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8/3/2019 72857953 Recyclable Coatings for Paper Food Service Packaging
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RECYCLABLE COATINGSFOR PAPER FOODSERVICE PACKAGING:FUNCTIONAL & SUSTAINABLE BARRIERS
Islem Yezza, Technical Director
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For decades, packaging was seen as nothing but waste, a nuisanceto be avoided
Packaging waste pales into insignificance compared with the losses
caused by food waste
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Source: United Nations Food and Agriculture Organization (FAO)
One-third of food in developing countries is
destroyed before it ever reaches the consumer
Worldwide food loss: 1.3 billion tons/year
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Food packaging—could now move frombeing the villain to being the hero
Three main messages came across with great importance for food packaging:
1. Packaging prevents food waste and saves resources
2. Packaging is part of the solution for an overall resource
efficient economy
3. Packaging facilitates more sustainable lifestyles
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Finding the balance between under-packaging and over-
packaging is the aim for all of our businesses
Source: Innventia
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Outline
1. Sustainable Packaging: Trends and markets
2. Enhancing barrier properties of paper: Why Wax is on the Wane?
3. Extrusion coating:
Conventional resin: PE, PEHD, PP, PET and Nylon
Bioplastics: Challenges, Hurdles & Success factors
4. Water-based coating: A bright Future
5. Paper Foodservice Packaging Innovations
6. Wrap-up…
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Eco-conscious Consumer demand for more Sustainableand Convenient packaging
Retailers and manufacturers perceive a marketing
advantage. Eco-friendly, Green, Bio-based, Compostable
& Biodegradable: big selling points
Legislation & regulations pushing for innovative eco-
friendly packaging
Sustainable packaging: Win-Win-Win for the environment,
for manufacturers and suppliers, and for consumers
Sustainable Packaging Sustainability is a Shared Responsibility
World demand for green packaging—including recycled-content, reusable, and degradable
packaging is projected to rise 5.7% per year to $212 billion in 2015 (Freedonia, 2011)
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Provides versatile and responsible packaging solutions for product
manufacturers, retailers, and consumers
Paper has an excellent image as packaging material (renewable, recyclableand biodegradable)
Paper packaging accounts for nearly 3/4 of all packaging materials recovered
for recycling (The Responsible Package, 2010)
Paper-based Packaging
The Responsible Package
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Improving paper's barrier properties is seen as a crucial step in increasing itsviability as a packaging material
The missing performance and barrier properties of paper can be compensated by:
Paper-based Packaging
Improving barrier properties
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1. Wax impregnation: curtain, cascaded
2. Extrusion coating: Petro-based resin and Bioplastics
3. Water-based coating
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Petroleum-based wax has traditionally been used as a
moisture barrier to preserve the strength of a corrugatedcontainer holding iced or wet products
Waxed paper-based packaging are raising Recyclability,Sustainability and Renewability Concerns
Wax-coated Packaging Wax is on the Wane
Growers and retailers are looking for alternatives to wax
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Wax-coated packaging are not recyclable: waxcoatings do not dissolve in water, so they cannot easily
be recycled
Wax-coated packaging are heavy
Paraffin based wax, a non-renewable resources isbecoming more expensive
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Why Wax is on the Wane Sustainability & Economic Concerns
Many leading retailers and grocers, including Wal-Mart and Costco have beendemanding an eco- friendly alternative to wax coated boxes from their suppliers
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The future is clear – wax replacement packaging willbecome a necessity
Opportunities to sharply reduce their landfill costs,while boosting their recycling levels
In 2010, the corrugated industry shipped 6.4 billionsquare feet of boxes using recyclable waxalternative coatings. That’s over 30% more than the
4.9 billion square feet shipped in 2009 and 385%more than when first measured in 2002, dramaticallyincreasing the volume of containers that could berecycled. (Source: Corrugated Packaging Alliance)
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Wax Alternative Growing market
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Inside: Products packaging requirements FDA compliant, moisture and gas barrier, water
repellence, grease and oil barrier, meatrelease…
Outside: Environmental considerations
Storage and handling conditions, Printing,glueability, scealbility, scuff resistance, water
resistance, anti-slip, anti-abrasive, heat
resistance, high gloss or matte…
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Wax replacement
Think Outside & Inside the Box
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Extrusion coating allows processing a variety of polymers and board
Paper and paperboard (SBS, CCNB, Bending Chipboard, Liner)
LDPE - most widely used material for extrusion coating applications: easy to
process, provides adequate moisture barrier, has excellent sealing properties,
grease resistance and lamination layer and cost competitive
PP and HDPE
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Extrusion Coating PE, PP and HDPE
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Hygroscopic resin consume more torque than the standard olefin
resin: Low shear (low speed), high torque
PET coated paperboard: Thermoformed paper-based trays,Ovenable/Microwavable paper-based trays/folding carton
Nylon coated paperboard: Corrugated box (pass through the
corrugators)
PLA coated paperboard: Compostable Paper-based bags, Take-
out box…
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Extrusion Coating Hygroscopic Resin
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BioplasticSustainable and Functional
LDPE: Shortage and Price increase
Biopolastcis can be used as barrier coatings
The bioplastic Market in 2010 was 771 million pounds. This is expected to reach nearly
932 million pounds in 2011 and then further increase to 2.5 billion pounds in 2016, at a
CAGR of 22% for the 5-year period (BBC Research 2011)
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Bioplastic
Confusion in terminology
Biopolymers are plastics that are biodegradable/
compostable and/or have bio-based content
Biomass based plastics are not always
biodegradable
Biodegradable plastics are not always biomass-based
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Biodegradable/Compostable/BiobasedDistinctions are subtle but significant
All biodegradable material are not compostable
Biobased not necessarily compostable
Biobased: Focus is on the ―origin of life‖ or where did the
carbon come from (ASTM D6866). Uses C14 content
measurement
Compostable: Focus is on ―end of life or disposal‖.
