Presentation on theme: "M&G’s new barrier solution"— Presentation transcript:
1M&G’s new barrier solution POLIPROTECTM&G’s new barrier solution
2Poliprotect & BicoPET: Poliprotect differs from M&G’s previous solution, Actituf, primarily because of the technology used, the BicoPET. BicoPET ™ is an innovative technology patented by M&G which allows to mix in a single chip the active barrier (preventing the oxygen entry) and the passive barrier, BASF’s new nylon Ultramid X17 (preventing the loss of CO2). In such a way M&G offers to converters the possibility to have both active and passive barrier without the need to dose. This avoids possible errors and limits the necessity for quality control.Standard PETBicoPETRECIPE 1RECIPE 2
3M&G’s new range of barrier resin: Poliprotect PB (passive barrier)this is the solution for products that require passive barrier only:CSDReady to drinkPoliprotect APB (active and passive barrier)this solution guaranties a high active barrier associated with the necessary passive barrier for the following applications:Juices, smoothies, juice based productsBeer, WineMilk and dairy productsFood applications (ketchup, salad dressing, etc...)Poliprotect JB (juice barrier)this solution suits particularly products that need medium active barrier:Juices, smoothies, fruit based beverages
4The BicoPET™ structure: NylonPolyprotect PBPET/new scavengerNylonPolyprotect APB & JBFor the PB grade, the core of the pellet contains the passive barrier.For the APB grade, the core contains the passive barrier while the shell is made of modified PET mixed with the active barrier.For the JB, the structure is identical to the APB but with a nylon content significantly lower.44
5What are the advantages of BicoPET™? No additional investment required by the converter because it is dried, injection molded, and reheat blow molded like standard PETNo separate handling system for nylonNo dosing errorsExcellent dispersionBarrier active only when bottles are blown which allows to keep preforms at stock without time limitRecyclableFully approved by FDA and EC
6With Poliprotect, a perfectly transparent bottle: Material testedHaze*, %Standard PET2.4Standard PET + 7% nylon (MDX6)15.5Poliprotect2.8*Haze is measured by Gardner haze meter.
7Ultramid® X17, the key to our transparency: What makes Poliprotect unique in comparison to the other existing solutions is the new nylon Ultramid® X17 included in each pellet.The development of Ultramid® X17 is the result of a considerable R&D investment from the part of BASF for the exclusive use of M&G.This innovative nylon has a perfect compatibility with our modified PET and allows to have high transparency in the final bottle appearance.The comparison with the MDX6 (in the same % of dosage) shows that the final haze on clear bottles is dramatically reduced.
8With Poliprotect, the same bottle resistance as standard PET: Burst (bar): it determines the bottle strength by pressurizing it until it bursts.Creep (%): it examines the progressive expansion of a bottle once it is filled andcarbonated and then put under pressure.Top load (kg): it measures a container's maximum resistance to a vertical pressure.
9With Poliprotect APB, a permanent barrier on O2 The red line indicates the rate of 1 ppm of 02 ingress which is the typical market requirement.It appears clearly that Poliprotect APB’s performance exceeds by far this target and therefore is the ideal barrier solution for sensitive beverages.
11High protection against Vit. C loss This test was commissioned by an Italian top-quality juice maker on a 250 ml bottle 100% Poliprotect APB + barrier cap filled with a smoothies (100% juices of mixed fruits)The Vit. C loss is very limited due to the fact that the oxygen ingress is prohibited by the barrier scavenger, also odour and color test show no evident change during time.
12Long lasting barrier for juices This graph represents a real test done with a premium orange juice (100% pure juice) that has given a very positive results after approx 9 months shelflife.The customer was using mulitlayer bottles and comparing the Poliprotect results on Vit. C loss saw no difference with its solution and switched to Poliprotect.This will grant the customer higher flexibility and economical convenience at the same barrier performance.
13With Poliprotect, a reliable and flexible barrier on CO2 CO2 loss simulation- 1L Bottle - 52 gPoliprotect was developed to meet current market requirements on CO2.Nevertheless, in case of higher performance needs on passive barrier, our solution can easily be adapted by adding a greater % of nylon.
