1. New Design-Enabling Technologies
For Flexible Packaging
Dr. Giancarlo Caimmi, Dr. Guido Kollbach
Aimcal R2R, Phoenix, October 2018

2. Market Applications for Metallized Films
Food Packaging
Decoration
Industrial
Snacks, Chips
Bakery products
Candy, Confectionary
Coffee, …
Gift and Flower Wrapping
Labels
Hot Stamping Foils
Holograms, …
Solar Window Films
Anti-Counterfeiting Films
Road Signs, …
New Design – Enabling Technologies for Flexible Packaging for Flexible Packaging
December 31, 2018

3. Estimated Market Growth1)
Market for Metallized and AlOx-Coated Films Strong Growth in India and Asia
Estimated Market Growth1)
Metalized Films
AI Ox-coated Films
Europe
North AmericaNorth America
India & Middle EastIndia & Middle EastIndia & Middle East
Asia
South AmericaSouth America
1) Market estimates based on information from Henkel, Nordmeccanica, and several market studies
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

4. Market Applications for Functional Coatings
Markets:
Food, Medical HS
Coating Functionalities
Sealability
Better anchorage
Improved barrier
Protection
Optical effects (gloss, matte, …)
Slip modification CS
Markets:
Food, Medical
Henkel’s Coating Technologies & Markets PR
Market:
Food BC
Markets:
Food,Medical
Trend: Multifunctional Coatings
Funct. Coating nothing new
Add or Enhance Properties (of films)
Henkel
You familiar - Adhesive Company
Recently – emphasis – Funct. Coatings also
Serving Mkt. – many years
Traditionally: HS, CS, PR
Recently: BC and OPV
Coating functionalities …
Trend: Multifunct.!
OPV
Market:
Food
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

5. Integration and Interaction of Product Lines Freedom of Design – Case Studies
Traditional
Lamination of metallized films with printed stock
High Performance Protective Top-Coatings
Top-coating fragile layers like AlOx with protective coatings
FlexPack: H + NM product lines – Multiple Touchpoints
H: Coatings + Laminating Adhesives
NM: Met.-Equip. + Laminating Equip.
Typically co-supplying
Traditionally …
More demanding
New innovations (equip. / chemistry / combinations)
Levering synergies – integrating add. Funct.
2 Case Studies
High perf. Top-coating for AlOx
Multifunct. Met. primer
Novel Metallization Primers
Metallizing on top of multifunctional metallization primers
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

6. Metal Deposition Principle & Key Technical Data
P (chamber pressure)= 5E-4 mbar
Aluminum layer deposited to films and paper in vacuum
Thickness: – 0.07 micron
Optical Density: 0.2 – 4
Electrical Resistance: 0.5 – 10 /m2
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

7. System Layout Schematic Representations
Rewind
Unwind
Roots
Pumps -
Vacuum
5 X 10-2 mbar
Diffusions
pumps -
Vacuum
2-5 X 10-4
mbar
Process drum
chill roller
Al evaporators
December 31, 2018

8. System Layout Product Pictures
Vacuum
chamber
AI evaporation
system
Winder
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

9. Process Schematic Metallization Process
High vacuum
chamber
Boat
Al evaporators
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

10. Coater Technology Product Pictures
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

11. Innovation Through Collaboration of Industry LeadersGK
Competitive Environment
Level of Open Innovation
Benefits: reduce Cost / Time – improve Quality
Barrier Film: Natural fit for NM + H
Dive into 2 case studies …
Safe and highly focused innovation process created fast results!
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

12. Case Study AlOx-Coated Films New High-Performance Protective Coating Technology
Protected AlOx-coated Film
AlOx-coated films
Very good oxygen and moisture barrier
Very fragile
Converting leads to dimished barrier performance
Current top-coating technologies provide mechanical protection
New top-coating technology
Mechanical protection
Significant barrier improvement
High-performance
Top-coating Technology
AlOx-layer
Substrate
(e.g. PET, OPP)
1st Case Study: High Perf. AlOx-Top-Coat
AlOx-coated films …
On the left side – schematic structure
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

