5-Santosh Joshi Latest Trend in Flexible Packaging.pptx

material packaging related documents

1. TECHNICAL SESSION 15th th & 16 th Dec - 2023 Latest trend in Flexible packaging / printing / laminate structures / different adhesives and extrusion lamination process Presenter : Santosh Joshi Co-Presenter : Saurabh Singh Expert : Mr. M.Murakami

2. PACKAGING INDUSTRY Packaging is now a much wider concept than we ever use to think about packing . It’s a scientific selection keeping in mind the PACK + AGE = PACKAGE concept. The age factor is related not only to the enhanced age of the pack but also to the enhanced age of the content packed inside the package.

3. PACKAGING INDUSTRY Earlier days Now

4. PACKAGING INDUSTRY T he packaging industry is driven by the factors such as R ising population, Increasing income levels, and Changing lifestyles are anticipated to drive consumption across various industries leading to higher demand for packaging product solutions . Top of that due to COVID-19 outbreak - as the country was under lockdown resulted in a sudden boom in the online food sector and packed food products. The market size of packed food products drastically increased

5. PACKAGING INDUSTRY The global flexible packaging market size is expected to reach USD 264.9 billion by 2030, growing at 4.8% CAGR during the forecast period.

6. PACKAGING INDUSTRY The flexible packaging market in India is estimated to grow at a CAGR of 12.6% between 2022 and 2027. 

7. Why Flexible Packaging is Popular ? The secret of its success lies in C heaper packaging cost , E asy to handle , E asy to store , E asy to transport , and most importantly easy to pack smaller quantity to make product available to poor section of society as well.

8. Why Flexible Packaging is Popular ?

9. Rigid to Flexible

10. PACKAGING TREND

11. CURRENT TECHNOLOGY IN CONVERTING INDUSTRY High Speed Printing Machines :- Now a day, printing m/c’s of high speeds are available. Due to High speed machines, convertors are able to increase productivity with saving in man hours, electricity, inks, solvent etc. in today’s competitive market.

12. Advanced vision technology is used to identified the defect and blow the alarm and light to inform the operator about the defect such as lines ,streaks scum etc. Working mechanism : This device consists one or more high speed line scan cameras which capture image of entire print line by line and displayed as a complete pattern on the monitor. AVT /Optical Inline Inspection Device

13. Benefits of Optical In-line Inspection Device 100% inspection and 100% documentation. No unrecognized waste, guaranteed product safety. Minimization of wastage due to defects. Overcoming the limits of human eyes. Maximization of yield with improved quality.

14. Auto Registration Controller (ARC) system Advantages : - ARC ensures higher registration accuracy (+/- 0.01 mm lengthwise and +/-0.02 mm side wise). ARC system helps to achieve higher machine speed. Wastage due to miss registration is reduced drastically. ARC system helps to achieve registration of colors in quick time after start up which reduces setting wastage in a great extent. After splicing quick reestablishment of registration of colors can be achieved which reduces splicing wastage.

15. Online inspection

16. CHANGE IN TRENDS IN CONVERTING INDUSTRY AUTO VISCOSITY CONTROLLER :- Helps to keep press running inks viscosity consistent during print run. The evaporation of solvent in the ink causes rise in ink viscosity. As the ink thickens, the load on the pump is also increased. By sensing viscosity through the loads placed on the diaphragm pump , the pump cycles getting fast.. INK CHILLING SYSTEM :- This helps to keep ink temperature at normal during print run.

