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AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Celplast Metallized Products Limited B ARRIER P ACKAGING.

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Presentation on theme: "AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Celplast Metallized Products Limited B ARRIER P ACKAGING."— Presentation transcript:

1 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Celplast Metallized Products Limited B ARRIER P ACKAGING IN THE R EAL W ORLD 1

2 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante FerrariOutline Background Introduction Films Laminate structures Adhesive laminating conditions Pre- and Post-Gelbo Flex Barrier Properties Laminated MET PE High Barrier MET PET Top-Coated MET PET Bond Strength of Adhesive Laminations Summary Conclusions 2

3 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante FerrariIntroduction PE and PET are two of the most commonly used base substrates in flexible packaging Two most important characteristic of a flexible package Barrier properties Lamination bond strength What happens to the package in the real world? 3

4 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante FerrariIntroduction This study was designed to evaluate the practical barrier of pouches The intention was to simulate flexing and handling that would be expected through the conversion and distribution chain Barrier data was collected at various stages in order to estimate and compare the potential degradation of initial barrier through practical usage Gelbo-Flex testing was used to simulate handling 4

5 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Introduction: Films High barrier MET PE Sealant film Previous studies 1 have shown that in a 2-ply structure, barrier properties are similar to a 3-ply structure using a standard metallized PET film, using less material 1 Sustainable Packaging: Reducing Material and Carbon Footprint with Metallized Barrier Sealants, Packaging Films, Sept PropertiesTypical ValueUnitTest conditions Thickness1.50mil OTR0.06cc/100in 2 /day23 C, 50% RH WVTR0.07g/100in 2 /day38 C, 90% RH Metal Adhesion>300g/inMA-1 5

6 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Introduction: Films Bi-axially oriented high barrier MET PET film PropertiesTypical ValueUnitTest conditions Thickness0.48mil OTR0.015cc/100in 2 /day23 C, 50% RH WVTR0.015g/100in 2 /day38 C, 90% RH Metal Adhesion400g/inMA-1 6

7 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Introduction: Films Bi-axially oriented inline top-coated MET PET Produced using proprietary in-vacuum EB top-coating process, which traps metal and improves barrier 2 2 Improve Barrier Properties and Significantly Reduce Your Carbon Footprint with In-line Metallizing and Top-coating, AIMCAL Fall Technical Conference, PropertiesTypical ValueUnitTest conditions Thickness0.50mil OTR0.003cc/100in 2 /day23 C, 50% RH WVTR0.002g/100in 2 /day38 C, 90% RH Metal Adhesion>300g/inMA-1 7

8 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Laminate Structures 3 laminate structures were prepared: SAMPLE 1SAMPLE 2 MET PE : 2 ply Laminated Structure MET PET : 3 ply Laminated structure Layer Description Layer Layer Description Layer Thickness Thickness Clear PET0.48 mil Adhesive Lamination HB MET PET0.48 mil Adhesive Lamination PE Sealant Web1.5 mil Clear PET 0.48 mil Adhesive Lamination MET PE Sealant Web1.5 mil 8

9 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Laminate Structures SAMPLE 3 Coated MET PET : 3 ply Laminated structure Layer Description Layer Thickness Clear PET0.48 mil Adhesive Lamination HB Top-Coated MET PET0.50 mil Adhesive Lamination PE Sealant Web1.5 mil 9

10 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Solvent-less Two part polyester/polyether urethane Standard 4-roll metering Adhesive at 113 °F (45 °C), nip at 113 °F (45 °C) Applied weight 1.1 – 1.25 lb./ream (1.8 to 2.0 GSM) Corona Treater for primary and secondary set to 0.2 WD Water-Based Two part acrylic urethane Standard gravure application Applied weight 1.5 to 1.7 lb./ream (2.5 to 2.8 GSM) Corona Treater for primary and secondary set to 0.2 WD Two zone dryer set to 170 and 180 °F (77 and 82 °C); nip at 180 °F (82 °C) Lamination Conditions 10

11 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Solvent-Based Two part curing polyester urethane Standard gravure application Applied weight 1.6 to 1.7 lb./ream (2.6 to 2.8 GSM) Corona Treater for primary and secondary set to 0.2 WD Two zone dryer set to 170 and 180 °F (77 and 82 °C); nip at 180 °F (82 °C) Lamination Conditions 11

12 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Bond Strength of Laminate Structures 12

