Polymers in Flexible Packaging
Polymers in Flexible Packaging
Polymers in Flexible Packaging
Abstract
The main aim of this report is to understand the Flexible
Packaging Industry and the Polymers used. B. Materials
The Industry - wise break up of Flexible Packaging market.
Types of polymers used in Flexible Packaging and their
compatibility for different industries like Food & Retail,
cosmetic, Pharmaceutical, and Industry products etc. TABLE 1
Choosing the right polymers, their manufacturing and LIST OF PACKAGING MATERIALS
printing process.
Various Barrier films used in flexible packaging with
different laminated structure.
Benefits and contributions of the flexible packaging industry Material Form Advantage Disadvantage
and its products. Paper & Cartons Low Cost Low Tear Strength
Various advantages like waste reduction, saving energy and Paper Boxes Relative Low Wet Strength
reducing greenhouse gas emissions, extended shelf life, easy based Bags Weightlessness Less Durability
storage, microwave ability and reseal ability. products Wrappers Easy Disposal
A comparative analysis of Flexible Packaging Polymers with Easy
other packaging material like Rigid Plastic, Glass and Availability
Aluminium. Plastics Bag Ease of Poor Strength
New Developments in flexible packaging films such as Wrappers Fabrication Temperature
Breathable properties, Biodegradable films, High-barrier Pouches Highly Versatile Sensitive
resins, MAP & CAP vacuum packaging, Gas flush packaging Cartons Light Weight Environment
resulting in Microwavable pouches, Reseal able Stand-up Bottles Highly Sensitive
pouches, Retort pouches and Pouring Spouts are also covered. Containers Corrosion Higher Shrinkage
Resistant Poor Creep
Ease of Behavior
Decoration
Highly Energy
I. INTRODUCTION
Saving
Aluminium Collapsible Good Barrier Not suitable for
A. Packaging Tube Properties Microwave oven
Packaging is the technique of storing or placing a product Foil Greaseproof More
in liquid, solid or powdered form into a protective Containers Shrink Proof Transportation
container or wrapper to protect, carry, identify and Cans Tasteless, Odor Cost
merchandise the product. Packaging of any product is a Closure less More Shelf Space
vital link between the manufacturer and the consumer for Hygienic
the safe delivery of the product through the various stages, Glass Bottles Transparent Higher Weight
starting from manufacturing, storing, transporting, Jars Good Strength Fragile
Jugs Higher Rigidity High Energy
distribution to marketing. Excellent Gas & Consumption
India’s packaging market is about Rs 40,000 Cr. with an Water Vapour Light sensitive
average growth of 15 percent per annum. On an average, Barrier
packaging costs constitute 45 percent of the final price of Chemically Inert
the product.
Tinplate Cans Good Strength Higher Weight Toothpaste Tubes Metal HDPE, LLDPE,
Containers Excellent Corrosive PP
Barrier More Shelf Space Soaps Paper Polyester film,
Properties PVC
Eco-Friendly Fertilizers Jute PP Woven Sacks
Longest Shelf Retail Carrier Bags Paper, Jute LDPE, HDPE
Life Oil Tinplate, Plastic PE, LDPE, Nylon
Laminates Pouches Good Strength Environment Rigid Containers Laminates
Films Good Barrier Sensitive
Tubes Properties Temperature
Bags Grease Sensitive
Resistance Lesser Shelf Life
Heat Seal
Flexible Packaging Consumption Pattern
Property Other Food
Tea
3% 11%
Snacks
Chewing
C. Flexible Packaging 6%
Tobacco
Biscuits 32%
Flexible Package is a material like foil or paper or plastic 6%
films sheeting which, when filled and sealed, acquires Confectionery
pliable shape and is used to form products like bags, 6%
envelopes, pouch, sachets and wraps Food Staples Other Non-Food
6% 30%
Polymers play a vital role in the field of packaging and
flexible packages in the form of laminates and multilayer
coextruded films are expected to dominate the field. These
are mainly used in Retail applications. Fig 1 Consumption Pattern
B. Co-Extrusion
Co-extrusion is the extrusion of multiple layers of material
simultaneously. This type of extrusion utilizes two or more
extruders to melt and deliver a steady volumetric
throughput of different viscous plastics to a single
extrusion head (die) which will extrude the materials in the
desired form. This technology is used on any of the
processes described above (blown film, over jacketing,
tubing, and sheet). The layer thicknesses are controlled by
the relative speeds and sizes of the individual extruders
delivering the materials.
