1 Materials innovation coupled with latest extrusion technologies to advance plastics packaging circularity Presented by: Luis Zalamea, Ph.D. Dow Europe GmbH Switzerland 16 TH TAPPI EUROPEAN PLACE CONFERENCE 2 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4 Design for Recyclability MDO Process Fundamentals Property Developent and Trade-offs Application Development Outlook and Conclusions Agenda
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1 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Materials innovation coupled with latest extrusion technologies to advance plastics packaging circularity
Presented by:
Luis Zalamea, Ph.D.Dow Europe GmbH
Switzerland
16TH TAPPI EUROPEAN PLACE CONFERENCE
2 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Design for Recyclability
MDO Process Fundamentals
Property Developent and Trade-offs
Application Development
Outlook and Conclusions
Agenda
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3 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Design for Recyclability
MDO Process Fundamentals
Property Developent and Trade-offs
Application Development
Outlook and Conclusions
Agenda
4 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Technologies to enable recyclable packaging
Barrier adhesive
Coating technologies
Process solutions
Polyamide substitution
Plasma coating & metallization
All-PE structures
all
PEReverse spout sealing
RecycleReady & Polymer
Compatibilization
Alternative sustainable packaging
designs
Film orientation
technologiesMDOPE / BOPE
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5 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Innovation Model: Engagement Across the Value Chain
6 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Design for Recyclability
MDO Process Fundamentals
Property Developent and Trade-offs
Application Development
Outlook and Conclusions
Agenda
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7 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
MDO Process Fundamentals
• MDO technology has been around for a very long time: more than 15 years
• All major OEMs are working on this subject: W&H, H-A, R-K, SML,…
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MDO System Configuration – W&H
Preheating, Stretching and Annealing units are necessary
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9 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Neck-In Phenomenon
10 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
MDO System Configuration – Hosokawa Alpine
The method behind TRIO (=Trim Reduction In‐line Orientation)
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11 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Trim Losses
Loss by trim
12 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Design for Recyclability
MDO Process Fundamentals
Property Developent and Trade-offs
Application Development
Outlook and Conclusions
Agenda
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13 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
MDO Structure Design
• Leading to optimal stiffness at lower overall density
14 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Property Trade-offs
Very significant stiffening effect in both directions
Interesting phenomenon observed on tear resistance
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15 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Property Trade-offs
The best properties are obtained the closer to the stretching limit
16 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Design for Recyclability
MDO Process Fundamentals
Property Developent and Trade-offs
Application Development
Outlook and Conclusions
Agenda
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17 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
MDOPE as BOPP/BOPET Replacement
Key Benefits Application Example
Extrusion Laminated MDO//PE structures have been fabricated at PackStudios and tested for hermeticity succesfully
Good HFFS line speed demonstrated with minimal film stretching
Sustainability
Cost efficiency
Appeal
Mono‐material compatible with existing recycling channelsMaterial saving potentialby improved toughness
18 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Extrusion Lamination as Enabling Technology
MDO25//PE80 Extrusion Laminated Prototypes Produced in PackStudios®
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19 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Reverse Spout Sealing Process
CONFIDENTIAL
When heat is applied through the pouch film:
HEAT RESISTANCE BECOMES A CHALLENGE
20 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
The Solution: Two-Step Process
CONFIDENTIALCONFIDENTIAL
In partnership with:
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21 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Design for Recyclability
MDO Process Fundamentals
Property Developent and Trade-offs
Application Development
Outlook and Conclusions
Agenda
22 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Structure Simplification Allowing Recyclability
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23 Luis Zalamea - Materials innovation coupled with latest extrusion technologies - 17th TAPPI European PLACE Conference 2019 Porto - Session 8 - Paper 4
Outlook and Conclusions
Proven formulations developed with major OEMs
Demonstrated viable printing, extrusion lamination and conversion
Proof-of-Concept of an all-PE pouch has been completed
We are looking for partners to bring it to the market!
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“Thank You” for listening,
time for stretching out….Presented by:
Luis Zalamea, Ph.D.TS&D Associate ScientistDow Europe GmbH [email protected]