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The Changing Market - From Monolayer to Multilayer Coextrusion FlexPackCon 2016 Memphis, TN Dan Falla October, 2016

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Page 1: The Changing Market - From Monolayer to Multilayer Coextrusion · The Changing Market - From Monolayer to Multilayer Coextrusion FlexPackCon 2016 Memphis, TN. ... vLLDPE or Peel Seal

The Changing Market - From Monolayer to Multilayer CoextrusionFlexPackCon 2016Memphis, TN

Dan FallaOctober, 2016

Page 2: The Changing Market - From Monolayer to Multilayer Coextrusion · The Changing Market - From Monolayer to Multilayer Coextrusion FlexPackCon 2016 Memphis, TN. ... vLLDPE or Peel Seal

Source: PMMI 2010 Report & NOVA Chemicals View

Flexible Packaging Statistics

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• Provides engineered films over a wider variety of widths and line speeds with unique properties

• Offers cost savings on the amount of premium resins used by filling the core layer with lower cost materials

• Allows multi-layer, multi-functional structures to be produced in a single pass

UNIQUE PROPERTIES LOWER COST SAVE TIME

Photo Courtesy Reifenhauser

Conversion from Mono-Layer to Co-extrusion

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Co-Extrusion Benefits

• Combine the desirable characteristics of multiple materials into one structure to achieve enhanced properties.

• Produce multilayer sheet, blown film, cast film, tubing, wire coating and profiles.

• Imparts unique properties to the film structure.

• Reduces need for lamination.• Tailor low seal initiation, stiffness, barrier

and sealant layer.• Use less expensive material in the bulk layer

to create a more functional, economical film.Photo Courtesy Reifenhauser

The goal of food packaging is to contain food in a cost-effective way that satisfies industry requirements and consumer desires, maintain food safety, and minimize environmental impact.

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Film Extrusion Equipment Trends

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Photo Courtesy Reifenhauser

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Co-ex FundamentalsThe making of an engineered film

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Horizontal Oscillating Nip

Photo Courtesy Brampton Engineering

Randomizing Haul-off

Bubble Stabilizing Cage

Air Ring

Extruders

Feeding & Control

Bubble Collapsing Frame

Control Panel

Secondary Nip

Typical Multi-Layer Co-extrusion Line

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Cost is always an important consideration while achieving the desired properties in a given film structure. The ultimate objective is to increase productivity, down-guage, and improve performance.

“The Balancing Act”: for Engineered Films

PERFORMANCECOST

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Print layer –advertise &

display graphics

Adhesive/Tie – bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced

film machinability & physicals

Abuse – protect package during handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

What do high performing films need?

Photo Courtesy: Robert Kneschke/Shutterstock.com

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Packages can be surface printed or reverse printed using flexographic and/or rotogravure printing. Reverse printing on PET/OPP protects the print from scratching. Surface printing may also have an over-lacquer applied to it to protect the print.

Print layer

Print layer –advertise &

display graphics

Adhesive/Tie– bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced film machinability & physicals

Abuse –protect

package during

handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

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Tie layers comprised of functional polymers extruded between dissimilar materials in coextrusion or coating are intended to keep different layers bonded and prevent delamination.

Tie Layer

*http://www2.dupont.com/Packaging_Resins/en_US/Modeling_Tools/Tie_Resin_Selector/

Chart courtesy of DuPont Packaging and Industrial Polymers

Print layer –advertise &

display graphics

Adhesive/Tie– bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced film machinability & physicals

Abuse –protect

package during

handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

PolyesterEVOH

Nylon 6Polystyrene

PolypropyleneHDPELDPE

EVAZinc lonomer

Sodium lonomerAcid Copolymer

Good

Fair

Poor

PolyethyleneTie

Nylon

Maleic anhydride modified polyolefins are commonly used for bonding to Nylon & EVOH for barrier structures

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Flexible packaging films provide barrier to gases such as oxygen, nitrogen, carbon dioxide, and water vapor. It is important to know the packaging environment during filling, processing, distribution, and storage to determine permeation needs. Taste and aroma barrier can be important in some applications. Oil/grease resistance of a polymer is influenced by its polarity and crystallinity.

