Unique technology from Kuraray

Transcription

1 EVOH Barrier Film

2 Unique technology from Kuraray Kuraray Co., Ltd. is the world leader in the production and development of EVOH (ethylene vinyl alcohol copolymer) resins under the trade name EVAL. EVAL EVOH is available either as a resin in pellet form, or as film for lamination. Combining the excellent gas barrier properties and resistance to organic solvents of polyvinyl-alcohol with the thermoforming and water resistance properties of polyethylene, EVAL is a crystalline polymer with the following molecular structure: 2 Ethylene and Vinyl ALcohol (CH 2 -CH 2 )m (CH 2 -CH)n OH General properties Superior gas barrier properties EVAL films have outstanding gas barrier properties. Without a gas barrier, oxygen may penetrate packaging and spoil the contents. EVAL keeps oxygen out and safeguards quality, making it especially suitable for food, medical, pharmaceutical, cosmetics, agricultural and industrial packaging applications. Flavour and aroma barrier While preventing oxygen and undesirable odours from sneaking into the package, the barrier properties of EVAL effectively maintain fragrances and lock the aromas in. This guarantees an extended shelf life for food and cosmetic products. Excellent flex-crack resistance High-barrier structures containing an EVAL layer have an excellent flex-crack resistance. An EVAL layer makes sure that the integrity of the barrier remains unharmed during transport, handling and storage or even when the package is folded. Resistance to oil and organic solvents An EVAL layer offers very high resistance to hydrocarbons, oils and organic solvents. When EVAL is used in a multilayer structure, it prevents the evaporation of chemical substances. This property makes EVAL films very suitable for use in applications involving chemicals, such as fuel tanks, chemical packaging and protective clothing.

3 Oxygen Odours 3 Outer layer Regrind Tie EVAL EVOH Tie Inner layer Freshness Flavour CO 2 Food safety Food regulation compliance status of EVAL films EVAL films are in compliance with the EC Directive for food packaging and its transposition in the national regulations of the member states. EVAL films have also been approved for use in direct food contact, indirect or multilayer food contact and for retort applications as outlined under the Food and Drug Administration regulations in the USA. EVAL has passed the specification/ standard test of Official Notice No.20 (1982) from Japan s Ministry of Health and Welfare. A one millimetre thickness of EVAL EVOH has about the same gas barrier properties as ten metres of LDPE. With such high performance, EVAL layers of only microns can add real function to multilayer laminated structures.

4 EVAL film types Typical applications Film types Film grades Processing Applications Casted grade EF-F Casted, Deep-draw molding Foods EF-E Casted, Deep-draw molding, Sealable Foods, Pharmaceuticals, Industrials Oriented grade EF-XL Biaxially oriented Foods, Pharmaceuticals, Industrials Metalized grade VM-XL Biaxially oriented, Aluminium-metalized Foods, Pharmaceuticals, Industrials Pre-coated grade/wallpaper application HF-ME Casted, Matted, Pre-coat adhesive for PVC (substrate of wallpaper) Wallpaper Processing of EVAL film 4 Typical Dry lamination dry lamination line Hot air Zone 1 Zone 2 Zone 3 Infeed Cooling roll Laminating NO.2 film NO.1 film Winder Infeed Anchor coating Extrusion lamination Typical extrusion lamination line Dry zone Laminating Some lines have anchor coating process also here NO.2 film extrusion material Nip roll Cooling roll powder Anchor coating NO.1 film Winder