Independent of carbon source standards (EN13432 and ASTM
D6400)
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Bioplastics Challenges & Hurdles
1. Confusion in terminology: Biobased, Compostable, biodegradable, Oxo…?
Education is needed to clarify in the minds of consumers and clients, the environmental
benefits of these new materials
2. End of life hurdles: the puzzle?
Consumers are confused when it comes to separating biodegradable, compostable andrecyclable plastics. Information about how to best dispose of it, is necessary
3. Carbon footprint: bioplastics not necessarily greener than oil based relatives?
Skeptics about LCA studies: data may not be accurate or complete and system
boundaries are not easily defined
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Bioplastics Challenges & Hurdles
4. Price: Current prices for bioplastics are significantly higher than the cost of PEPeople are environmentally conscious when it’s convenient and affordable
Higher oil prices are lowering the gap in prices of bioplastics and conventional plastics
5. Weak barrier properties: MVTR, OTR, heat resistance, microwavable…?
Barrier and physical properties may limit applications
Blends and compounding
6. Value proposition: Promoting Biobased, Biodegradable or Compostable?
Is not yet clear in the minds of most consumers and clients
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Renewability and sustainability Effect on food scarcity
(Source: London Biopackaging, Bioplastics Magazine, Cargill Dow )
At full capacity, PLA will take 0.15% of the total corn for grain production in the USA
This cannot be considered to have an effect on food scarcity, especially when
compared to bio-fuels: No impact on the food supply
The raw material for bio-plastic production is plant starch. With technologicaldevelopments, soon the starch will be taken from any biomass or crop waste and not
the crop parts used in food production: Triticale very promising
Renewability and sustainability of bioplastics are questioned? Bio-resins are madefrom crops that would otherwise be used for food
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1. Compostable and/or bio-based resin
2. Good adhesion
3. Comparable barrier to PE
4. High water and oil resistance (MVTR, oil &
grease resistance…)
5. Cost-effective
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Bio-resin extrusion coating
Expectations
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Bio-resin extrusion coating
Processing Challenges: Screw & Dryer
Bio-resin could not be processed at existing PE screw: Stability is poor, melt
temperature are too high, and the available torque is inadequate
1. Bio-resins consume more torque than the standard olefin
resin: Low shear (low speed), high torque → Newscrew
2. Bio-resins are very hygroscopic. Hygroscopic materialsabsorb water, even from the air: In-line drying is essential
→ Dryers
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1. Biopolymer-coating: sustainable and functional barrier
2. Bio-resin extrusion coating: dedicated screw and dryers
3. Trends: volatile oil prices; energy security concerns; environmental benefits;
favourable regulatory initiatives; and the improving performance and
competitiveness
4. The distinctions are subtle but significant: not all bioplastics are created equaland there are a lot of misleading claims out there
5. Education: has to be a combined effort from resin makers, converters and the
companies that will be selling these products to the consumer
Bio-resin extrusion coating
Market education
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Water-based coatings
Repulpability, an Important Route to Sustainability
With the push towards sustainability, repulpability and recyclability, water-based
technologies are gaining acceptance
The packaging combines the best aspects of two materials: environmentally
friendly paperboard and good barrier properties of water-based coatings
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Sustainable and Functional barrier : can be custom-
formulated to meet the packaging requirements of a
wide range of products - Can be recycled, repulped
and/or composted
Alternative solution to current wax, PE extrusion coating
and film lamination
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Latex (as binder, other polymer can also be used)
Mica (pigment, like rocks to achieve moisture barrier)
Clay (second filler, can also be Talc, calcium carbonate)
Dispersant (for processing)
Defoamer
pH control agent
Water-based Coatings
Basic Formulation
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Talc Mica
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26Source: Claude Tremblay, Cascades
Water-based Coatings
SEM Image
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Water-based coatings can be custom-formulated to meet the packaging requirements
of a wide range of products
1. Barrier properties : Moisture - Oil and grease barrier 2. Physical & Chemical properties : Scuff resistance, anti-slip, non-abrasive,
stacking strength, corrosion inhibitor, heat sealing, conductive & anti-static).
