Unique High Oxygen Barrier Coatings for Food Packaging · 2018-10-08 · Unique High Oxygen Barrier Coatings for Food Packaging . Flexible Packaging Conference 2016. October 10, 2016

Unique High Oxygen Barrier Coatings for Food Packaging

Flexible Packaging Conference 2016 October 10, 2016

michelman.com

Agenda

Two very different oxygen barrier coatings will be presented

– Coatings onto BOPET film– Coatings onto AlOx coated BOPET film

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Coatings onto BOPET Film

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Objective

• Reduce oxygen transmission through thin, transparent packaging film to retard oxidative spoilage and prolong product freshness, extend shelf life

• Demonstrate a very thin layer of coating on film can have a high impact on barrier, without adding significant cost or weight to a package structure.

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In Line Barrier Coating Application

Used in line in the film production process BOPET substrate

Substrate selection is critical, smoother is better

Better properties achieved through the stretching process – e.g. adhesion

Coat weight range 0.04 – 0.07 dry gsm Enhance barrier properties by metalizing on

top of the coating Work done at Bruckner

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Michem® Flex Barrier 3510

• Applied in-line with BOPET line• Applied between machine

direction and transverse stretching

• Used either– As a pre coating prior to

metallization– Or as a transparent barrier for

dry conditions• Applying in-line gives low coat

weight and better properties.

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Gravure Coating Head

Inline Film Coating

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10% solids in water Single component Excellent shelf life No mineral nano-particulate content No chlorine Food compliant Adhesion

To film substrates To vacuum deposited metal, AlOx and SiOx

Promising water resistance >500 g/in metal adhesion between film and metal

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Barrier Coating Characteristics

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12u BOPET film12u BOPET/0.07gsm

MFB3510

12u BOPET/0.07gsm MFB3510/2.7 OD

metallizing

0.1

1

10

100

0.01 0.1 1 10 100 1000

MVT

R g

/m2/

day

@ 3

8C a

nd 9

0% R

H

OTR cc/m2/day @ 0% RH

12uBOPET/0.07gsm MFB3510/adhesive//80uCPP

Michelman In Line Barrier Coating

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12u BOPET/MFB3510@ 0% RH

12u BOPET/ MFB3510/

2.7 OD metallizing @ 0% RH

12u BOPET/MFB3510@ 90% RH

12u BOPET/ MFB3510/

2.7 OD metallizing @ 90% RH

0.1

1

10

100

0.01 0.1 1 10 100 1000

MVT

R g/

m2/

day

Oxygen Barrier cc/m2/day/atm

Barrier Coating - Effect of Humidity

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Chart1

0.620.081.720.04


12u BOPET/0.07gsm MBC @ 0% RH

12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 0% RH



MVTR g/m2/day

12u BOPET/MFB3510 @ 0% RH

12u BOPET/ MFB3510/ 2.7 OD metallizing @ 0% RH

12u BOPET/MFB3510 @ 90% RH

12u BOPET/ MFB3510/2.7 OD metallizing @ 90% RH

40

3

40

3

Data 1 elevated RH

After converting simulation

Barrier resultsOxygen barrierMVTROxygen barrierMVTR

SubstratesOTR @ 0%RH, cc/m2/dayMVTR @ 38°C 90%RH, g/m2/day0%RH, cc/m2/day38°C 90%RH, g/m2/day

12u BOPET film12840

UFLEX BOPET F-PLX22Commercial high barrier films

Camvac 300931.5

dai Nippon IB-PET-P22

Aryalox AQ41145

Aryalox AB41011

Mitsubishi Techbarrier TX0.50.5

Mitsui Maxbarrier0.80.3

Reiko Fine barrier AT-R1.51

Toppan GL -RD0.10.2

Toray Barriarlox 1011HG-CX1.51.5

Toray Barrierlox 1011SB-R20.10.3

Trias Sentosa AZB1.51.5

Ultimet CeramAlox 1561.51

12u BOPET/AlOx1.150.7515.65.82

12u BOPET/0.07gsm MBC @ 0% RH0.6240Our coating constructions

12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 0% RH0.083

12u BOPET/0.07gsm MBC @ 90% RH1.7240

12u BOPET/0.07gsm MBC/2.7 OD metallizing @ 90% RH0.043

Besela PET0.720Competative coating constructions

Kurarister PET0.320

PVDC coated PET10.93.9

12u BOPET/0.07 gsm MBC//CPP0.20.6

12 micron film, in line coated

MILBC = Michelman Barrier Coating

Data 1 elevated RH


12u BOPET film





MVTR g/m2/day

12u BOPET/0.07gsm MILBC/2.7 OD metallizing @ 0% RH

Data 1



SubstratesOTR @ 0%RH, cc/m2/dayMVTR @ 38°C 90%RH, g/m2/day0%RH, cc/m2/day38°C 90%RH, g/m2/day

