www.bobst.com 2016 AIMCAL Web Coating & Handling Conference USA The Peabody, Memphis, Tennessee, 9 th – 12 th October 2016 Conversion of aluminium oxide coated films – From a single layer material to the finished & filled pouch Carolin Struller, Manchester Metropolitan University & Bobst Manchester Peter Kelly, Manchester Metropolitan University Nick Copeland, Bobst Manchester
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2016 AIMCAL Web Coating & Handling Conference USAThe Peabody, Memphis, Tennessee, 9th – 12th October 2016
Conversion of aluminium oxide coated films –From a single layer material to the finished & filled pouch
Carolin Struller, Manchester Metropolitan University & Bobst Manchester Peter Kelly, Manchester Metropolitan UniversityNick Copeland, Bobst Manchester
Slide 2
Outline
Introduction Motivation and market potential Previous work & findings AlOₓ conversion project
Topcoat development Conversion trials Machine platforms Pouch design & structure Barrier through conversion Flex-durability & barrier retention on elongation Laminate bond strength
Motivation and market potentialMarket size and growth
Allied Development Corp.Applied Market information Ltd.C. Reardon (AWA) AIMCAL Europe 2014
Annual growth rate
0
10
20
30
40
50
60
70
80
90
100
200 300 400 500 600 700 800
Tran
smis
sion
[%]
Wavelength [nm]
12 μm PET AlOₓ
12 μm PET (uncoated)
12 μm PET metal 2.0 OD
Global market volume UV barrier properties: metallised PET vs. AlOₓ coated PET(chart based on metric tons)
CAGRAluminium foil < 1 %
PVdC coated films Negative growth
AlOₓ & SiOₓ coated films 7 – 8 %Metallised films 4 – 5 %
Alumnium foil
EVOH (coextruded & coated)
PVdC coated films
High barrier metallised films
AlOₓ & SiOₓ coated films
Slide 7
Summary: Previous work/resultsSingle layer AlOₓ & initial conversion work
AFM
TEM
SEM
Surface energy
Characterization of: Base film surface defects and surface chemistry
and impact on barrier performance AlOₓ and base film surface topography
AlOₓ thickness, adhesion & surface energy
Stretch durability of AlOₓ coated films AlOₓ coating composition/stoichiometry
Lamination of non-printed/non-topcoated material Slitting of AlOₓ coated material
Slide 8
0
0.2
0.4
0.6
0.8
1
1.2
0.0 1.0 2.0 3.0W
VTR
[g/(m
² d)]
OTR [cm³/(m² d)]
AlOₓ PET laminated with CPP
Shaded area: AlOₓ PET (before lamination)
OTR
23
°C, 5
0 %
RH
WVT
R 3
7.8
°C, 9
0 %
RH
AlOₓ coated PETAlOₓ coated BOPPRESULTS Lamination
Summary: Previous work/resultsSingle layer AlOₓ & initial conversion work
0
5
10
15
20
25
30
35
40
45
50
BOPP/ALOₓ BOPP/ALOₓ/AD/BOPP
OTR
cm
³/(m
² d)
Slide 9
AlOₓ conversion projectProject aims/deliverables
Overall Project Aim: Offer the film producer and/or the convertor part or full turn-key conversion solutions utilising AlOₓ transparent barrier. This involves both the machine platforms and the associated raw materials (films, ink, adhesives, coatings etc.).
Drivers for project: Environmentally friendly packaging ‘chlorine free’/ sustainable packaging, cost reduction (triplex to duplex solutions), transparency/ product visibility, microwaveable, improved shelf life.
Project Funding: KTP – Innovate UK (formerly TSB) & Bobst Manchester
Duration: 3 years
Start Date: Oct 2013
Vacuum metallizer
CI flexo press
Gravure press
Laminating machine
Slide 10
AlOₓ conversion projectProject team
Industrial Project PartnersEquipment Providers: Bobst Manchester Ltd – Metalliser platform
AlOₓ conversion trialsBarrier retention on elongation – Gravure printing
EXPERIMENTAL & RESULTS Characterization of stretch durability Stretching of laminate to a predefined elongation using tensile tester Assess capability of laminated film to withstand downstream processing
0
2
4
6
8
10
0 1 2 3 4 5
OTR
[cm
³/(m
² d)]
Elongation [%]
Barrier topcoat
Protective topcoat
0
2
4
6
8
10
0 1 2 3 4 5
WVT
R [g
/(m² d
)]Elongation [%]
Barrier topcoat
Protective topcoat
OTR
23
°C, 5
0 %
RH
WVT
R 3
7.8
°C, 9
0 %
RH
Slide 35
AlOₓ conversion trialsLaminate bond strength – Gravure printing
RESULTS Laminate bond strength investigations (conducted by project partner Printpack)
Bond strength
g/inch N/(15 mm)
Barrier topcoat
261 ± 13 1.5 ± 0.1
245 ± 8 1.4 ± 0.1
Protective topcoat
741 ± 84 4.3 ± 0.5
589 ± 169 3.4 ± 1.0
Picture source: ISO 11339
Slide 36
AlOₓ conversion trialsBarrier through conversion – Flexographic printing
0.0
0.2
0.4
0.6
0.8
1.0
1.2
PET/ALOₓ TOPCOATING PRINTING
OTR
cm
³/(m
² d)
OTR in cm³/(m² d) @ 23 °C, 50 % RHWVTR in g/(m² d) @ 37.8 °C, 90 % RH
RESULTS Barrier topcoat
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
PET/ALOₓ TOPCOATING PRINTING
WVT
R g
/(m² d
)
OTR improvement by factor > 10
WVTR improvement by factor ≈ 2
Slide 37
AlOₓ conversion trialsBarrier through conversion – Flexographic printing
OTR in cm³/(m² d) @ 23 °C, 50 % RHWVTR in g/(m² d) @ 37.8 °C, 90 % RH
RESULTS Protective topcoat
0.0
0.2
0.4
0.6
0.8
1.0
1.2
PET/ALOₓ TOPCOATING PRINTING
OTR
cm
³/(m
² d)
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
PET/ALOₓ TOPCOATING PRINTING
WVT
R g
/(m² d
)
OTR improvement to < 1 cm³/(m² d)
Slide 38
Summary & conclusions
Development of protective off-line topcoats for AlOₓ coated PET film (protective topcoat and barrier topcoat)
Successful application of off-line topcoat on AlOₓ-optimised industrial coater Full conversion of AlOₓ coated PET film to the final package, using standard
industrial printing, laminating and pouch making equipment Barrier maintained successfully throughout conversion chain (across web width) Laminate shows very good flex & stretch durability (barrier topcoat) Final laminate fulfils market requirements in terms of bond strength
Slide 39
Acknowledgements
BOBST Italia SpA and BOBST Bielefeld GmbH Manchester Metropolitan University Printpack Inc. Michelman SARL
Collaborative work also presented in: ‘Unique High Oxygen Barrier Coatings for Food Packaging’,Vince Zabrocki, Michelman, SPE/FlexPackCon, Monday 9/10/2016, 2:30 pm – 3:00 pm
Flint Group Italia SpA& Flint Group Germany GmbH
Dow/Rohm and Haas Italia Srl Innovia Films Ltd RDM Test Equipment Ltd Innovate UK
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Thank You!
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