C. Impulse sealing
TABLE 5 TABLE 7
MECHANICAL PROPERTIES OF POLYMER MONOLAYER SHRINK FILMS
F. Structure
TABLE 9
STRUCTURE OF LAYERS
Fig 7 Multilayer Film Structure
3 layer Outer layer Printing, Seal ability, strength &
barrier
Middle layer Strength, barrier mainly gas
aroma retention G. Multilayer Films – Three Layer Films
Inner layer Seal ability, Machine ability,
strength barrier TABLE 10
Outer layer Printing, Seal ability, Strength 2 LAYER FILMS
Bonding layer Good bond strength,
compatibility Material Properties Applications
Middle layer Gas barrier strength Combination
5 layer Bonding layer Good bond strength PP/ PP + Chalk/PP Low Shrinkage Precooked Food
Inner layer Machine ability, Seal ability, Smooth Outer Packaging
Strength, Hot Tack Strength. Layer
Easily Printable
PP/ PP + Regernate Low Temperature Deep Freeze
/PP Resistance Packs
Low Material Cost
LDPE/EVA/PP High Impact Blood Packaging
Resistance Bag Production
Non Stick Outer
Layer
Good
Transparency
EVA/LLDPE/LDPE High Extensibility Stretch film for
Good Adhesive Palette Packaging
Properties Adhesive
Packaging Sheet
Ionomer /PA/ Ionomer Good Seal ability Vacuum
Good Packaging
Transparency
Reduced tendency
to Roll
pouches are that they have excellent print ability with easy
H. Multilayer Films – Five Layer Films tearing material.
Materials used in making packaging pouches are Polyvinyl
TABLE 11 Chloride, Polyolefin, PP, Polyester etc.
MULTILAYER FILMS
Types of packaging pouches
Material Properties Applications
Combination
LDPE/ION/PA/ION/ Gas, Steam & Meat, Fish, Cheese 1) Vacuum Pouch
LDPE Aroma Tight
No tendency to Vacuum pouches help preserve the sealed product in cold
curl and hot temperatures and are used in conjunction with
LDPE/BA/EVOH/ Gas, Steam & Milk Powder vacuum packaging equipment. These pouches reduce the
BA/LDPE Aroma Tight Wine Packaging atmosphere in a package to protect and preserve the
Moisture Barrier Fish freshness of food products, like meat and poultry, seafood,
LDPE/Bonding/PA6/ Moisture Barrier Vacuum cheese etc. They are also used to keep other non-food
Bonding/LDPE Good Seal Packaging
ability Packaging of
products like medical and pharmaceutical items sterile and
Good Sausage, Meat, to prevent oxidation. This vacuum packaging and can be
Transparency Ham UV resistant. They extend the shelf life of products as the
vacuum slows down the oxidation process.
2) Stand-Up Pouch
V. TYPES OF FLEXIBLE PACKAGING Packaging bags are available in a wide variety of shapes,
styles and materials. These bags are used for holding
A. Packaging Pouch objects in bulk. They are used in a variety of applications.
Packing bags are meant for everyday use. They are
The packaging pouches are used for packing all kinds of convenient to use and protect various contents through safe
items but not large quantities. The packaging pouches or storage. They have visual appeal.
sachets provide sealing safety. The greatest advantages of
Materials used in making packaging bags are Plastic, layer LDPE blown film with EVOH, Nylon, PVDC as
Nylon, and Polyester etc. barrier layer is used. This is mainly used for Perishable
Foods.
Types of packaging bags
B. CAP
1) Vegetables Bag
Specially designed to store vegetables and fruits in Intentional alteration of the natural gaseous environment
refrigerators. They are breathable bags to keep vegetables and maintenance of that atmosphere, at a specified
and fruits fresh. condition through out the distribution cycle regard less of
the temperature or other environmental variations.
2) Vacuum Bags
A good packaging bag to pack frozen food, red meat, bread C. Bag – in – Box
and process meat and which also which lengthens the shelf
life of the food. Bag-in-Box is bulk packaging system for both solids and
liquids. It consists of a collapsible bag housed in a rigid
3) Woven Packaging Bags outer container. The bag actually consists of 2 bags: an
Woven bags in both laminated and un-laminated variety are inner bag to contain the liquid and an outer one to provide
capable of bearing heavy weight. barrier properties. The inner bag is heat sealed around the
edges to the outer bag. A tubular spout is heat sealed onto
4) Courier Packaging Bags the inner and outer bags during the bag manufacturing
Such bags are high quality, water-proof packaging bags process and is fitted with a valve through which the product
which find wide application in the postal departments and is filled and dispensed. Combination of LDPE, HDPE,
courier agencies. LLDPE, VLDPE, EVA, Metalized Polyester and Nylon are
most commonly used for most bag applications.
