Polymers In Flexible

Packaging
J R RAIKAR

HUHTAMAKI-PPL

27/09/2007
 MAN AND NATURE
¾ Nature provides Abundant Resources to
Man’s Needs
¾ Ready to Eat Food -- Fruits and Vegetables
¾ Processed Food By Man
¾ Needs Methods of PACKAGING
 MAN AND NATURE
¾ Man emulates nature

¾ On ALL fronts

¾ Including “PACKAGING”
PACKAGING EXAMPLES OF
NATURE

¾ Walnuts

¾ Coconuts

PACKAGING MATERIAL - BIODEGRADABLE

 OUR ANSWER…
¾ Wooden boxes
¾ Metal containers
¾ Glass containers
¾ Plastic containers

ALL EXCEPT WOODEN BOXES –

NON BIODEGRADABLE
 FLEXIBLE PACKAGE OF
NATURE

¾ Oranges

¾ Sweet limes

PACKAGING MATERIAL -
BIODEGRADABLE + MEDICATED
OUR ANSWER…

FLEXIBLE LAMINATES
 What is Flexible Packaging?
z Packaging which is not rigid like glass,
metal containers.

z It is a laminate of a combination of layers of

Polymers, Aluminium foil & Paper bonded
together using adhesives
 WHY PACKAGE?
¾ To deliver items//food//contents to the end
user/consumer in the intended quality
¾ To provide required shelf life
¾ Safe delivery
¾ 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
z PET -- 10, 12 micron
z BOPP -- 15 to 30 micron
z Met PET -- 10, 12 micron
z Met BOPP -- 15 to 30 micron
z Foil – 7 to 12 micron
z PE Sealant – 20 to 140 micron
z 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 OTR WVTR

Optical Density cm3 /m2 d bar g / m2 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….

¾ High Gas Barrier(transparent)

….Nylon,EVOH
¾ Medium light barrier
…..White opaque films
¾ High light Barrier
…..Foil and Metallised films
¾ 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
z Ready meals, soups, meal components, pizza
z Sausages
z Baby food (incl. ready meals)
z Marmelade and jam
z Fruit and fruit mixes
z Dry foods such as coffee, soup and sauce mixes, milk and cocoa
powders, herbs and spices
z Fresh meat and poultry packed in MAP (modified atmosphere)
• Sliced meat products like salami, ham, bacon
z Cheese
z Fresh pasta
z Personal care (e.g. tube laminate) and health care
z Soft drinks and beer
Indicative Product Requirements
(variation depending on the material thickness)

Food OTR WVTR

(cm3/m2 d bar) (g/m2 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

z SiOx coated PET

z Al Ox coated PET
z PVDC coated PET
z Aclar
z 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
z Source Reduction
z Cost Effectiveness
z Energy Saving
z Ease of Handling
z Increased Productivity
z Wide variety of laminate options leading to
“Optimum Packaging”
 Requirements of Flexible
Laminates
z Aesthetics
z Barrier------Moisture, Gas, Flavor
z Non Toxic
z Maintain Odour And Taste of Packed Food
z Processability
z Strength To Withstand Transportation
z Provide Shelf Life
z Sealability
z Cost
Typical Structures for Typical
applications
 LAMINATE STRUCTURES….
¾ PET/Foil/Poly...Light, Moisture and Gas
Barrier
Example…Coffee Powder

¾ PET/MetPET/Poly.... Light, Moisture

and Gas Barrier
Example…..Milk Powder , Biscuits

¾ BOPP and PET are interchangeable as printing

layers
 Biscuits
z BOPP / BOPP hs
z BOPP / Met BOPP hs
z BOPP / Met PE
z PET / Met PET / PE
 Candies
Medium Barrier :

z BOPP / CPP
z PET / PE
z 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

z PET / Met PET / PE

 Beverages
TEA COFFEE

PET / PE PET/Foil/PE

BOPP / Paper / PE PET/Met PET/PE

 Milk Powders & Health drink

ƒ PET / FOIL / PE

ƒ PET / Met PET / PE

 Ketch-up/Jams

z PET / Foil / PET / PE

z PET / Met PET / PE

z PET / PE / Foil / PE
RETORT PACKS

PET / Foil /Nylon/ CPP

 Oil Packaging

z PET/ Nylon PE

z PET/Met PET/PE
 Ice Creams

z BOPP / PE

z 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

¾ Bananas

¾ Packaging material -- biodegradable

 OUR ANSWER…
¾ PEELABLE – jelly cups

¾ PEELABLE – cheese pack

¾ PEELABLE – cereal pouches

NATURE’S MASTERSTROKE
Ultrathin,Edible Packaging
¾ Apples

¾ Chikoos

¾ Guavas

¾ Grapes
 The Technologies for Future…

Learning from Nature…

…Developing for Consumer
Active Packaging
Active Packaging
• “Oxygen Scavenging” Ö Higher Shelf-Life

• Antimicrobials Ö Low Perishability

• Odour and Flavour absorbing/releasing Ö Odour / Flavour Retention

• Moisture Absorbing
Ö Longer usability

• Ultra-thin Edible Packaging

Ö Convenience & Sustainability

• Modified Atmosphere Packaging

Ö Longer packed life

A presentation by The Paper Products Ltd. 56

 The Technologies for Future…

Consumer Needs…
…Packaging Answer
Intelligent Packaging
Intelligent Packaging
• Time-Temperature History Ö Heat Sensitive Product
• Microbial Growth Indicator Ö Perishable foods
• Microbial Spoilage Indicator Ö Perishable foods
• Light Protection Ö Pharma products
• Physical Shock Indicator Ö Pharma, Shock sensitive product
• Leakage Indicator Ö Liquid product
• Self-Heat / Self-Cooling Packaging Ö Fast Food, Ready to Eat food products
• Keep Hot food hot, cold food cold Ö Easy to use food for fast urban lifestyle
• Tamper-Proof Packaging Ö Counterfeit Control
• Easy-to-Open Packaging Ö Support to aged people; specific use

A presentation by The Paper Products Ltd. 57

 Technological Trends
Smart Packaging
z ‘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
z 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
z 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