17. CHANGE IN TRENDS IN CONVERTING INDUSTRY AUTO VISCOSITY CONTROLLER

18. Ink Handling Process

19. CHANGE IN TRENDS IN CONVERTING INDUSTRY MACHINE RELATED CHILL ROLLERS : - For high speed printing machines, there is chill roller for each unit. Use of chilled roller is to bring down printed web temperature which is coming thro’ drier to normal temp. before reaching next unit. Chill Roller

20. Tray trolley Design Specially designed Cart facilitates ease for insertion and extraction from the printing station. To carry out loading and unloading of gravure cylinder there is a lifting system on board on the cart, which consist of hydraulic piston, levers etc. Possibility to remove only the inking system, leaving the printing cylinder in the printing station Possibility to remove only the printing cylinder, leaving the inking system in the printing station Possibility to remove the printing cylinder together with the inking system at the same time

21. Tray trolley Design

22. Trolley Design

23. CHANGE IN TRENDS IN CONVERTING INDUSTRY INK METERING/FURNISHING ROLLER :- To overcome ink splashes issue at high speeds and uniform metering of ink on the cylinder. Furnish roller is specialized rubber roller (with very high solvent resistance to strong gravure ink solvents) which transfer and meters the ink from tray to gravure cylinder The ratio of furnisher roller speed can be adjusted based on press speed

24. Ink Furnishing Roller

25. CHANGE IN TRENDS IN CONVERTING INDUSTRY Unwinding & Rewinding unit: Double shafts turret type unwinding and rewinding unit In high speed printing machine, Auto splicing unit is available at unwinding and Rewinding Helps to reduce machine stoppages at the end of substrate rolls or on splicing in the middle. With this auto splicing system splicing of substrate can be done at full operating speed with excellent control on registration. . Hence , reduces un-printed & printed wastage

26. Unwinder / Re-winder Unit

27. CHANGE IN TRENDS IN CONVERTING INDUSTRY ESA :- Electrostatic Assist (ESA) was developed to improve the transfer of ink to the substrate. The electric field generated by the ESA between cylinder and impression roller (apprx.-300 to 1000 volts) cause the ink to be pulled completely out of cell and transfer to substrate.

28. CHANGE IN TRENDS IN CONVERTING INDUSTRY Electrostatic repulsion generated between the ink and the gravure cylinder is alleviated by electrostatic attraction between the ink and the impression roller ,which lies just beyond the substrate. The ink is then pulled electrostatically onto the substrate. After ESA Before ESA

29. ESA

30. Advantages of Electrostatic Print Assist (ESA): Optimum ink transfer to the substrates can be achieved. Dot missing issue can be completely eliminated. Optimal print results can be achieved even on low quality papers, board and plastic materials. Reduced impression roller pressure ensures longer life of impression rollers. Faster production speed with consistently best print results Built in antistatic safety bars before and after each print station ensure complete dissipation of static charge.

31. Importance of Laminates in Flexible Packaging In Flexible Packaging, the use of a single material may not satisfy all of the properties demanded of the product in many applications Laminate is a composite consisting of two or more layers of material may provide the desired performance. Laminate is actually a composite of various substrates (polymeric films / paper / Al foil), prepared with the help of various bonding materials. It is exclusively used as flexible packaging material

32. Importance of Laminates in Flexible Packaging LAMINATES has been growing at very faster rate over past two decades Some new advanced application has given a non-comparable edge to flexible packaging. Boil in bags, Retort grade application, Deep freeze packaging, Wine packaging etc. are few examples. Hence, before selecting a laminate structure, we must refer to the following aspects:

33. ROLE OF LAMINATE STRUCTURE IN PACKAGING MOISTURE BARRIER : Products like biscuits, chocolate, coffee etc use to get contaminated by moisture, IMC (Internal Moisture Content :- level of moisture in product) and CMC (Critical Moisture content :- level of moisture content at which degradation of product starts) should be available for the selection of laminate to maintain the ERH( Equilibrium related humidity) which is a stage of product where no loss or moisture is attained.