Barrier Layer

Moisture (WVTR)

Al-FoilmOPPmPET

Barrier HDPEHDPEOPPPVdCLDPEEVA

IonomerPET

EVOHNylon

Oxygen (OTR)

Oxygen(OTR)

Al-FoilEVOHmPETPVdCNylonMOPPPETOPP

Barrier HDPEHDPELDPEEVA

Ionomer

Barrier properties –decreasing performance

Chart data source: NOVA Chemicals

Print layer –advertise &

display graphics

Adhesive/Tie– bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced film machinability & physicals

Abuse –protect

package during

handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

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This layer provides machinability, a balance of stiffness and toughness, and sometimes optics. As density increases, stiffness increases, and toughness and optics decrease. Stiffeners add bulk to the package, allowing it to hold its shape more easily. HDPE blends with butene LLDPE and/or octene LLDPE may offer a good balance of stiffness and toughness.

Structural/Stiffness Layer

The ability of a film to run on

packaging equipment

without difficulty

Photo Courtesy Macro Engineering

Print layer –advertise &

display graphics

Adhesive/Tie– bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced

film machinability & physicals

Abuse –protect

package during

handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

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• Machine direction or cross directional tear strength and puncture are important for packaging sharp objects

• Dart impact is the ability of package to withstand a drop from a store shelf or countertop• Abrasion, flex crack resistance are also important attributes

Abuse Resistance Layer

Print layer –advertise &

display graphics

Adhesive/Tie– bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced film machinability & physicals

Abuse –protect

package during

handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

Scuff marks are caused by packages rubbing against each other as well as with secondary packaging during handling and transportation.

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Sealants maintain package integrity and protect its contents. Choose a sealant that is able to seal over a wide range of temperatures, has good hot tack, heat seal, and is able to seal through contamination.

Sealant Layer

Resins Hot Tack

Temp Range

Low Seal temp

Seal throughcontamination

LDPE X X X X

LLDPE XX XX X XX

ULDPE XX XX XXX XX

mPEPlastomer XXX X XXXX XX

EVA XX XX XXX XX

EEA XXXX XXX XXX XXXX

Ionomer XXXX XXX XXX XXX

X = Poor; XX = Average; XXX = Good; XXXX = Excellent

Print layer –advertise &

display graphics

Adhesive/Tie– bonds

incompatible materials

Barrier –improved shelf life

Structural –enhanced film machinability & physicals

Abuse –protect

package during

handling and transportation

Sealant –maintain package

integrity at faster

packaging speeds

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Engineered Structure: I-Beam Effect

Stiffer films feel thicker than softer films. Also, downgauging of films can be limited by film stiffness due to packing systems. Separation of HDPE will result in higher film stiffness: I-Beam Effect

http://commons.wikimedia.org/wiki/File:Beam_mode_3.gif

http://commons.wikimedia.org/wiki/File:Beam_mode_2.gifLLDPE

LLDPELLDPELLDPE

HDPE

HDPE

Stiffness

HDPE

HDPE

vLLDPE vLLDPEvLLDPE

HDPE

OTR 67.8 cc/100in2/day 67.6 cc/100in2/day 67.7 cc/100in2/day

WVTR 0.16 g/100in2/day 0.16 g/100in2/day 0.17 g/100in2/day

1% Secant 564 Mpa 568 Mpa 568 Mpa

MD Tear 491 g 506 g 507 g

Bending Stiffness

5.0N-um 5.8N-um 7.7N-um

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LLDPE

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Cost Savings from Downgauging: Poultry Bag