14Poliprotect performances versus competitors solutions
15MasterbatchesM&G has homologated a family of colorants from Holland Colours, which have perfect compatibility with our Polyprotect resin.The same co-operation is ongoing with Colormatrix, Clariant, Repi, Toyo, Sukano, Polyone.Upon request, M&G can homologate a specific masterbatch in short time.Already a list of colorants tested and approved to be used with Poliprotect is available.
16PoliProtect is recyclable as part of the regular PET stream : Extensive testing has shown that PoliProtect has the same physical properties as PET when recycled at 25%PoliProtect is fully recyclable in the colored bottle streamDue to the presence of nylon a color shift can occur during recycling of bottles into the clear streamAt projected market penetrations of around 2%, testing has shown color shift well within the recycling industry’s tolerance levelsSorting equipment exists which can move nylon containing flakes to the colored streamRecycled resin can be toned16
17EEC approval – FDA - Migrations Poliprotect fulfills the requirements of the European Community and national food packaging regulations.None of the substances listed in Directive 76/769/EEC are present in this resinPoliprotect has received the FDA in 2008.In Fraunhofer Institute Poliprotect PET bottles for juices were screened for migration of relevant compounds with satisfactory results. (available report with results)
18Manufacturing areas and R&D Poliprotect resins are produced today in:Europe, Italy, Patrica (south of Rome) – M&G Polimeri ItaliaInstalled capacity: MT/yearUSA, West Virginia (Apple Grove) – M&G Polymers LLCInstalled capacity: MT/yearM&G is working on improvement and innovation in barrier PET through the work of the two R&D centers:- R&D in USA, Sharon Center for resin- R&D in Italy, Rivalta for packaging application of the barrier resins
19M&G a reliable partnerThanks to our past experience as preform producer (M&G sold its Packaging BU in 2008 to Plastipak), we work with our customers as consultants also for specific projects.In this context our Technical Assistance, and our R&D people combine their know-how to offer a support for launching new product packaging or for the restyle of existing one.In this area we provide together with the support of Proplast Institute the following services:Production of preforms/bottles samplesStudy for new design of preforms/bottlesTests on permeation (02 and Co2)Test on Vit. C for juices or other beveragesMechanical tests: creep, burst, top load
20M&G Registered Patents Polyester resin blends with high-level gas barrier properties(Barrier Composition)PET/ PA mix with domains between nmMg41:Transparent polyester resins and articles there from(Appearance)PA domains in Bottle or Preform in the range of:30 – 110 nmMg48:Article comprising light absorbing composition to mask the visual haze and related methodUse Colour to mask Haze: any Domains between 400 – 700 nm
22M&G Group Business Units The structure of the Mossi & Ghisolfi GroupM&G Group Business UnitsPolymers BUChemtexFilmAcetate BUPET standard gradesR&DDiocetate PlasticPET barrier gradesEng. & TechFilmTriacetate PlasticPET foamable gradesProject ManagementRecyclingDiacetate TextileProcurementPTAConstructionPolyester Fiber
23kt/year 2000 TOTAL APPROX M&G is the global leader in PET production The M&G group is today the biggest PET producer thanks to its total capacity of 2 Millions tons of PET per yearkt/yearSuape, BrasilAltamira, MexicoApple Grove, WV USAPatrica, Italy600650450300TOTAL APPROX2000
24Polymers B.U. - Market Shares M&G Group: a 10% market share in 2009 that makes M&G Group the world leader of the PET marketM&G 10%Others 49%Eastman 8%Invista 7%Far Eastern 5%La Seda 5%NanYa 4%Wellman 4%Indorama 4%San Fang Xiang 4%Based on 2009 capacities
25A worldwide presence: Wilmington Tortona Milan Apple Grove Verbania EngineeringCentral OfficeTortonaGroup Head OfficeMilanGroup Head OfficeEurope Reg. OfficeApple GroveResinVerbaniaResinCellulose AcetateSharon Center R&D CentreRivaltaR&D CentreHoustonNorth AmericaRegional OfficePatricaResinAltamiraResinBeijingEngineeringPoços de CaldasResinFiberR&D CentreShangaiEngineeringMumbaiEngineeringMumbaiEngineeringSao PauloSouth AmericaRegional OfficeBangaloreEngineeringCaboFiberPignataro M.FilmSuapeResinIndaiatubaRecyclePaulíniaPTA