13. Case Study AlOx-Coated Films Process Flow-Chart
AlOx-Coating
Top-Coating
Printing
Lamination 01 02 03 04
Protection of AlOx- layer
Ink anchorage
High mechanical and thermal stress
Good anchorage of ink on AlOx during lamination
Keeps top barrier performance throughout process
Optimal anchorage
Superior barrier performance
Best clarity
Fragile AlOx-layer unprotected
Additional functionality for very high performance
Look at Entire Process Flow
Aspects to consider
AlOx-Coating Step: Anchorage / Barrier / Clarity
Top-Coating: Protection / Add. Funct.
Printing: Protection / Printability / High Mech. and Thermal Stress
Laminating: Good anchorage (AlOx + Ink) / Maintain High-Barrier
How to test?
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

14. Case Study AlOx-Coated Films Testing Mechanical Protection
Strongly improved robustness
Barrier performance not reduced by stretching or abrasion
Gelboflex testing
Significantly more robust than traditional top-coat
(2%)
Verify Mechanical Protection
Small Scale trial - LaboCombi
Before: Non-Top coat OTR higher (Slitting) – more important trad. Vs. new Top-coat
Stretching (2%) …
Abrasion Test – explain – results
Gelboflex – 50 cycles
Proof is in the pudding: Scale-Up
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

15. Case Study AlOx-Coated Films Production Scale Testing
Strong barrier improvement by AlOx-coating
Significant boost in oxygen barrier performance by Henkel’s new top-coating technology
Moisture barrier stabilized or improved
Very good stability throughout entire process
Tested under Production Conditions
From Met to Lam
Roll of couple 1000 m …
Opens up new applications (highest level barrier)
New Design – Enabling Technologies
December 31, 2018

16. Case Study Metallized Films Novel Metallization Primer Technology
Metallization is state of the art
Improvement of anchorage of metal layer to plastic substrate
Henkel’s novel coating technology provides additional improvement in oxygen barrier
Improve Barrier of Metallized Film
Metallization
Novel Metallization
Primer Technogoly
Substrate
(e.g. PET, OPP)
2nd Case Study: Multifunctional Metallization Primer
Trade war - special import duties/tariffs
High level interest: Al-foil replacements
State of Art
Primers: Improve bonds
Target of innovation: Improve bonds and barrier - Multifunctional
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

17. Case Study Metallized Films Process Flow-Chart
Primer Application
Metallization
Lamination 01 02 03
Full coverage and smooth laydown
Strong anchorage to film
Optical density determines barrier
Primer holding both materials in place
Good anchorage of metal-layer to substrate
Withstand mechanical and thermal stress
Similar to 1st Case Study – Aspects of each Process Step
Full scale trial
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

18. Case Study Metallized Films Barrier Performance Development on PET Film
120
Very strong improvement of barrier performance by Henkel’s new coating technology
Significant barrier improvement by metallization
Very good stability throughout entire process
Optical appearance slightly different, less shiny, slightly grey-ish
Still working on optimization
50% reduction of OTR
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

19. Summary Enabling new designs for flexible packaging
Metallization
Coatings
Films
Inks
Adhesives
Processes
New
packaging
design
Summary Enabling new designs for flexible packaging
Synergy of metallizing technology and multifunctional coating
High barrier metallized films
More sustainable transparent barrier films
Layer reduction
Access to high barrier recyclable structures (Circular Economy)
In summary …
Barrier Films - Not Just Project - but Field of Innovation
Formed Alliance BarrEnhanceTech Alliance
More to come …
Enabled by BarrEnhanceTech Alliance by Nordmeccanica and Henkel. Two industry leaders working in perfect collaboration
New Design – Enabling Technologies for Flexible Packaging
December 31, 2018

20. Thank you!