Innovation in Flexible Packaging

1. Flexible Packaging Technology
Insight view into a market driven segment of packaging with future

3. Composite principles: laminates

4. Flexible Packaging Materials
Components of Flexibles
• aluminium 6,35 µm - 200 µm
• film 12 - 100 µm (PE, PP, PET, PA, PVC,..)
• paper 20 - 300 g/m²
• coatings 0,5 - 10/ 50 g/m²
• polymer resin
• ancillary materials (adhesives, lacquers,wax, inks,..)
=> these composite products are used for specific packaging systems,
generic systems
(pouches, lidding, blisters, laminate tubes, wrappers,..)

5. Composite principles: adhesion

6. Composite principles: adhesion
Wetting of surfaces:
The principles of
surface tension

7. Composite principles: adhesion

8. Composite principles: adhesion

9. Composite principles: sealing
Joining of thermoplastic layers
under the influence of heat and
pressure, while substrates
remain uneffected

10. Composite principles: sealing

11. Composite principles: sealing

12. Composite principles: sealing

13. The Polyethylene Family

14. The Polyethylene Family

15. The Polyethylene Family

16. The Polyethylene Family

17. The Polyethylene Family
Linear Polymers – short branches

18. The Polyethylene Family
Molecular Weight Distribution

19. The Polyethylene Family

20. The Polyethylene Family

21. The Polyethylene Family
Peel test:
Adhesion and
cohesion

22. The Polyethylene Family

23. The Polyethylene Family
Tear test

24. The Polyethylene Family
Dart impact

25. The Polyethylene Family
COF:
Coefficient
Of
Friction

26. The Polyethylene Family

27. The Polyethylene Family
Optical properties:
Haze

28. The Polyethylene Family
What is heat sealing?

29. The Polyethylene Family
The heat sealing curve ...

30. The Polyethylene Family
The heat sealing curve ...

31. The Polyethylene Family

32. PET films
• mono materials
• composite principles Advantages of Coextruded
• raw materials PET-Films in Flexible Packaging Applications
• converting process Richard Davis
Marketing Technical Service Consumer Films
Mitsubishi Polyester Film GmbH

33. PET films
Monolayer PET Films
• Commodities
• More than 50 producers worldwide
• Modifications: corona and chemical pretreatment (ILC)
New Coex Lines
Coextruded PET Films for the Flexible Packaging Market
• Advantages of the coex technology for PET films
• Examples of coextruded Hostaphan® films and their
applications
• Coextrusion is the future of PET films

34. PET films
Corona + ILC
Surface layer
Core layer
Surface layer
• High mechanical • Surface Gloss Slip
strength Layers Adhesion Sealing
• Good dimensional Barrier
stability
• Very good barrier • Core Stiffness Transparency
properties after Layer Barrier Mechanics
coating

35. PET films
Stiffness
Topography
Dimensional
Process- Stability
mono
ability
Barrier
A
B Haze Gloss
C

36. PET films
• Film layers can be arranged so that they do not
compete with each other.
• The films have balanced properties without
compromises.
• A large range of different properties can be
realized.
PET-Films are the tool for individual problem solutions

37. PET films
PET surface layers with antiblock filler
Clear PET core layer without antiblock filler
• ABA coex structure
• Good mechanical and thermal properties
• Very low haze, high gloss
• Standard quality for printing, laminating and metallizing
• Available with chemical and corona pretreatment

38. PET films
PET surface layer with reduced
antiblock filler
Clear PET core layer without antiblock filler
PET surface layer with antiblock filler
• ABC coex structure
• Functional surface has high COF against itself
• Good mechanical and thermal properties
• Extremely low haze and high gloss
• Excellent processability

39. PET films
LDPE Sealant Film
Reverse Printed HOSTAPHAN® RD 12,
high COF surface on the outside
• Functional surface of HOSTAPHAN® RD 12
eliminates need for antislip coating
• Bags will not slip off paletts when stacked
• Low haze and high gloss of HOSTAPHAN®
RD 12 ensure excellent reverse roto or flexo
print quality

40. PET films
PEN surface layer without
antiblock filler
Clear PET core layer without antiblock filler
PET surface layer with antiblock filler
• ABC coex structure
• Functional surface optimized for evaporated barrier layers
• Almost ten times better barrier than standard PET films
• Extremely low haze and high gloss
• Excellent processability

41. PET films
HOSTAPHAN® RHB 12
LDPE Sealant Film Metallization
Reverse printed OPP film
OTR Specification < 0.5 cm³/m² d bar @23°C 50% r.h.

42. PET films
LDPE Sealant Film Metallization
HOSTAPHAN® RHB 12
OTR Specification < 0.3 cm³/m² d bar @23°C 50% r.h.
WVTR Specification < 0.5 g/m² d @ 23°C 85 % r.h.

43. PET films
HOSTAPHAN® RHB 12
CPP Sealant Film SiOx Coating
Standard PET Film
OTR measured < 0.1 cm³/m² d bar @23°C 50% r.h.
WVTR measured < 0.1 g/m² d @ 23°C 85 % r.h.