5 EVAL film grades and typical characteristic values EVAL films have the advantage of excellent gas barrier properties, aroma preservation, oil resistance, resistance to organic solvents, gloss and transparency as well as being thermoformable, in addition to food packaging, they are employed in a wide range of applications, including packaging for chemicals and cosmetics, wallpaper and industrial uses such as for construction materials. Characteristic values of EVAL films according to grade Grade EF-XL EF-F EF-E VM-XL HF-M Type Biaxially oriented High-barrier Non-oriented High-barrier Non-oriented Deep-draw molding Biaxially oriented Aluminium-metallized Non-oriented Matted Wallpaper use Ultra-high barrier Thickness (µm) Width (cm) *cut to even number custom made 96 Roll length (m) 4,000 2,000-4,000 2,000 4,000 4,000 Item Unit Method of Conditions EVAL TM films Other films measurement EF-XL EF-F EF-E VM-XL HF-M CPP LDPE OPP OPA PET Thickness (µm) µm Tensile strength MD 23 C at break MPa ISO1184 TD 50%RH Tensile elongation MD % ISO C at break TD 50%RH Young s modulus MD GPa ISO C TD 50%RH Elmendorf tearing MD N/mm ISO C strength TD 50%RH Impact strength J Kuraray 23 C method 50%RH Puncture strength N JAS 23 C %RH Moisture g/m².day JISZ C * permeability 90%RH Water absorption rate % Kuraray 30 C method 24 hr Moisture % Kuraray 23 C absorption rate method 50%RH Dimensional MD % Kuraray 140 C change on heating TD method 1 hr Oxygen Transmission cm³/ ISO C <0.05-1,300 2,700 2, Rate m².day. atm 0%RH 20 C <0.05-1,300 2,700 2, %RH 20 C <0.05-1,300 2,700 2, %RH Surface electrical Ω Kuraray 23 C 2x x x x x x x10 14 >10 16 resistance method 50%RH Transparency (haze) % JISZ C %RH Slip C Kuraray method 23 C 50%RH * 2 This value was determined by eliminating from the measured value obtained from laminated products using PET or polyolefin film the influence of the moisture permeability of the PET or polyolefin film.

6 Gas barrier properties of EVAL film Relative humidity and oxygen transmission rate of various materials 10,000 OTR (cc.20µm/m 2.day.atm) LDPE ISO standard (65% RH) 1,000 BOPP 100 PVC-U OPET 10 OPA6 PAN MXD-6 PVDC EVAL E type (44% ethylene) EVAL F type (32% ethylene) EVAL FILM (EF-XL) 0% 20% 40% 60% Relative humidity (%RH) 80% 100% EVAL layer thickness and OTR Conditions: EVAL EF-F multilayer film 35 C, 0% RH 100 OTR (cm³/m 2.day.atm) Thickness of EVAL layer (µm) 100

7 Relative humidity of EVAL layer in laminated structures liquid products dry products Exterior 65%RH Interior Exterior Interior 100%RH 100%RH 84%RH 80%RH 91%RH Exterior 65%RH Interior Exterior 80%RH Interior 34%RH 40%RH 10%RH 10%RH OPP/EVAL /LDPE µm 20/15/50 OPP/EVAL /LDPE µm 20/15/50 OPP/EVAL /LDPE µm 20/15/50 OPP/EVAL /LDPE µm 20/15/50 Exterior 65%RH Interior Exterior Interior 100%RH 80%RH 100%RH 81%RH 66%RH Exterior 65%RH Interior 63%RH Exterior 80%RH Interior 40%RH 10%RH 10%RH OPA/EVAL /LDPE µm 15/15/50 OPA/EVAL /LDPE µm 15/15/50 OPA/EVAL /LDPE µm 15/15/50 OPA/EVAL /LDPE µm 15/15/50 7 Heat seal properties a. Flavour absorption of EVAL film Item Unit Measurement Flavours Material EF-E LDPE CPP d-limonene 280 1,480 2,040 Flavour absoption (liquid) ppm Kuraray method n-butyl acetate Ethyl acetate <50 <50 <50 Flavour absoption (gas) mg/g Kuraray method 1-Menthol 0,2 9,6 21 Salicylic acid methyl b. Heat seal curve of EVAL film 100 Seal strength (N/15mm) LLDPE-50µm CPP -50µm EVAL EF-E - 30µm Sealing temperature ( C)

8 Examples of use and structure of EVAL film Typical applications Typical structure (out/in) - Dried Bonito flakes - OPP/EVAL film/pe - Miso paste and bouillon - OPP/EVAL film/pe - OPA/EVAL film/pe - EVAL film/pe - Soup - OPA/EVAL film/pe - Rice cakes - OPA/EVAL film/pe - Fruit jelly (lid material) - OPA/EVAL film/pp - Cooked rice (lid material) - OPA/EVAL film/pe - Sweet bean jelly - OPA/EVAL film/pe 8

9 Typical applications Typical structure (out/in) - Bean sprouts - CPA/EVAL film/cpp - Drip coffee packs - PET/EVAL (VM-XL)/LLDPE - Ketchup for restaurant use - OPA/EVAL film/pe - Long-lasting balloons - PET/EVAL (VM-XL)/PE - Wallpaper - EVAL /PVC/Paper - Vacuum insulation panels - OPA/VM-PET/EVAL (VM-XL)/PE 9

