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Jan 31, 2024 116 likes •336 views

Extrusion-Lamination of Flexible High Barrier Laminates 1 H.R. Naegeli Transparent high barrier laminates manufactured by extrusion lamination process Packaging Examples: Extrusion-Lamination of Flexible High Barrier Laminates 2 H.R. Naegeli

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Packaging Examples:

Transparent high barrier laminates manufactured by extrusion lamination process

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Chips Laminate

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RCPP Seal Layer PP homo Core Layer RCPP Sealant Ink Primer Adhesive Metallisation Base Layer for Metallisation PP homo Core Layer RCPP Seal Layer

  • PP 20

Ink Adhesive

  • PP 20

Metallisation

Chips Laminate - 10 Layers

Transparent high barrier laminates manufactured by extrusion lamination process

Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Principle Adhesive Lamination (SB)

Transparent high barrier laminates manufactured by extrusion lamination process

Incineration (VOC) Unwind 1 Winder Hot Room Lam Nip Dryer Coater Unwind 2

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Principle Extrusion Lamination

Winder > No Dryer > No Solvents > No Curing Time Unwinder 2 Extrusion Die Unwinder 1

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Inorganic Barrier Layer Electron Beam Evaporation Process

  • Advantages:

> No crucible > Continuous material transport allows controlled evaporation

  • f target material

> Plasma enhanced evaporation

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Transparent High Barrier Materials

Transparent high barrier laminates manufactured by extrusion lamination process

  • Transparent
  • Outstanding Barriers for O2, H2O

and Aromas

  • No “Retort Shock”
  • Microwave Transparent
  • Applicable for aseptic, pasteurization

and retort processes

  • Printable
  • Processable on standard packaging

lines

  • Allows metal detection

Basic Substrates: > oPET 12µm > oPA 15µm > oPP 20µm > PP > PE

Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Plasma Metal Deposition

Plasma Pretreatment EB Evaporation Unwind Upwind

Plasma- Metal Deposition

Transparent High Barrier Materials

Transparent high barrier laminates manufactured by extrusion lamination process

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent High Barrier Materials Extrusion Coatable Surface

Transparent high barrier laminates manufactured by extrusion lamination process

Metal layer SiOx layer Base film

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Transparent High Barrier Materials Adhesion of Different Extrusion Coating Resins

Basic Substarte µm Tie Layer µm PE EXBE µm

  • Extr. Temp.

Bond N/15mm 90°, 50mm/min.

PET -SiOx-pnb 12 Pure LDPE 20 LDPE 20 310 not separable PET -SiOx-pnb 12 Low acid EAA 1% 20 LDPE 20 280 not separable PET -SiOx-pnb 12 High acid EAA 8% 20 LDPE 20 280 not separable PET -SiOx-pnb 12 High acid EMAA 9.2 20 LDPE 20 300 not separable PET -SiOx-pnb 12 Ionomer 20 LDPE 20 260 not separable PET -SiOx-pnb 12 LLD-MAH 20 LDPE 20 310 4.9 PET -SiOx-pnb 12 PP-MAH 20 LDPE 20 280 0.1 PET -SiOx-pnb (high level) 12 PP-MAH 20 LDPE 20 280 3.6

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Diffusion Trough Inorganic Barrier Layers

PUR Adhesive

  • PP

PE Copo

  • PP
  • PP
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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Barriers of Adhesive vs. Extrusion Laminated Inorganic Barrier Structures

PUR Adhesive Lamination

  • PP

PUR adhesive SiOx

  • PP

Oxygen Barrier: 7.5 cc/m2*d*bar

Extrusion Lamination

  • PP

LDPE SiOx

  • PP

Oxygen Barrier: 15 cc/m2*d*bar

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Combining Primers with Extrusion Coating For Inorganic Barrier Structures

Unwind 2 Unwind 1 Winder Dryer Lam Nip Coater

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Improving Barriers of Inorganic Barrier Structures with Primers

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Mechanical Stress Resistance

200 400 600 800 1000 1200 1400 1600 0% 2% 4% 6% 8% Dehnung Helium- Permeation

Zugfestigkeit einer 7µm Alu Folie

PET/AlOx/PE PET/SiOx/PE

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

O2 Barrier:

  • k

WVTR :

  • k

Bond level:

  • k

Seal strenght:

  • k

Lid for Cheese Packaging

  • PA

15 SiOx PNB Ink Tie Layer 10 PE Film 20

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Pouches for Enteral Nutrition

Transparent high barrier laminates manufactured by extrusion lamination process

PET 12 SiOx PNB Tie Layer 20 PNB SiOx BOPA 15 Corona Primer Tie Layer 10 PP 10 PP 90

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Reduce laminate complexity with extrusion lamination

Transparent high barrier laminates manufactured by extrusion lamination process

PET 12 SiOx PNB Tie Layer 20 PNB SiOx BOPA 15 Corona Primer Tie Layer 10 PP 10 PP 90 PET 12 SiOx PNB PP-MAH 10 Polyamide 20 PP-MAH 10 PP-Film 110

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Results: Laminate for Enteral Nutrition

Transparent high barrier laminates manufactured by extrusion lamination process

Manufacturing ways: > with tie layer: PP-MAH or LLDPE-MAH > with pnb or retortable primer > Manufacturing reduced complexity > Barrier

  • k

> Bond level

  • k (improves during retorting)

> Seal behaviour different to adhesive laminates > Pouch performance to be verified

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Extrusion-Lamination of Flexible High Barrier Laminates H.R. Naegeli

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Transparent high barrier laminates manufactured by extrusion lamination process

Our best thanks for their excellent cooperation goes to all BMBF project partners: Du Pont IVV Munic Huber Group Munic Lorenzen Snack World Novartis Wipack As well as to my colleagues within Alcan Packaging