12u BOPET film12840


Camvac 300931.5


Aryalox AQ41145

Aryalox AB41011




Toppan GL -RD0.10.2





12u BOPET/AlOx1.150.7515.65.82

12u BOPET/0.07gsm MILBC0.6240Our coating constructions

12u BOPET/0.07gsm MILBC/2.7 OD metallizing0.083


Kurarister PET0.320


12u BOPET/0.07 gsm MILBC//CPP0.20.6

12 micron film, in line coated

MILBC = Michelman in line Barrier Coating

Data 1

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12u BOPET film

12u BOPET/0.07gsm MILBC

12u BOPET/0.07gsm MILBC/2.7 OD metallizing

Besela PET

Kurarister PET

PVDC coated PET

12u BOPET/AlOx

12u BOPET/0.07 gsm MILBC//CPP

MVTR g/m2/day

Performance sheet



Substrates0%RH, cc/m2/day38°C 90%RH, g/m2/day0%RH, cc/m2/day38°C 90%RH, g/m2/day

BOPET film12840


Camvac 300931.5


Aryalox AQ41145

Aryalox AB41011




Toppan GL -RD0.10.2





BOPET plus barrier precoat1.150.7515.65.82

BOPET with Michelman product in line0.6240Our coating constructions

BOPET with michelman product applied in line and then metallised0.083

BOPET with michelman topcoat over barrier precoat0.0010.470.030.44

BOPET with EKF1402 primer under Alox with a further topcoatingTBDTBD

BOPET :AlOx: MC95 acrylic1.630.961.830.96

BOPET with EXP0915.E over ALOx0.630.50.420.52


Kurarister PET0.320


Actual commercial lamination using Michelman coating0.20.6

12 micron film

Performance sheet

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BOPET film

BOPET with Michelman product in line

BOPET with michelman product applied in line and then metallised

BOPET with michelman topcoat over barrier precoat

Besela PET

Kurarister PET

PVDC coated PET

BOPET plus barrier precoat

Actual commercial lamination using Michelman coating

Costing sheet

Barrier resultsOxygen barrierMVTRPrecoat weight (gsm)Topcoat weight (gsm)Typical cost addition of coatingManufacturing cost

Substrates0%RH, cc/m2/day38°C 90%RH, g/m2/day$ per square metre (based on base price)$ per square metre

BOPET with EKF1402 in line4400.040.002592

BOPET with EKF1402 in line and metallised0.0830.0400.002592

BOPET with EKF1402 primer under ALOx0.081.500.50.00324

BOPET with EKF1402 topcoat over ALOx0.0010.4700.50.00324

BOPET with EKF1402 primer under Alox with a further topcoatingTBDTBD0.040.50.0034992

BOPET with MC95 over AlOx1.630.9400.64

BOPET with polyester over AlOx0.630.501

BOPET with AlOx only1.150.75

BOPET film

Metallized BOPET Film0.0896

AlOx coated film1.51.50.0973

SiOx coated film0.60.60.1883

Prices usedBase pricevolume price based on 250tpa

EKF14026.48 USD/Kg

MC95

Polyester

1 m2 = 1550 in2

0.0016722581$/msi @0.04 dry gsm

$0.0045/m2, 0.0029/msi @0.07 gsm

MVTR 38°c, 90%RH(g/m2/day)

AlOx and EKF1402 interaction

AlOx and EKF1402 interaction

Experimental set upOxygen transmission (cc/m2/day)Comments

Oxygen sideSubstrateStructureCarrier gas at humidty0%RH90%RH

at 0%RH

12µm PETPET/AlOx2.662.46bobst sample

23µm PETPET/EKF14020.2436.3without alox - pilot coated

12µm PETPET/AlOx/EKF14020.10.24With MF crosslinker- overcoated bobst sample

12µm PETPET/AlOx/MFP8880.140.12Without MF crosslinker- overcoated bobst sample

12µm PETPET/AlOx/ME90508P0.20.08Conventional PVOH

Tg

sampleCure temp (°C)Tg (°C)Comment

G-Polymer plus adhesion enhancer125°c69.2No cure

G-Polymer plus adhesion enhancerplus Xlinking package125°C72.9Incomplete cure



G-Polymer plus adhesion enhancerplus Xlinking package170°C90.4Complete cure

Barrier with humidity

Sample PreperationPrimermetallisation?Oxygen barrier (cc/m2/day/atm)