13 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Bond Strength All results below shown after 7 days, similar to 24 hour results Solventless and solvent-based provided best bonds Water-based gave high bonds, adhesive transfer to PE Bond strength units of measurement are all g/in Note: Blue highlight is the interface tested for bond strength. ADHESIVE PRODUCT Clear PET/Met PEClear PET/Met PET/PE Clear PET/Coated Met PET/PE Bond, Hi/Lo Mode of failure Bond, H/L Mode of failure Bond, H/L Mode of failure Solvent-based551/45730 –50 % Metal Transfer 1454/488 PE stretch 1463/ 568 Destruct Solventless675/53990 % Metal Transfer > 1482Could Not Separate, PE tear 1669/ 1038 PE tear Water- Based300/293Adhesive transfer 549/505Adhesive transfer 584/553Adhesive transfer 13

14 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Barrier Properties of Laminate Structure 14

15 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari The laminations were measured for OTR: Initial, after 20 and 270 flexes ASTM 23°C and 0% RH WVTR: Initial, after 20 and 270 flexes ASTM 38°C and 90% RH Bond strength Initial, 24 hours and 7 days Instron Bond testing -10 in/min separation 90 degree peel Barrier & Bond Testing 15

16 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Automated or Manual operation Flat material mounted as a tube on each end Flex is both rotational (270 degrees) and compressive Gelbo-Flex Testing 16

17 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari 2 Ply Clear PET/MET PE Adhesive Lamination 17

18 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari PET/ MET PE : Oxygen Barrier Solvent-based and solvent-less adhesive based laminate structures provided better barrier than water-based adhesive The change in OTR values for all 3 structures were minimal even after 20 and 270 flexes The effect of Gelbo-flexing is less significant for solvent-based and water-based lamination 6.7% 6.3% 13.3% 5.9% 5%0% 18

19 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari PET/ MET PE : Water Vapor Barrier Initial barrier properties indicate that solvent-based and solvent-less adhesive systems produce a better laminated structure After the first 20 flexes, the change in WVTR is higher for solvent-less laminate 23.1% 18.8% 50.0% 5.6% 22.7% 3.7% 19

20 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari 3 Ply Clear PET/MET PET/PE Adhesive Lamination 20

21 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari PET/ MET PET /PE : Oxygen Barrier All laminated structures showed similar Pre-flex barrier properties After 20 flexes, the barrier of water-based laminated structure deteriorated faster than solvent-based and solvent-less laminate structure 450%9% 366% 71% 766% 11% 21

22 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari PET/ MET PET /PE : Water Vapor Barrier Excellent WVTR values with solvent-based adhesive lamination. No significant change after 20 or 270 Gelbo-Flexes Initial WVTR value for water-based was better than solvent-less. However, after flexing the performance of solvent-less and water-based laminate was similar 0% 31.6% 26.7% 11.1% 221% 50% 22

23 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Solvent-based Laminations: Oxygen Barrier After 20 flexes, the barrier of Met PE 2-ply laminated structure is close to High Barrier Met PET 3-ply structure, likely would be better than Standard Barrier Met PET 3-ply structure 23

24 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Solventless Laminations: Oxygen Barrier After 20 flexes, the barrier of Met PE 2-ply laminated structure is nearly same as High Barrier Met PET 3-ply structure, is even better at 270 flexes 24

25 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Water-Based Laminations: Oxygen Barrier After 20 flexes, the barrier of Met PE 2-ply laminated structure is better than High Barrier Met PET 3-ply structure 2-ply barrier after 20 flexes would be significantly better than Standard Barrier Met PET 3-ply structure 25

26 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari 3 Ply Clear PET/Coated MET PET/PE Adhesive Lamination 26

27 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari PET/ Coated MET PET /PE : Oxygen Barrier Coated Met PET retains OTR properties better than HB Met PET in equivalent 3-ply structure, both before and after Gelbo flexing 27

28 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari PET/ Coated MET PET /PE : Water Vapor Barrier For solvent-based laminations, both met PET films perform very well For solventless and water-based laminations, Coated Met PET retains WVTR properties much better than HB Met PET in equivalent 3-ply structure 28

29 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante FerrariConclusions Bond strengths were higher with solvent-based and solventless laminations for all three structures being studied, water-based bonds still acceptable for most applications The effect of Gelbo-Flexing on barrier properties was more significant for MET PET compared to MET PE For solventless and water-based adhesive systems, 2-ply lamination with Met PE holds oxygen barrier better than 3-ply lamination with High Barrier Met PET 3-ply structures with Coated Met PET retain their oxygen barrier better (~ 2x) than the same structure using High Barrier Met PET, and retain their water vapour barrier much better (~ 3x) 29

30 AIMCAL Fall Conference October 27 – 30, 2013 Presented by Dante Ferrari Presented by Dante Ferrari Special Thanks A special thank you to Larry Jopko and the entire team at the Dow Chemical Adhesive Research Centre in Buffalo Grove, IL for preparing the laminations using Dow adhesives and carrying out the Gelbo Flex testing, bond strength testing and barrier measurements. 30


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