34. ROLE OF LAMINATE STRUCTURE IN PACKAGING Water Vapour Transmission Rate (WVTR) of laminate is studied to suggest a suitable laminate structure. It measures the rate of water vapour passes through a laminate as a function of time (ASTM F 1249) Temperature and relative humidity affects WVTR and hence the unit is grams/100 sq.inch (or 1 sq. meter)/24 hrs at 38°C and 90% humidity Higher the WVTR, poor is the laminate structure for moisture sensitive products

35. ROLE OF LAMINATE STRUCTURE IN PACKAGING B. OXYGEN BARRIER: It protects fatty foods such as potato chips from becoming rancid. The Oxygen Transmission Ratio (OTR) test provides the value of steady rate of transmission of oxygen through a laminate. The unit of OTR is CC/100 sq. inch (or 1 sq. meter)/24hrs. Temperature and relative humidity of gas is very important on both side of sample is important. This test method is described in ASTM D1434

36. ROLE OF LAMINATE STRUCTURE IN PACKAGING C . LIGHT BARRIER : Oil rancidity is accelerated in case of fatty foods / fats / oils in presence of oxygen from UV light. It may cause vitamin degradation as well D. Grease / Fat Resistance ; Some times, the product containing fat / grease may affect adversely the packaging material itself during storage and results in ink removal and delamination.

37. ROLE OF LAMINATE STRUCTURE IN PACKAGING E . Quantity of Material to be packed : Thickness of laminates to provide adequate stability of the pouch depends on the quantity of the product to be packed. F. Storage condition and duration : While selecting a laminate structure the market duration is also considered. Some products are fast moving, some are slow moving and some are displayed in direct sunlight.

38. ROLE OF LAMINATE STRUCTURE IN PACKAGING G. Convenient Pouches : Pouches are designed such so they are easy to use like: easy tear, Stand-up pouches, Zipper pouch and also for directly use for boil and retort pouch. H. Aesthetics : The laminate structure is largely guided in Indian market on the appearance of the pouch and the converter keep on trying different types of structure to woo customer on its aesthetics appeal as well. I. Cost Economics : The feasibility of Packaging depends on the cost it involves and the market acceptance.

39. Lamination Processes Specific processes differ primarily by how the adhesive/coating is applied and converted from a liquid to a solid. There are several laminating processes that can be easily adapted to production. These are generally classified as either Adhesive lamination or Extrusion coating/lamination.

40. What is laminate ?? Outer Layer Third Layer Innermost Layer Adhesive Layer Ink Layer Second Layer

41. LAMINATION PROCESSES

42. DRY LAMINATION OR SOLVENT BASE PROCESS In the Dry bond laminating process a liquid adhesive is coated on a substrate, dried with heat and airflow, and then laminated to a second substrate via a heated compression nip.

43. WET LAMINATION OR SOLVENT BASE LAMINATION PROCESSES In the Wet bond laminating process liquid adhesive is applied to a substrate, then immediately laminated to a second substrate via a nip followed by drying with heat and air flow (one substrate must be porous to allow evaporation of water or solvent).

44. LAMINATING ADHESIVES In Lamination process - Laminating adhesives are used to combine multiple layers of films, foils and/or papers to meet performance requirements from general to medium and to high performance packaging In addition to holding the substrates together, the adhesive might have to perform certain other functions that are necessary to the success of the final product. Every day the food and pharma industries are developing new products that require packaging having good heat resistant, humidity resistant, chemical resistant, UV resistant or retortable ...

45. LAMINATING ADHESIVES APPLICATION PERFORMANCE Detergent & medical application Ready-to-eat meal, Pet food High heat & moisture resistance for Retort Application Fruit Juice Packaging Coffee Packaging Good adhesion on film/film and film/foil Good product resi. And moisture resistance for hot fill and pasteurization Fresh produce Frozen foods Snake Food Packaging Good adhesion on plastic and metallized film Easy Handling Variety of end-use Application Higher Shear strength

46. LAMINATING ADHESIVES General Purpose Adhesives : General Purpose laminating Adhesives are used for packaging applications where there is no exposure to extreme heat or processing.(Snake food & confectionary) Good chemical resistance, Due to the flavouring, packages such as peppermint candies or salty snacks need chemical resistance. Structures :- OPP/CPP, OPP/PE OPP/MET CPP, OPP/met OPP, PET/MET CPP, PET/MET PET/PE PET/PE, PET/CPP