C. Laminated Tubes
Laminated Tube has a sleeve comprising even up to 10 D. High Barrier Resins –
layers. A threaded or a plug-type, which is injection-
moulded is also provided. Polyolefin Plastomers
TABLE 13
TYPICAL STRUCTURE Performance Benefits
Superior Seal Ability Package Integrity & Faster Filling
High Hot Tack & Heat Speeds
From Outside to Inside
Seal Strength
Layer Function
Low Heat Seal Initiation
LDPE & Antistat Dust Preventive Temperature
LDPE/Printing Ink Printed Cover Excellent Optics Consumer appeal
White pigmented LDPE Back-up for Printed Surface Very Good Toughness Package Integrity
Paper Non-stretch web-base Good Process Ability Can run on LLDPE lines
LDPE Paper Lamination/Primer Cost Efficiency Much lower cost than Ionomers
Ethylene Acrylic Acidic Bonding Layer
Copolymer
Aluminium Foil/Met Films Barrier
Ethylene Acrylic Acidic Bonding Layer E. Vacuum Packaging
Copolymer
LDPE Sealant Layer The vacuum environment removes atmospheric oxygen,
protecting the food from spoiling by limiting the growth of
aerobic bacteria or fungi, and preventing the evaporation of
VI. NEW DEVELOPMENTS volatile components. Vacuum packing is commonly used
for long-term storage of dry foods such as cereals, nuts,
A. MAP cured meats, cheese, smoked fish, coffee, and crisps. It is
also for storage of fresh foods such as vegetables, meats,
The Shelf-life extension is achieved by ‘Modifying the and liquids such as soups in a shorter term because vacuum
atmosphere inside the structure. Generally this is done by condition cannot stop bacteria from getting water which
injecting gas mixture inside the container – either Carbon – can promote their growth. Vacuum packaging food can
Dioxide, Nitrogen or Oxygen. In most MAP applications, extend its life by up to 3-5 times. The mainly used
conventional Multilayer, high barrier films such as a 5 polymers are EVOH, PC, PVDC, Nylon etc.
F. Slider Zipper
25 cm3 sample
The printed and laminated stand up pouches with zip lock
are provided smooth and stable finish with wide sealing,
temperature tolerance. These features make it compatible to aluminum foil
store contents on extreme temperature. These pouches have
been provided such dimensions that can be used to position water petri dish
these pouches straight in display.
The Double Zipper ensures complete bag closure and J. Retort Packaging
provides added seal security to lock out air and keep foods
fresh. It features two sets of interlocking profiles Retort able Flexible packaging materials are defined by the
strategically spaced to guide consumers' fingers along a ASTM as ‘those capable of withstanding specified thermal
path when closing a package. As a result, the closure processing in a closed retort at temperature above 100
mechanism is more easily aligned, providing a complete degree C. The polymers used are PET, PC, and PP. It is
seal each time the product is used. preferred for low acid food with moderate to large-size
particles because of ease of removing oxygen from the
H. Spouts head space by gas flushing and also because a crisp texture
obtained through freezing is possible only with the retort
The pouch can contain a multitude of liquid and semi- packaging system.
viscous products, including a wide variety of condiments
such as tomato ketchup, mayonnaise, sauces, gravies and K. Aseptic Packaging
beverages. The current non-food applications are for
products such as shampoo, lotions, detergents, motor oil Aseptic Packaging involves a sterile product that is sealed
and paint. The spout closure may be applied and positioned into a sterile package under sterile conditions thus
in the top corner, top centre or front panel. A spout can eliminating the need to sterilize the product package system
even be sealed into the top or bottom gusset of the pouch, after filling. The commonly used polymers are PET, PVC,
depending on the specific design attributes of the and PVDC. These are used for packaging of Jams, Jellies,
application. and Sausages etc.
I. Breathable Films
VII. REFERENCES
“Films allowing the transfer of the gases at moderate to [1] Library Reference
high transmission rates are considered as breathable.” Indian Institute of Packaging, Mumbai
Breathable films are capable of transmitting water vapor Indian Plastic Institute, Mumbai
but resistant to the passage of water in a liquid form. A film [2] URL
is called as "breathable" if it has a water vapor transmission http://packartpackaging.tradeindia.com
rate of at least 100 g mil / day / m2, measured using ASTM http://www.packaging-films.com
E96-93 method, with minor variations as described in the http://www.marketresearch.com/product
http://www.medicalpackagingindia.com/industry
test. (7, 8, 9) . Breathable films are produced by http://www.expresspharmaonline.com
compounding a PP or PE resin with mineral filler. www.flexpackmag.com
www.flexpack.org
TABLE 14
BREATHABLE FILMS [3] Magazines
Packaging Today
Breathability testing Popular Plastics & Packaging
The gases which are most commonly used to describe the Plastics & Polymers
breathability of films are water vapor (moisture vapor) and IPI Journal
oxygen. The water vapor transmission test (WVTR) and Packaging Technology
Modern Plastics India
oxygen transmission test (OTR) are used to measure the Polymer Business
mass or volume of gas transported through the cross- Plastic Sandesh
section of the film in a given unit of time at a defined set of
environmental conditions. (6) This test procedure follows
the Modified ASTM E96-93 test. (4)