44. PET films
Heat sealable copolyester
surface layer
Clear PET core layer without antiblock filler
PET surface layer with antiblock filler
• ABC coex structure
• Functional surface heat seals against itself, OPET, APET, CPET
• Good mechanical and thermal properties
• Low haze and high gloss
• Excellent processability

45. PET films
Seal Strength vs. Sealing Temperature
HOSTAPHAN RHS 12
3,0
FIN-SEAL(HS/HS)
/15m ]
m
2,5
ond trength [N
2,0
LAP-SEAL(HS/plain)
1,5
B S
1,0
Pressure: 1,7 bar
Dwell time: 0,5 s
0,5
80 100 120 140 160 180 200
Sealing Temperature [°C]

46. PET films
• Ovenable Products:
⇒ Bake-in-Bag breads
⇒ Ready meals (microwave or conventional oven)
⇒ Frozen pizza
⇒ Roasting bags for meats and poultry
• Single ply Modified or Controlled Atmosphere Packaging
• Hot fill packaging (pasta or bisquits)
• High speed packaging with sealing temperatures > 200 °C

47. PET films
Matte PET surface layer
Clear PET core layer without antiblock filler
PET surface layer with antiblock filler
• ABC coex structure
• Matte functional surface with gloss of 40 to 50
• Stable matte surface, no rub off
• Low haze, excellent visability of reverse print on standard surface
• Good mechanical and thermal properties

48. PET films
Gloss vs. Layer Thickness Hostaphan MPK 14
120
100 Filler System A
Gloss @ 60°
80
60
Filler System B
40
Filler System C
20
Thickness of Functional Layer

49. PET films
Aluminum Foil
LDPE Sealant Film
Reverse printed HOSTAPHAN MPK® 14,
matte surface on the outside
• Functional surface of HOSTAPHAN® MPK 14 eliminates need for
matte laquer
• Low haze and high gloss of HOSTAPHAN® MPK 14 ensure excellent
print quality

50. Vergleich von Packstofflaminaten VAW aluminium AG
( Gemahlener Röstkaffee, 500g, vakuumverpackt ) Forschung und Entwicklung
PET 12µm Überlack PET 12µm oPP 26µm
Konterdruck Druck Druck Druck
Lack oPP 35µm Lack Lack
Al-Folie 7µm metallisiert coex 80g/m² Metallisierung
Laminate Lack Lack PE+HV 18µm
( PE-HV-
LDPE 80µm LDPE 80µm EVOH-10µm- EVOH 8µm
HV-PE ) HV 3µm
PE gefüllt 18µm
Zwischenschicht
PE gefüllt 30µm
PE 20µm
WVTR [ g/m² ] ( 23°
C/85% r.F. ) < 0,2 0,2 4,8 < 0,2
O 2 - Permeabilität [ ml/d . m². bar ] < 0,2 0,4 0,2 < 0,2
Füllgut - Shelf - Life bei 25°
C > 2 Jahre 2 Jahre 2 Jahre > 2 Jahre
relative Kosten [ 1/ m² ] 1,00 1,13 1,15 1,6
OK-019.cdr
09.03.98
DSD-Gebühr, zusätzlich [ DM/m² ] 0,31 0,36 0,32 0,39

51. Comparison of packaging laminates VAW aluminium AG
Tomato ketchup, 12g-pouch Research and Development
PET 12µm overlacquer PET 12µm
Laminates counterprinting printing counterprinting
adhesive PET 12µm adhesive
Al-Folie 7µm ( metallised ) LDPE 60µm
adhesive adhesive
LDPE 50µm LDPE 60µm
WVTR [g/m² . d] ( 23°
C/85% r.F. ) < 0.2 0.6 1.5
O2 - permeability [ml/d . m² . bar ] < 0.2 0.2 130
Filling good-shelf-life at 25°
C
Storage in the dark > 1 year > 1 year 3 weeks
Relative costs [ 1/m² ] 1.00 0.89 0.77
OK-018a.cdr
09.03.98

52. Packaging systems
•

53. Packaging systems
Packaged Goods and Functionality
Packaging Machine
Packaging Material

54. Packaging systems
The Magic Triangle of Packaging:
Functionality
Customer
compliance
Packaging Material Packaging Machine
Packaging System

55. The Basic Functions of Packaging
The Basic Functions of Packaging
1. Fillgood Protection (barrier function)
2. Handling the Fillgood (convenience function)
3. Warehousing / Distribution (logistic function)
4. Communication with Consumers (marketing function)

56. New Polymers

57. More polymers

58. Product life cycles
Product Delivery System
(from McDonald,
Marketing Plans)

59. Logistics and the packaging value chain

60. Customer Delivered Value
Customer delivered value
CDV
Total customer value Total customer cost
TCV TCC
Product Services Personnel Image Monetary Time Energy Psychic
value value value value cost cost cost cost
CDV = TCV - TCC
TCV = Bundle of benefits expected from product
TCC = Bundle of costs expected to evaluate, obtain,
and use the product

61. Conveniences

62. Security Features

63. Easy Authentication
Overt Security Ink printed
on pack
SICPA reader detects
authentic product
Ink appears red
under LW UV
Ink appears green
under SW UV

65. The digital age

66. The digital age

67. The digital age

68. The digital age

69. AMCOR FLEXIBLES INDONESIA – Henkie Wibawa
•THANK YOU ALL
69