C8 LLDPE

HDPE

C8 LLDPE

vLLDPE

HDPE

C8 LLDPE

vLLDPE

Barrier HDPE

C8 LLDPE

3.25 mil9.06¢/msi

C8 LLDPE

1990

1996

2000

20162010

4.0 mil 3.0 mil 2.75 mil 2.75 mil

8.36¢/msi 7.12¢/msi 6.67¢/msi10.6¢/msi

Cost

vLLDPEB.HDPE

LLDPE

B.HDPE

C8 LLDPE

Desired Properties

Medium oxygen barrier

Seal-through contamination

Dart and puncture resistance

Burn-through resistance

VFFS capability

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C8 LLDPE

Tie

Tie

C8 LLDPE

EVOH

3.5 mil

15.90¢/msi

3.25 mil

14.08¢/msi

vLLDPE

C8 LLDPE

Tie

EVOH

Tie

C8 LLDPE

vLLDPE

C8 LLDPE

HDPE

TieEVOH

TieBarrier HDPE

C8 LLDPE

vLLDPE

3.25 mil

13.73¢/msi

19952008 2016

Film Application Structures: Barrier Meat

Cost

Desired Properties

Medium/ High oxygen barrier

Abuse resistance

Seal-through contamination

Excellent clarity, high gloss

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C8 LLDPE

www.dupont.com

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Typical Film Structures

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Blown Film Coextrusion

Film Application Structures

HDPE (Moisture Barrier type)

HDPE (Moisture Barrier type)

Peel Seal PB / EVA/ LDPE blends or Ionomer

HDPE

LLDPE

Cereal Inner Liner

Moisture barrier HDPE such as SURPASS HPs167-AB resin offer a best-in-class solution, with as much as 50% improvement in barrier performance (both moisture and oxygen) and significant improvement in stiffness over conventional high density polyethylene resins.

Desired PropertiesMoisture barrier

Good peel seal properties

VFFS machinability• Hot tack strength• Designed stiffness

Puncture resistanceBarrier HDPE

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Adhesive Lamination

Film Application Structures

Adhesive

C8LLDPE

C4LLDPE or sLLDPE

C4LLDPE or sLLDPE

C8 LLDPE

vLLDPE

OPPInk

Retail Salad Bag

Lettuces continue to "breathe" even after they've been picked. To keep salads at peak freshness, special breathable bags are designed to allow the right amount of oxygen in and carbon dioxide to escape, preserving their just-picked flavor.

Desired Properties

Oxygen barrier (breathability)

VFFS machinability• Hot tack strength• Seal-through

contamination

Reverse Printed OPPThin seal layer with vLLDPE

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Adhesive

C8LLDPE

C4LLDPE

C4LLDPE

C8 LLDPE

C8 LLDPE

OPP or PETInk

Film Application Structures

Adhesive Lamination

Frozen Microwavable Vegetable Bag

From freezer to your dinner table in seconds? Yes, the microwavable frozen steam bag offers not only quick and easy meal preparation, but also healthy choices for families.

Desired Properties

Ability to withstand wide range of temperatures

VFFS machinability• Hot tack strength• Seal-through

contamination

Abuse and scruff resistance

Octene LLDPE are ideal sealants for microwave bag

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Surpass HPs167-AB HDPE has excellent clarity

Separation of HDPE gives I-Beam effect

Film Application Structures

C4LLDPE

C4LLDPE

PB / EVA/ sLLDPE blends or Ionomer

PP

sLLDPE

Blown Film Coextrusion

Single Slice Cheese Innerwrap

Desired Properties

Machinability

Peelable, hermetic seal

Contact clarity

Easy cheese release

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Film Application Structures

Blown Film Coextrusion

C4LLDPE or HDPE

C8 LLDPE

Tie

EVOH

Barrier HDPE

C8 LLDPE

vLLDPE or Peel Seal blend

vLLDPE

Tie

Block Cheese Packaging

Desired Properties

Moisture barrier - minimal

Machinability

Peelable, hermetic seal

Contact clarity

Cheese release

vLLDPEs impart excellent physical properties and processibiltiy

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Film Application Structures

vLLDPE

Barrier HDPETie

Nylon

Tie

HDPEPeel Seal (PB / EVA/ vLLDPE blends or Ionomer)

Nylon

EVOH

Blown Film Coextrusion

Forming Film for Processed Meat

EVOH barrier properties decrease with moisture. Barrier HDPE is used to the EVOH from moisture by placing it on the wet side. Nylon strength increases with moisture.

