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
Transparent high barrier laminates manufactured by extrusion lamination process Chips Laminate Extrusion-Lamination of Flexible High Barrier Laminates 3 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Chips Laminate - 10 Layers RCPP Seal Layer oPP 20 PP homo Core Layer RCPP Sealant Ink Ink Primer Adhesive Adhesive Metallisation Base Layer for Metallisation oPP 20 PP homo Core Layer Metallisation RCPP Seal Layer Extrusion-Lamination of Flexible High Barrier Laminates 4 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Principle Adhesive Lamination (SB) Incineration (VOC) Unwind 1 Hot Room Winder Dryer Lam Nip Coater Unwind 2 Extrusion-Lamination of Flexible High Barrier Laminates 5 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Principle Extrusion Lamination > No Dryer Unwinder 2 > No Solvents > No Curing Time Extrusion Die Winder Extrusion-Lamination of Flexible High Barrier Laminates 6 H.R. Naegeli Unwinder 1
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 of target material > Plasma enhanced evaporation Extrusion-Lamination of Flexible High Barrier Laminates 7 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Transparent High Barrier Materials - Transparent - Outstanding Barriers for O 2 , H 2 O 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 8 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Transparent High Barrier Materials Plasma Metal Deposition Plasma- Metal Deposition Upwind Unwind Plasma EB Evaporation Pretreatment Extrusion-Lamination of Flexible High Barrier Laminates 9 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Transparent High Barrier Materials Extrusion Coatable Surface Metal layer SiOx layer Base film Extrusion-Lamination of Flexible High Barrier Laminates 10 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Transparent High Barrier Materials Adhesion of Different Extrusion Coating Resins Bond N/15mm Basic Substarte µm Tie Layer µm PE EXBE µm Extr. Temp. 90°, 50mm/min. PET -SiOx-pnb 12 20 LDPE 20 310 not separable Pure LDPE PET -SiOx-pnb 12 Low acid EAA 1% 20 LDPE 20 280 not separable PET -SiOx-pnb 12 20 LDPE 20 280 not separable High acid EAA 8% PET -SiOx-pnb 12 High acid EMAA 9.2 20 LDPE 20 300 not separable PET -SiOx-pnb 12 20 LDPE 20 260 not separable Ionomer PET -SiOx-pnb 12 LLD-MAH 20 LDPE 20 310 4.9 PET -SiOx-pnb 12 20 LDPE 20 280 0.1 PP-MAH PET -SiOx-pnb (high level) 12 20 LDPE 20 280 3.6 PP-MAH Extrusion-Lamination of Flexible High Barrier Laminates 11 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Diffusion Trough Inorganic Barrier Layers PUR Adhesive PE Copo oPP oPP oPP Extrusion-Lamination of Flexible High Barrier Laminates 12 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Barriers of Adhesive vs. Extrusion Laminated Inorganic Barrier Structures PUR Adhesive Lamination oPP Oxygen Barrier: PUR adhesive 7.5 cc/m2*d*bar SiOx oPP Extrusion Lamination oPP Oxygen Barrier: LDPE 15 cc/m2*d*bar SiOx oPP Extrusion-Lamination of Flexible High Barrier Laminates 13 H.R. Naegeli
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 Extrusion-Lamination of Flexible High Barrier Laminates 14 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Improving Barriers of Inorganic Barrier Structures with Primers Extrusion-Lamination of Flexible High Barrier Laminates 15 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Mechanical Stress Resistance 1600 1400 Helium- Permeation 1200 PET/AlOx/PE Zugfestigkeit 1000 einer 7µm Alu Folie 800 600 400 200 PET/SiOx/PE 0 0% 2% 4% 6% 8% Dehnung Extrusion-Lamination of Flexible High Barrier Laminates 16 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Lid for Cheese Packaging O 2 Barrier: ok WVTR : ok Bond level: ok Seal strenght: ok oPA 15 SiOx PNB Ink Tie Layer 10 PE Film 20 Extrusion-Lamination of Flexible High Barrier Laminates 17 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Pouches for Enteral Nutrition PET 12 SiOx PNB Tie Layer 20 PNB SiOx BOPA 15 Corona Primer Tie Layer 10 PP 10 PP 90 Extrusion-Lamination of Flexible High Barrier Laminates 18 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Reduce laminate complexity with extrusion lamination PET 12 SiOx PNB Tie Layer 20 PET 12 PNB SiOx SiOx PNB BOPA 15 PP-MAH 10 Corona Polyamide 20 Primer PP-MAH 10 Tie Layer 10 PP 10 PP-Film 110 PP 90 Extrusion-Lamination of Flexible High Barrier Laminates 19 H.R. Naegeli
Transparent high barrier laminates manufactured by extrusion lamination process Results: Laminate for Enteral Nutrition Manufacturing ways: > with tie layer: PP-MAH or LLDPE-MAH > with pnb or retortable primer � reduced complexity > Manufacturing � ok > Barrier � ok (improves during retorting) > Bond level > Seal behaviour � different to adhesive laminates � to be verified > Pouch performance Extrusion-Lamination of Flexible High Barrier Laminates 20 H.R. Naegeli
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 Extrusion-Lamination of Flexible High Barrier Laminates 21 H.R. Naegeli
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