10 Environmental benefits of EVAL resins and film As the impact we create on our environment becomes an ever greater concern, the world continues to look for solutions that are truly sustainable. EVAL EVOH resins and films can help, providing valuable function while conserving resources, improving efficiency and avoiding waste, often throughout the entire life cycle of the product. 10 A one millimetre thickness of EVAL barrier function, usually allowing Recyclable and recoverable EVOH has about the same gas barrier a decrease in the total amount of EVAL EVOH is recyclable as post- properties as ten metres of LDPE. packaging materials used. Optimized consumer plastic waste, and will not With such high performance, EVAL portion size, lightweight and extended disrupt polyolefin or PET recycling layers of only a few microns can add freshness help improve the efficiency of streams. real function to multilayer structures. storage, transport and display, saving Barrier performance previously only costs and preserving resources. EVAL has excellent and safe energy available from metal or glass can thus be added to lightweight structures Reduced emissions recovery properties, often reducing the amount of extra fuel necessary for based on other recyclable and energy When used in barrier structures for energy generation from the thermal recoverable plastics, or renewable construction, agricultural and automo- disposal of sorted waste. Under per- resources like PLA and paperboard. tive fuel system applications, EVAL fect combustion, the few microns of Protecting quality and value helps create lightweight structures that help protect the environment from gas, fuel or chemical emissions. EVAL in the package emit only small amounts of CO 2 and water vapour. Although product development tends to focus specifically on EVAL s functional barrier properties, EVAL helps conserve resources and avoid waste throughout a product s life cycle. Reducing waste, and thus avoiding the loss of all resources invested in the production and distribution of fresh food, is the best way to reduce environmental impact. When used in laminated structures for food packaging, EVAL film layers of just microns providing valuable

11 Introducing Kuraray and EVAL Kuraray Co., Ltd. was established in 1926 in Kurashiki, Japan, for the industrial manufacture of chemical fibres. As the world s largest producer of vinyl acetate monomer (VAM) derivatives, Kuraray has long been a leader in high gas barrier technology and development. Today the Kuraray Group consists of about 70 companies, employing around 7,000 people worldwide. Kuraray has been manufacturing and marketing ethylene vinyl-alcohol copolymers (EVOH) under the name EVAL since 1972, and remains the world leader in EVOH production and market development. 11 EVAL is one of Kuraray s core businesses. EVAL resins are produced in Japan, the USA and Europe. EVAL films are produced in Japan. The sales and technical development of EVAL resins and films is supported by specialised local teams in each region. Building better barriers EVAL adds superior barrier functionality to multilayer plastic structures. Even very thin EVAL layers provide excellent results. EVAL is widely used as a functional gas and flavour/aroma barrier in food, medical, pharmaceutical and cosmetic packaging, and as a gas and solvent barrier in industrial, construction, agricultural and automotive fuel system applications.

12 Antwerp Houston Okayama Shanghai Tokyo Singapore EVAL the world s leading EVOH Europe EVAL Europe nv (Antwerp, Belgium) Capacity: 24,000 tons/year Europe s first and largest EVOH production facility Americas EVAL Company of America (Pasadena, Texas, USA) Capacity: 35,000 tons/year The world s largest EVOH production facility Asia-Pacific Kuraray Co. Ltd. (Okayama, Japan) Capacity: 10,000 tons/year The world s first EVOH production facility NOTICE The information, specifications, procedures, methods and recommendations herein are presented in good faith, are believed to be accurate and reliable, but may well be incomplete and/or not applicable to all conditions or situations that may exist or occur. No representation, guarantee or warranty is made as to the completeness of said information, specifications, procedures, methods and recommendations or that the application or use of any of the same will avoid hazards, accidents, losses, damages or injury of any kind to persons or property or that the same will not infringe patents of others or give desired results. Readers are cautioned to satisfy themselves as to the suitability of said information, specifications, procedures, methods and recommendations for the purpose intended prior to use. FIL.OCT Copyright Kuraray Co. Ltd. Photos used in this brochure are representative of potential product applications only. Contact EVAL Europe nv Haven 1053 Nieuwe Weg 1 - Bus 10 B-2070 Zwijndrecht (Antwerp) Belgium Telephone Fax EVAL resins are produced worldwide under unified Kuraray product and quality specifications.