47. LAMINATING ADHESIVES Medium Performance Adhesives :- Medium Performance Laminating Adhesives are used when the package will be exposed to some heat, and/or some relevant chemical resistance is needed due to the nature of the product being packed.(Sauces/liquid soaps/juices/meat/cheese/coffee pack etc) Good adhesion on film/film and film/foil Good heat and product resistance Good moisture resistance for hot fill and pasteurization Structures PET/AL/PE PET/PE Nylon/PE

48. LAMINATING ADHESIVES High Performance Adhesives :- High Performance Laminating Adhesives are used when the package is exposed to high heat (retort or sterilization) and/or the package contents are aggressive materials.(Hot Fill bags/retort) Excellent moisture resistance for hot fill and pasteurization Meet FDA requirements Structures :- PET/AL/CPP PET/AL/OPA/CPP PET/CPP

49. LAMINATING ADHESIVES Typical adhesives used in these laminating processes are :- Water born Adhesive Solvent based Adhesive Hot melt or reactive (100% solids).

50. WATER BORNE LAMINATING ADHESIVES Waterborne laminating adhesives are commonly formulated from natural occurring materials, such as Dextrins , Sodium silicates and natural rubber, as well as synthetic organic polymer emulsions based on vinyl acetate, acrylic, polyurethane, etc. The naturally occurring adhesives are more commonly used for labelling and other packaging applications; whereas the synthetic emulsions are mostly used for either wet or dry laminating. Waterborne laminating adhesives have become popular mainly due to governmental pressure for laminating converters to reduce VOCs.

51. WATERBORNE LAMINATING ADHESIVES Advantages with Water based Adhesives :- General to medium performance adhesive available Acrylic emulsions offer a low cost adhesive with moderate performance properties. Excellent gloss and clarity in laminates. Most suitable for short lamination run, lamination of metallised structure and film-paper lamination User friendly-Easy mixing, no viscosity adjustment Superior economics compare to solvent base Odour -free laminates Most commonly used Water Base Adhesive is ROBOND-L90 Runs on existing dry laminators with minor modification.

52. WATERBORNE LAMINATING ADHESIVES

53. SOLVENT BASED LAMINATING ADHESIVES Solvent-borne laminating adhesives can be formulated from many of the same polymers described for waterborne systems G enerally found in dry laminating applications. The speed of which the solvent evaporates is a significant benefit in most production operations. Because of the lack of emulsifiers and surfactants, the moisture resistance of solvent-based adhesive is generally superior to waterborne systems.

54. SOLVENT BASED LAMINATING ADHESIVES One of the most popular solvent based laminating adhesives is polyester. These materials provide excellent adhesion to polyester film and very good adhesion to many other polymeric films and metal foils. The reaction of the hydroxyl of the polyester with a poly- iso - cyanate produces a cross-linked adhesive network with very good thermal and chemical resistance. The polyester laminating adhesives have high green strength, are fairly fast curing, and well suited to fast production processes.

55. SOLVENT BASED LAMINATING ADHESIVES The Laminating Process : - • Mixing the adhesive components and solvent. • Applying the correct weight of adhesive. • Removing the solvent. • Combining (nipping) the two webs. • Re-reeling the laminate.

56. SOLVENT BASED LAMINATING ADHESIVES

57. SOLVENT BASED LAMINATING ADHESIVES APPLICATION WEIGHT OF ADHESIVE :- The amount of adhesive weight will depend on: – Amount of Printing ink. – End use Normally, adhesive coating weight should be higher than Ink GSM. Most commonly used Solvent Base Adhesives are , CAC 2511 CAC 1580 BOSTIK EPS 7280 / KN 75 ADCOTE 548D

58. SOLVENT LESS ADHESIVES Definition: An adhesive with 100% Solids and delivered without solvents. It can be used as it is without any dilution. The need for Solventless adhesives was felt due to: Increasing Solvent Cost Scarce and rising cost of Energy resources Environmental regulations

59. SOLVENT LESS ADHESIVES The options available to convertors were : High Solids Adhesives to be used. Solvent recovery systems. Solvent incineration systems. Aqueous Adhesives. 100% Solids Adhesives. The 100% Solids adhesives option was the best alternative as it eliminated solvent emissions, need for solvent recovery systems, lower energy cost as it eliminated need of long drying chambers.