3. Aesthetic & decorative : color coatings
Water-based coatings
Tailored solutions
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Greater heat sealability = more blocking
Higher coating water retention = poorer water barrier effectiveness
Higher water barrier = poorer cold glueability
Higher oil resistance = poorer hot melt adhesion
Higher effectiveness = higher cost
Water-based Barrier
A Balancing Act
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There are always exceptions, but …
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Replace not easily Recyclable and Non Renewable EPS containers
To-Go containersGrease and Moisture Barrier
Packaging Requirements: Moisture barrier, grease barrier, heat resistance,
microwavable, Gluable. FDA compliant, Compostable/recyclable/Repulpable
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Corrugated Boxes
Produce, meat, poultry and Fish
Replace not easily recyclable waxed box and Petro-plastic filmlaminated board
Packaging Requirements: Avoid water wicking inside the linerboard, Endure both
packing house and transport conditions, FDA compliant, withstands Corrugating
process heat up to 375°F/190
°C, Recyclable/Repulpable
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Folding BoxesDry and fatty foods
Replace not easily recyclable Petro-plastic film laminated board/eliminates bags
Packaging Requirements: Prevent Caking and moisture picking, Grease-resistant
linerboard, Holds up to hot-melt glue and cold set adhesives, FDA compliant,
Recyclable and Repulpable
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Food waste bags
Functional, Repulpable and Compostable
Packaging Requirements: Leak proof, Odour proof, Grease barrier, Sealable,
Recyclable, Repulpable and Compostable
Replace Petro-plastic film laminated paper and plastic bags
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Thermoformed paper trays
Functional and sustainable
Packaging Requirements: Leak proof, Grease barrier, FDA compliant,
microwavable, Recyclable, Repulpable and Compostable
Alternative to the traditional Styrofoam trays, PET microwavable trays and others plastic
trays and plates
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Italian organic products distributor Ecor, together
with Italian bioplastics maker Novamont and
agricultural group Filogea, has developed a new
100% home compostable folded tray for ready-
to-eat washed salads
Mater-Bi Coated Paperboard (Italy) Compostable folded tray
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Coextrusion coating of PE/EVOH/PE
The EVOH provides the O2 barrier properties needed for the MAP
Material printed black, which is done for aesthetic reasons
Marks & Spencer has launched sliced
meat in paper packaging
Paperlite material is paper with high
stretchability, which can be formed in
existing thermoforming lines without
requiring costly investments
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Sliced meat (UK)
Flextrus Paperlite
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Walki Lids (Sweden)
Durable & Recyclable
In 2010 growth was at 25% and this year sales are expected to increase by some 15-20%
Replace aluminum-based lids
The extrusion coated paper-based lidis durable, easy to print on and can be
cut into different sizes and shapes
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Coated Tecta paperboard offers a good resistance against water, water vapour and grease
Replace plastic in many applications: Repulpable, recyclable and
compostable sandwich packaging
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Tecta Paperboard (Finland)Eco-friendly alternative to plastics
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Boxerchips (Ireland)
Box-in-bag: Innovative Crisp Packaging
Delivers the same volume of product as a standard 40g bag of crisps, but the
compact arrangement allows for an overall reduction in size by as much as 50%
and dramatically crunches the amount of packaging materials used by 35%
The 40 grams product is currently available on 17 European airlines, with 4 millionboxes being sold last year
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Major companies are beginning to take note and a few have stepped forward
to lead the ―sustainable packaging revolution‖
Market drivers: Increased focus on recyclability and Increased demand for
sustainability
Innovative paper-based packaging offers environmental, convenience, food
safety and preservation and economics benefits for both customers and
packaging actors
Both the packaging industry and consumers need to work together to develop
a unified set of standards that will end confusion and maintain
transparency in the rapidly growing sustainability sector.
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Wrap-up… Keep the Molecule in Play
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Divert from landfill is sustainable, but we must keep in mind the
packaging basic functions: Protect – Inform – Contain –
Transport – Preserve – Display
Wax-coated papers are usually overkill and packaging specs are
frequently unknown
In order to offer custom-formulated wax alternatives, we need to
better understand customer specific needs and packaging
requirements (see Check List)
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Wrap-up… Functionality & Sustainability
At the end of the day: How might we help our customer make more money?
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Sustainable
Biobased
Recyclable
Compostable
Quality
Green
Practical
Functional
Safety
Reliable
Smart
Performance
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Contact Information:
Islem Yezza, Technical Director Email: Islem_yezza@cascades.com
Tel: 819 352-0817
Thank you
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