2 and low O2

atmosphere • Prevent the growth of bacteria/insect by MAP (low O2

and high CO2 concentration) Typical structure; PE/tie/EVOH/tie/PE co-ex blown

WHAT IS FUMIGATION

&

WHY IS EVOH REQUIRED

Fumigation is needed for “Kill disease or weeds”

Disease increase by continuous cropping/grow same crop and same area continuously.

For efficient farming

bacterium Nematoda

Fumigants

Fumigant Risk Status

Methyl bromide ozone layer destruction Decided full phase-out untill Y15 by Montriol Protocol.

Chloropichrin strong tear gas/smell Increasing as alternative. Developed by Nazi as wepone.

Dichloropropene carcinogen Increasing as alternative.

Alternative chemicals still

pose health hazards to

field workers and

bystanders

Chloropicrin,

1,3-dichloropicrin

Dimethyl disulfide Methyl

iodide

METHYL BROMIDE being

phased out worldwide due

to ozone depletion

potential

Fumigant is injected or dripped into the soil prior to transplant High barrier

mulch film

retains

moisture and

fumigant

vapors

Nematodes, bacteria, fungi

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ISSUES WITH FUMIGANTS USED

Fumigant Methyl bromide

Chloropicrin

1,3-Dichloropropene

Methyl iodide

STD

(Standard film)

Fumigated soil

PE

PE

PE

TIF

(Totally Impermeable Film)

PE

EVALTM

PE

Film

EVOH FOR FUMIGATION FILM

• Increase the fumigation efficiency • Higher yield and/or lower fumigant cost

Typical Commercial Structure of a

TIF Film

1.5 – 2.0 µm

25 – 35 µm

Proper material selection and processing technique will

influence the mechanical properties of the film

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PE

PE

Adhesive

EVOH

Adhesive

PE

PE

“Economical merit”

552

639

921

991 1020 1006

975

526

595

781 829

945 914

991

300

400

500

600

700

800

900

1000

1100

Control = 0 lb/ac

Pic-Clor60 = 50 lb/ac

Pic-Clor60 = 100 lb/ac

Pic-Clor60 = 200 lb/ac

Pic-Clor60 = 300 lb/ac

Pic-Clor60 = 400 lb/ac

MBPic = 350 lb/ac

gra

ms m

ark

eta

ble

fru

it /

pla

nt

Strawberry Yield

TIF

75% reduction

TIF

（EVAL)

STD

(LDPE)

EVOH FOR SILO BAGS

EVOH SILO BAGS

DECREASE OF O 2 CONCENTRATION AND INCREASE

IN CO 2 LEVELS

DETORIATION REDUCED BY CREATING HERMETIC

ENVIRNOMENT

ODOR BARRIER AND PEST CONTROL

GRAIN LOSS REDUCTION & EXTENDED SHELF LIFE

RESULTING IN INCREASE IN COMMERCIAL VALUE OF

FOOD GRAIN

Summary

• Multilayer film with EVAL™ can add value to agriculture

– It protects the environment by reducing fumigant

emissions without sacrificing the yield or quality of

fruits of vegetables

– It preserves the quality of grains and animal feed by

limiting the gas exchange in/out and reducing the

metabolic activity of the packaged food

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EVOH FOR FOOD SAFETY

PREVENTS MIGRATION OF

“MINERAL OIL HYDROCARBONS “

FROM RECYCLED CARTONS

Prevent migration of mineral oil (MOSH, MOAH)

from recycled cardboard into food

Proving EVOH barrier to MOSH/MOAH

(1) Barrier inner liner with EVOH

(2) EVOH lamination onto cartonboard

Inner liner with EVOH (coated paper or all-plastic bag)

Sources of Mineral Oil Hydrocarbons

Contamination of rice by different sources

8

EVOH MAINTAINS FRESHNESS OF FOOD AND EXTENDS

SHELF LIFE WHICH CONTRIBUTES TO REDUCTION IN

FOOD WASTAGE .

CONVENTIONAL PACKAGING REPLACEMENT BY

BARRIER PLASTIC PACKAGING INCORPORATING

EVOH IS A GROWING MARKET TREND .

EVOH IS EASILY PROCESSED ON CONVENTIONAL

EXTRUSION PROCESS.

KURARAY IS A LEADING COMPANY OF BARRIER

TECHNOLOGY .

SUMMARY

THANK YOU