60. SOLVENT LESS ADHESIVES Why Solventless Adhesives • No Solvents contained or used for dilution. • Lowers Energy cost as long drying ovens are not required. • No retained solvents due to adhesive. • No need for Solvent recovery systems. • Works at lower adhesive coat weights. • Faster line speeds. • Favourable health and safety characteristics. • Promotes the Green Image of Packaging.

61. SOLVENT LESS ADHESIVES Disadvantages – Have low initial bond strengths as compared to the solvent based products. – Need sensitive tension controls and rewind systems . – Require Meter , Mix & Dispense (MMD) system to handle the adhesive.

62. SOLVENT LESS ADHESIVES Types of Solvent-less Adhesive :- Single component Adhesives :- They are used generally for Film, Foil to Paper application. They are high viscosity products and need to be preheated for 4-5 hrs at 65 - 70 deg C before use. They need high applicator roller temperatures of 80–90 deg.C for processing. They cure in the presence of moisture present in the atmosphere, on the film surfaces or in the film itself.(Nylon & PVOH)

63. SOLVENT LESS ADHESIVES 2. Two Component Adhesives :- – The cure is the result of a chemical reaction and hence not moisture dependent. – There are types available which can be applied at room temperatures and also at elevated temperatures. – They have much better heat and chemical resistance as compared to the single component type.

64. SOLVENT LESS ADHESIVES Basic Chemistry :- The reaction between a Polyol and a Di- isocyanate gives Polyurethane OH-R-OH + OCN-R’-NCO ----> --[-CO-NH-R’-NH-CO-R-O--]- n A typical Polyurethane will consist of many such building blocks to form a large molecular chain.

65. SOLVENT LESS ADHESIVES Solvent Less Lamination Process :- Adhesive dispensed by MMD. Applying correct weight of adhesive. Combining (Nipping) the two webs. Re-reeling the laminate.

66. SOLVENT LESS ADHESIVES SOLVENT LESS LAMINATION PROCESS Following are the areas of critical importance:- – Mixing unit – Application unit. – Heating of the rollers – Quality of the rollers – Adhesive distribution

67. SOLVENT LESS ADHESIVES - Level control in the nip – Adjustment and control of the application weight – Cleaning of the application unit – Nip temperature – Laminating pressure – Winding tension – Finished product stock

68. SOLVENT LESS ADHESIVES IMPORTANT FACTORS TO BE CONSIDER DURING APPLICATION :- Application Roll Temperature – Temperature controls the viscosity of adhesive – Check the temperature in the “Dam”. Do not rely on the temperature settings – Too high application temperature • Too thin adhesive - hard to achieve coating weight, shorter pot life – Too low application temperature • Too thick - poor flow & appearance at correct coating weight

69. SOLVENT LESS ADHESIVES Transfer (sleeve) & impression roller hardness – Recommended to be 80-90 shore hardness – Softer rubber will result in poor appearance. Cleanliness - Best lamination appearance is achieved with an application system with smooth clean rollers. – Keep rollers(transfer/impression rollers) clean and free from any surface defects. e.g. dried adhesive – Watch for cured adhesive abrading the chrome from edges of cylinder. Do not use knives or scrapers on steel cylinders

70. SOLVENT LESS ADHESIVES APPLICATION WEIGHT OF ADHESIVE :- The amount of adhesive weight will depend on: – Amount of Printing ink. – End use The three controlling factors include: – The dosing roll gap. – Speed of transfer roller. – Viscosity of adhesive.

