March Seal Integrity

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1 March 2011 Seal Integrity

2 Amcor Company overview A top 5 multinational packaging company. A$14 billion estimated annual sales in 2010 Headquartered in Melbourne, Australia. Listed on the Australian Stock Exchange (ASX) and London Stock Exchange (Eurobonds). Sales* A$14 billion Co-workers 35,000 Countries 43 Sites Amcor 2010 *A$14 billion is approximately US$10.6 billion or 7.6 billion at average 2008/09 exchange rates.

3 Amcor Flexibles Europe & Americas 3 3 Amcor 2010

4 What is seal integrity? It means different things depending on what you are packing 4 Amcor 2010

5 Water Barrier Do you have the right barrier? Oxygen Barrier

6 The right barrier for the required shelf life Product: Shelf-life: Baguettes Approx. 3 weeks Gas-flushing: CO 2, N 2 Top web: 15µ OPA/print/adh/25µ (PA-EVOH-PA)/adh/50µ PE-Peel Bottom web: 80µ PE/adh/80µ (PA-EVOH-PA)/adh/80µ PE-Peel Product: Shelf-life: Cheese (block) Approx. 3 months Gas-flushing: CO 2 Packaging: 15µ OPA/print/adh/50µ PE Product: Shelf-life: Grated cheese Approx. 3 months Gas-flushing: CO 2, N 2 Packaging: 15µ OPA/print/adh/50µ PE 6

7 The right barrier for the required shelf life Product: Shelf-life: Gas-flushing: Packaging: Frozen vegetables Approx. 1.5 year No Print / 70 µcoex pe (lapseal) Product: Shelf-life: Vacuum: Packaging: Ground coffee Approx. 1 year Yes 12µ OPET/print/adh/7µ Alu foil/adh/15µ OPA/adh/80µ PE-Peel Product: Shelf-life: Dehydrated food Approx years Gas-flushing: None / N 2 Packaging: Print/60g paper/adh/9µ Alu foil/50µ PE 7

8 What makes a seal? 1. Temperature 2. Pressure 3. Time / Dwell

9 Importance of end seals vs back seal on form fill seal m/cs On horizontal form fill machines the end seals generally have a shorter sealing time. There is often more than one set of heaters for the back seal. The end seal has to seal through a thicker area that includes the back seal and possibly creases. The end seals on vertical form fill machines have to cope with the weight of the product and also may have to seal through multiple layers where block bottom or 4 side seal pack styles are involved.

10 Pack Styles hffs flowrap Can it be pushed?

11 What kind of seal profiles? Crimp and high pressure Crimp High pressure

12 Pack Styles vffs flowrap - Can it be dropped?

13 What kind of seal profiles? Crimp and poly weld Crimp Poly weld

14 Pack Styles vffs Stabillo / Quad / Quadra, etc

15 What kind of seal profiles? High pressure

16 Jaw Profiles Impulse Single bar about 3mm wide. Strong seals on unsupported films such as PE and CPP. Risk of piping leaks in corners and near back seal.

17 Jaw Profiles Constant Heat 10 to 15mm typically Gives added mechanical strength to heat seals especially on coated films. Risk of piping leaks in corners and near back seal Reduces piping leaks, and gives strong secure seals

18 Cross seals Sealing Wire PTFE tape Rubber strip Heating element Temperature probe Knife Air blast Impulse Seal Poly-weld Constant Heat

19 Pack Styles pouches Being pre-made the packer is only concerned with sealing one edge out of four so less chance of a leaker.

20 Lidded trays and top/base web solutions For packing products that can t be pushed or dropped. Easy filling of packs at their largest open side, directly from above

21 Sealing to trays and base web. Trays and base webs may be many structures, e.g. Polypropylene Polyester Polystyrene Apet/pe PVC/pe. The seal layers of the lidding films reflect this and may be the same or a universal polythene.

22 What is a piping leak? It is a small non-sealed area in the seal of a bag. They can be found in many heat sealed bags. Usually they appear near the back seal on VFFS and HFFS, near a crease or at the edge of the seal. If we take a typical VFFS bag and look at it end on, it might look something like this. x x x The critical areas are indicated with an X Piping Leaks can be detected by immersing a pack under water and gently squeezing it. Bubbles will give away the position of any piping leaks. Creases can increase the number of piping leaks, so should be reduced if possible. The Oxygen Transmission Rate (OTR), through a piping leak is very small. Sealing jaws with a horizontal pattern, will normally result in better seal integrity than jaws with a vertical pattern.

23 How do we test for leaks? A water exicator

24 How do we test for leaks? Measuring System ceramic sensor for CO2 Measuring range 0 ppm ppm Resolution 1 ppm Non-destructive testing

25 How do we test for leaks? Dye test

26 How do we analyse the leaks? Cheese in seal Cross section shows the cheese in the seal is holding the two webs apart Microtome

27 Cross seal at the back seal image shows the piping leaks caused by the slack film folding over and holding the webs apart How do we analyse the leaks? Folds / creases in the cross seal at the back seal arrows show position of the cross section Folds in film Back seal fin Piping leaks Folds in film Piping leaks

28 Cross seal at the corner image shows the piping leaks caused by the slack film folding over and holding the webs apart How do we analyse the leaks? Folds / creases in the cross seal at the corner Piping leaks

29 When is a polythene not a polythene? Plastic film Components Structure LDPE (Low density polyethylene) Ethylene LDPE EVA (Ethylene-vinyl acetate) Ethylene + Vinyl acetate Zn IONOMER Ethylene + Acrylic acid + Zinc EVA IONOMER LLDPE (Linear low density polyethylene) Ethylene + Butene HDPE (High density polyethylene) Ethylene + Butene POP (Polyolefin plastomer), mettalosene Ethylene+ Octene LLDPE HDPE 29

30 And a polypropylene not a polypropylene H-PP (Homopolymer polypropylene) Propylene R-PP (Random co-polymer polypropylene) Propylene + Ethylene POP PP

31 Melting point and solidification point E (J/ºC) E (J/ºC) E (J/ºC) ºC ºC ºC LDPE EVA IONOMER Temp. (ºC) Temp. (ºC) Temp. (ºC) E (J/ºC) E (J/ºC) E (J/ºC) Ex. 120 ºC 109 ºC LLDPE Temp. (ºC) ºC HDPE Temp. (ºC) Ex. 101 ºC POP Temp. (ºC) 31

32 Melt Flow Index Melt flow index (MFI) The MFI describes how easy-flowing the plastic is when melted and is a measurement of the mean molecular weight of the plastic. Decreasing mean molecular weight => plastic is more easy-flowing => increasing MFI at a defined temperature. Increasing MFI generally means decreasing mechanical strength and hottack strength, improved sealing properties and optical properties and a more difficult extrusion (poor bubble stability)

33 Other film properties - Hot Tack How strong is the seal while still hot? Bad Good

34 Other film properties - Peelability How do films peel? 1. Distruption Plan view LD Film surface Polybutylene islands Where the polybutylene and the low density pe meets themselves they will seal. Where they meet each other they won t

35 Other film properties - Peelability 2. Burst Peel Top web Base Web Nylon Polythene Polythene Polythene Polythene Apet Side view Weak tie layer Strong seal When the pack is opened the failure is within the polythene of the top web and not at the seal.

36 High Speed PE Customer Benefits Same thickness but improved sealing properties Special sealant layer designed for flow-pack Increases speed from 30ppm up to 45ppm (Flexcan Case) without compromising performance For all bagged products

37 Thank You! 37 Amcor 2010

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