0%RH90%RH

Pet- offllineG-Polymer plus adhesion enhancerNo0.419

PET-offlineG-Polymer plus adhesion enhancerplus Xlinking packageNo0.44.5

PET- onlineG-Polymer plus adhesion enhancerplus Xlinking packageNo0.61.7

PET- onlineG-Polymer plus adhesion enhancerplus Xlinking packageYes0.080.04

Sample PreperationPrimermetallisation?Oxygen barrier (cc/m2/day/atm)Dry coat weight/gsm

0%RH90%RH

PET-offlineEKF1402.ENo0.44.50.3

PET- onlineEKF1402.ENo0.61.70.07

PET- onlineEKF1402.EYes0.080.040.07

0.3 - 0.5 dry gsm

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Summary: Coating for BOPET

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TransparentOxygen Barrier

Primer for Metallization

Functional Inline PET

Coating

Aqueous0.05 – 0.10 micronsRecyclableSustainableStrong O2 BarrierEasy to coat – one componentFood Compliant Excellent adhesionConverter FriendlyMetalizable

Multi-functional

New Building Block Structure for higher performance and/or

lower cost

Can we eliminate lamination?

Can we eliminate PVDC?

Where are alu foil structures over-

engineered?

Improving AlOx Coatings

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Experiment

• In cooperation with BOBST• Objective - Improve the performance of

AlOx coating especially in durability and retention of barrier properties through converting operations

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Ceramic Clear Barrier Coatings

Advantages over polymer based transparent barrier films (PVDC, EVOH) No barrier loss at high relative humidity Thickness in nanometer range – other technologies in the

micron range Economical raw materials consumption and cost Chlorine free

Advantages of metalized polymer films Product Visibility Microwavable Suitable for met detection

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Barrier Retention

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AlOx Coated PET-Vacuum Metallization

• Bobst K5000 Vacuum Metallizer

• AlOx deposition (10nm) onto

12µm BOPET film

• Speed 720m/min

• Widths 1250mm to 3650mm

• OTR

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Topcoating – AlOx Coated PET Film

Experimental• Bobst CL 850D coater/laminator

- modified for AlOx suitability • 12 micron AlOx coated BOPET• 10 nm AlOx coating• Rotogravure coating application• Coating speed 250 m/min

• Water based topcoats• Coat weights between 0.5 to 1.5

grams/m2 DRY • Three different coating chemistries

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RESULTS• Topcoats successfully applied

without damaging AlOₓ• Barrier performance post-

topcoating depends on topcoat chemistry

• Barrier topcoat C improves OTR and WVTR significantly

• Barrier properties of topcoat material are important for barrier enhancement

Topcoating – AlOₓ coated PETBobst – CL 850D

0

0.5

1

1.5

0.0 0.5 1.0 1.5 2.0 2.5

WVT

R**

[g/(m

² d)]

OTR* [cm³/(m² d)]

AlOₓ PET + Topcoat A

AlOₓ PET + Topcoat B

AlOₓ PET + Topcoat C

AlOₓ PET (no topcoat)

*OTR 23 °C, 50 % RH**WVTR 37.8 °C, 90 % RH

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0.5-0.7 gsm dry

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Barrier Through Converting Processes

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OTR WVTR Conversion Process Structure cm3/(m2 d) g/(m2 d)

AlOx coatings PET/AlOx 1.0 -1.5

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Gelbo Test Results

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

0 5 10 15 20 25

Tran

smis

sion

(eith

er O

TR o

r WVT

R)

Gelbo Flex Number

Coating B OTRCoating C OTRCoating B WVTRCoating C WVTR

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Acknowledgments

• To BOBST– Nick Copeland – R&D Director– Dr. Carolin Struller – Research Associate

• To Michelman– Robin Cooper – Strategic Program

Manager

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Next Steps – Whole ProgramBOPET Coatings and AlOx Coatings

• Build Prototypes – film/convert/fill/shelf life• Offline comparison to inline coating• Work with BOPP film • Retort Testing

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THANK YOU! Vince ZabrockiGroup Marketing Manager Printing & [email protected]

Slide Number 1AgendaSlide Number 3ObjectiveSlide Number 5Michem® Flex Barrier 3510Slide Number 7Barrier Coating CharacteristicsSlide Number 9Slide Number 10Slide Number 11Slide Number 12ExperimentCeramic Clear Barrier CoatingsSlide Number 15Barrier RetentionAlOx Coated PET-Vacuum MetallizationTopcoating – AlOx Coated PET FilmSlide Number 19Barrier Through Converting ProcessesGelbo Test ResultsAcknowledgments Next Steps – Whole Program�BOPET Coatings and AlOx CoatingsSlide Number 24

Documents

Unique High Oxygen Barrier Coatings for Food Packaging · 2018-10-08 · Unique High Oxygen Barrier Coatings for Food Packaging . Flexible Packaging Conference 2016. October 10, 2016