71. SOLVENT LESS ADHESIVES Most commonly used Adhesives are :- CAC 7728/6028 Morfree 698A/C 79 Brilliant S641 / S400

72. SOLVENT LESS ADHESIVES Coating Weight Guidelines Unprinted Webs - 1.3 - 1.6gsm Lightly Printed Webs - 1.6 - 1.8gsm Heavily Printed Webs - 1.8 - 2.5gsm

73. APPLICATION Food Packaging Wall Paper Wrapping Paper Furniture Laminates Greeting Cards Magazines

74. EXTRUSION COATING/LAMINATION E xtrusion lamination - a molten curtain of two or more thermoplastic materials are extruded separately and combined either internally in the die or immediately after leaving the die. Is applied as an adhesive layer between two substrates which is followed by nipping to form a laminated structure. Here, Conventional adhesive is not used in this process .. It can apply by (1) PE Extrusion and (2) PP extrusion The extrusion process is generally preferred over the coating / laminating process for high volume production

75. LAMINATION PROCESSES

76. EXTRUSION COATING/LAMINATION The substrates may be- Paper Paper board Polyester film Polypropylene film, Aluminum foil Woven fabric, etc.

77. EXTRUSION LAMINATION PROCESSES

78. EXTRUSION COATING PROCESSES

79. Working mechanism of PE & PP tie layer Establishment of Adhesion

80. Mechanism of Chemical adhesion In case of PE extrusion - first partial oxidation of PE molecules of tie layer takes place in presence of aerial oxygen during it’s stay between nip and die of extruder. This gap between extruder die and nip is called Air gap. This oxidation develops many reactive sites which are involved in chemical reaction with the reactive sites available in the polymer chains of associated substrate.  Air Gap

81. Mechanism of Chemical adhesion in PE Extrusion Now development of reactive sites in associated substrates for chemical reaction with tie layer is also equally important. For printed substrate PRIMER coating is done over ink layer to generate the reactive sites.Commonlly used Primers are Mica 131 X, Mica H722, Perfac AC110, Perfac AC38 , Coim 8099 Moreover some additive resin is also mixed with PE resin prior to extrusion which can incorporate reactive sites in PE tie layer. Like, Nucryl , Lotader , Tefmer ( 5% to 15% according to BS require

82. Mechanism of Chemical adhesion in PP Extrusion In case of PP extrusion - normally there is no scope of oxidation of PP tie layer during it’s stay at air gap as the molecular structure and the additive present in PP for it’s heat resistance make the polymer inert to aerial oxygen. So in case of PP extrusion, PP resin has to be mixed with 20% to 30% LDPE which undergo partial oxidation and generate reactive sites in tie layer which will involve in chemical bond formation with polymers of associated substrate. For unprinted second substrate corona treatment does the job. Corona treated PET type, PP type and PE type films are to be used for lamination

83. EXTRUSION COATING/LAMINATION Use of Extrusion coating Snack pouches Biscuits Woven sack bags (Rice bag/Atta bag) Tetra-Pack

84. GOOD BOND STRENGTH FOR VARIOUS STRUCTURE

85. BOND STRENGTH STRUCTURE BOND STRENGTH (GMS/15MM) 1 PLAIN PET/PE ≥ 200 or PET Tear 2 Plain PET/MET CPP ≥ 125 or Metal transfer 3 Corona pet/PE ≥ 250 or PET Tear 4 Chem.CTD PET/PE ≥ 300 or PET Tear 5 Chem.CTD PET/Al-Foil/PE >300 or Lower with PET Tear 6 Treated BOPP/W/op Treated BOPP ≥ 100 7 BOPP/MET BOPP 80-100 8 BOPP/Holographic MET BOP P 70-80 with METAL Transfer BOND STRENGTH IN SOLVENT BASE/SOLVENT LESS

86. BOND STRENGTH STRUCTURE BOND STRENGTH (GMS/15MM) 1 CT PET/INK/MICA PRIMER/ PE EXTRU. /MET/PET 110-120 GMS WITH FILM BREAK 2 BOPP FILM/INK/PRIMER /PE EXTRU. /MET PET 90-100 GMS OR FILM BREAK 3 BOPP FILM/INK/PRIMER /PE EXTRU. /MET BOPP 90 GMS OR TEAR 4 BOPP FILM/INK /PP EXTRU ./PP FABRIC 180-190 GMS BOND STRENGTH IN PP/PE EXTRUSION

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