Desired Properties

Medium oxygen barrier

Abuse resistance

Seal-through contamination

Excellent clarity, high gloss

Thermoformability

Peelable sealBarrier HDPE for EVOH layer

Barrier HDPE

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HDPE

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LLDPE/LDPE

LDPE

LDPE

Film Application Structures

Collation Shrink Film

Products packaged using collated shrink films have eliminated cardboard trays and evolved to nested or staggered configurations resulting in increased product quantity for a given footprint resulting in HUGE savings.

Desired Properties

Reproducible shrink properties

Low-tunnel-temp shrink initiation

Stiffness for high converting speeds

Excellent tear, puncture, and tensile yield characteristics

Blown Film Coextrusion

LDPE skins for shrinkage Core for strength

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EVA/PBPE

NylonPE

Sealant layer

Barrier

Sealant layer

Barrier and improvedthermoformability

PE contains tie concentrate to

ensure bonding with Nylon

4-mil Peelable Lid

7-mil Bottom Base

Balanced HDPE to help reduce curl

Film Application Structures

Nylon

Peel Seal

Nylon

Tie

Nylon

Tie

sLLDPE

HDPE + Tie

Barrier HDPE + Tie

Nylon

Tie

Nylon

Tie

sLLDPE

HDPE + Tie

Nylon

Barrier HDPE + Tie

C8 LLDPE

Self Rising Frozen Pizza Package

Key AttributesExcellent thermoforming and resistance to flex cracking

Clarity and peelablity for opening

Maintenance of package integrity

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• Co-extrusion continues to drive conversion from rigid to flexible packaging

• Key drivers include excellent shelf presence, convenience, and improved manufacturing efficiencies

• Balancing performance and cost becomes a critical factor in co-extruded performance films

• Cost-performance relationships is a critical factor to consider for co-extruded performance films

• Contents of the package drives the demand for different film structures

• Technology will continue to drive multilayer co-extrusion lines to provide even more precise properties in the most cost-effective configurations possible

• It is critical to understand market requirements when designing a film structures to determine best fit.

• Asking the right questions will help improve understanding of what the customer/market really wants/needs

Conclusion

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Questions?

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is a registered trademark of NOVA Brands Ltd.; authorized use/utilisation autorisée. Advanced SCLAIRTECH™ is a trademark of NOVA Chemicals. SCLAIR® is a registeredtrademark of NOVA Chemicals Corporation in Canada and of NOVA Chemicals (International) S.A. elsewhere; authorized use/utilisation autorisée. NOVAPOL® is a registered trademark of NOVA Brands Ltd.; authorized use/utilisation autorisée. SURPASS® is a registered trademark of NOVA Chemicals Corporation in Canada and of NOVA Chemicals (International) S.A. elsewhere.

The information contained herein is provided for general reference purposes only.By providing the information contained herein, NOVA Chemicals makes no guaranty or warranty and does not assume any liability, with respect to the accuracy or completeness of such information, or product results in any specific instance, and hereby expressly disclaims any implied warranties of merchantability or fitness for a particular purpose or any other warranties or representations whatsoever, expressed or implied. Nothing contained herein shall be construed as a license to use the products of NOVA Chemicals in any manner that would infringe any patent. Nothing herein shall be copied, reproduced, distributed or otherwise used without the express written permission of NOVA Chemicals.

412.490.4170 // 800.222.7213 // [email protected] // www.novachemicals.com