Polymers In Flexible Packaging J R RAIKAR HUHTAMAKI-PPL 27/09/2007
MAN AND NATURE Nature provides Abundant Resources to Man s Needs Ready to Eat Food -- Fruits and Vegetables Processed Food By Man Needs Methods of PACKAGING
MAN AND NATURE Man emulates nature On ALL fronts Including PACKAGING
PACKAGING EXAMPLES OF NATURE Walnuts Coconuts PACKAGING MATERIAL - BIODEGRADABLE
OUR ANSWER Wooden boxes Metal containers Glass containers Plastic containers ALL EXCEPT WOODEN BOXES NON BIODEGRADABLE
FLEXIBLE PACKAGE OF NATURE Oranges Sweet limes PACKAGING MATERIAL - BIODEGRADABLE + MEDICATED
OUR ANSWER FLEXIBLE LAMINATES
What is Flexible Packaging? Packaging which is not rigid like glass, metal containers. It is a laminate of a combination of layers of Polymers, Aluminium foil & Paper bonded together using adhesives
WHY PACKAGE? To deliver items//food//contents to the end user/consumer in the intended quality To provide required shelf life Safe delivery Convenience & ease of use
SOURCE REDUCTION Coffee Pack- 50 gms Glass Bottle Laminate Plastic Cap...9.2g Glass Bottle. 180g +Paper Label +Foil. 189.2 gms 2.8 gms Rs 5.00 Rs 0.82
Another Example.. Milk Powder-500 gms Metal Container Laminate 102 gms 7.8 gms Rs 7.50 Rs 2.05
Materials Involved In Flexible Packaging PET -- 10, 12 micron BOPP -- 15 to 30 micron Met PET -- 10, 12 micron Met BOPP -- 15 to 30 micron Foil 7 to 12 micron PE Sealant 20 to 140 micron Paper Maplitho, Glassine, Kraft
Barrier - general definition Many packed products need barrier against oxygen, moisture, light and aroma to maintain their freshness throughout the anticipated shelf life Balance of: Shelf life Quality Cost Light Optical Density OTR cm 3 /m 2 d bar WVTR g / m 2 d High > 2.8 < 1.0 < 0.5 Medium 2.0 2.8 1.0-10 0.5 5 Low < 2.0 > 10 > 5
PROTECTION-BARRIER -Oxygen Barrier...PET -Moisture Barrier...BOPP, CPP, HDPE -High Gas & Moisture Barrier (Opaque)...Foil, Metallised Films -High Gas & Moisture Barrier (transparent) PVDC coated films
Barrier. High Gas Barrier(transparent).Nylon,EVOH Medium light barrier..white opaque films High light Barrier..Foil and Metallised films Physical Barrier(puncture resistance) Nylon and Polyester
Indicative material characteristics (variation depending on the material thickness) Material OTR cc/m2/24 h WVTR gr/m2/24 h EVOH 0.15 22 PVDC 0.5 0.5 Aluminum <0.1 <0,1 CPET 14 8 APET 18 4 PVC 30 5 PE high density 300 1 PP 350 1.5 ABS 420 7 PS 1100 10 PE low density 1250 2
Product examples that require barrier packaging Pet foods Ready meals, soups, meal components, pizza Sausages Baby food (incl. ready meals) Marmelade and jam Fruit and fruit mixes Dry foods such as coffee, soup and sauce mixes, milk and cocoa powders, herbs and spices Fresh meat and poultry packed in MAP (modified atmosphere) Sliced meat products like salami, ham, bacon Cheese Fresh pasta Personal care (e.g. tube laminate) and health care Soft drinks and beer
Indicative Product Requirements (variation depending on the material thickness) Food OTR (cm 3 /m 2 d bar) WVTR (g/m 2 d) Snacks, Chips 5-10 0.3 0.5 Chocolate 10-20 1.0 1.5 Ready made meals < 5 4.0 5.0 Pizza, Pasta < 5 < 2 Meat/Sausages 40-60 1.0 1.5 Powdered products 1.0 1.0 Petfood, dry 1.0 1.0 Enteral Nutrition (ster.) < 1.0 <1.0
Transparent barrier SiOx coated PET Al Ox coated PET PVDC coated PET Aclar Nano-Particles filled Films
Sealant Layer Polyethylene based -- LDPE, LLDPE, Metallocene LLDPE, Nylon PE, EVOH PE, MDPE, HDPE, Polypropelene Based -- CPP
Attributes of Flexible Packaging Source Reduction Cost Effectiveness Energy Saving Ease of Handling Increased Productivity Wide variety of laminate options leading to Optimum Packaging
Requirements of Flexible Laminates Aesthetics Barrier------Moisture, Gas, Flavor Non Toxic Maintain Odour And Taste of Packed Food Processability Strength To Withstand Transportation Provide Shelf Life Sealability Cost
Typical Structures for Typical applications
LAMINATE STRUCTURES. PET/Foil/Poly...Light, Moisture and Gas Barrier Example Coffee Powder PET/MetPET/Poly... Light, Moisture and Gas Barrier Example..Milk Powder, Biscuits BOPP and PET are interchangeable as printing layers
Biscuits BOPP / BOPP hs BOPP / Met BOPP hs BOPP / Met PE PET / Met PET / PE
Candies Medium Barrier : BOPP / CPP PET / PE PET / PP-PE
Chocolates Cold Seal For : 1. Sealing without exposure to heat. 2. Excellent seal integrity. 3. High line speeds. 4. Registered
Snack Food Gas Flushed PET / Met PET / PE
Beverages TEA COFFEE PET / PE PET/Foil/PE BOPP / Paper / PE PET/Met PET/PE
Milk Powders & Health drink PET / FOIL / PE PET / Met PET / PE
Ketch-up/Jams PET / Foil / PET / PE PET / Met PET / PE PET / PE / Foil / PE
RETORT PACKS PET / Foil /Nylon/ CPP
Oil Packaging PET/ Nylon PE PET/Met PET/PE
Ice Creams BOPP / PE PEARLISED BOPP hs
Thermoformed Packs for Convenience Packs with Easy-peel lid Bottle to flexible mini bottle A presentation by The Paper Products Ltd. 22
Conversion of forms for enhanced appeal Glass bottle to flexible stand-up profile pouch A presentation by The Paper Products Ltd. 23
Key pouching Solutions being targeted. Shaped Standup Pouches: A presentation by The Paper Products Ltd. 41
Key pouching Solutions being targeted. Shaped Standup Pouches: A presentation by The Paper Products Ltd. 42
Key pouching Solutions being targeted. Block Bottom pouches : A presentation by The Paper Products Ltd. 45
Key pouching Solutions being targeted. Spout insertion capabilities A presentation by The Paper Products Ltd. 46
PEELABLE PACKAGING OF NATURE Bananas Packaging material -- biodegradable
OUR ANSWER PEELABLE jelly cups PEELABLE cheese pack PEELABLE cereal pouches
NATURE S MASTERSTROKE Ultrathin,Edible Packaging Apples Chikoos Guavas Grapes
The Technologies for Future Learning from Nature Developing for Consumer Oxygen Scavenging Antimicrobials Active Packaging Active Packaging Higher Shelf-Life Low Perishability Odour and Flavour absorbing/releasing Moisture Absorbing Ultra-thin Edible Packaging Modified Atmosphere Packaging Odour / Flavour Retention Longer usability Convenience & Sustainability Longer packed life A presentation by The Paper Products Ltd. 56
The Technologies for Future Consumer Needs Time-Temperature History Microbial Growth Indicator Microbial Spoilage Indicator Light Protection Physical Shock Indicator Leakage Indicator Self-Heat / Self-Cooling Packaging Keep Hot food hot, cold food cold Tamper-Proof Packaging Easy-to-Open Packaging Intelligent Packaging Intelligent Packaging Packaging Answer Heat Sensitive Product Perishable foods Perishable foods Pharma products Pharma, Shock sensitive product Liquid product Fast Food, Ready to Eat food products Easy to use food for fast urban lifestyle Counterfeit Control Support to aged people; specific use A presentation by The Paper Products Ltd. 57
Technological Trends Smart Packaging Smartness in packaging is a broad term that covers a number of functionalities, depending on the product being packaged, including food, beverage, pharmaceutical, household products etc. Smartness would be in packages that Retain integrity and actively prevent food spoilage (shelf-life) Enhance product attributes (e.g. look, taste, flavour, aroma etc.) Respond actively to changes in product or package environment Communicate product information, product history or condition to user Assist with opening and indicate seal integrity Confirm product authenticity, and act to counter theft.
Industry Trends The Environment The environment will remain a major issue for the packaging industry. Issues involving recycling, reducing the amount of waste going to landfill and source reduction will remain on the agenda of all governments The driving forces are threefold the consumer, commercial interests and government legislation. On the commercial side, supply chain factors will play a key role.
Packaging Innovators Always there with you, Thank You