application of food films with copa and terpolyamidesc.catarozzo@ube.ind.br . title: troubleshooting...

Application of Food Films with

CoPA and TerPOLYAMIDES

Presented by: Carlos Catarozzo UBE Latin America Serviços Ltda

EVOLUTION OF PA FOR FLEXIBLE PACKAGE

SOLUTIONS FOR EXISTING FLEXIBLE PACKAGES

NYLON POLY BAGS

THERMOFORMING

LIQUID PACKAGING

SHRINK BAGS

SOLUTIONS FOR THE FUTURE OF THE PACKAGE

CONCLUSIONS

INDEX

Versatility / Many applications

Mechanical properties

Puncture resistance

Processability & output

WHY PA FOR FLEXIBLE PACKAGING?

PA6

PA6 Specialties

CoPA 6/6.6

CoPA 6/12

CoPA 6/6.6 Specialties

TerPA

6/6.6/12

EVOLUTION OF PA FOR FLEXIBLE PACKAGING

PA with high cristallinity

PA with reduced cristallinity

Chill-roll Water

Air cooling

PA

Medium Barrier

Mechanical properties

EVOH

Transparency

High Barrier

PE

Sealing

Flexibility

Tie

Extrudable

Compatibility

EVOLUTION OF PA FOR FLEXIBLE PACKAGING

EVOLUTION OF PA FOR FLEXIBLE PACKAGING

EVOLUTION OF PA FOR FLEXIBLE PACKAGING

Bags Thermoforming

Flexible bottles

Shrink film

CoPA

Applications

CoPA SOLUTIONS FOR EXISTING FLEXIBLE PACKAGES

Bags

CoPA SOLUTIONS FOR

PROBLEMS / CHALLENGES

Nice aspect

Production speed

Curling

Toughness

Retort

Very good transparency and gloss

CoPA FOR : TRANSPARENCY

Puncture resistance

CoPA FOR : PUNCTURE

ºC Tm (PA) TC (PA) Tm (PE) TC (PE) Tg (PA)

Both polymers

are in molten

status

PA crystallizes

(“solidifies”)

and shrinks.

PE is still

molten, it can

go with the PA

PE crystallizes (“solidifies”)

and shrinks.

PA is solid, it cannot go

anymore with the PE

Stresses are created in the PA

PA6/6.6 and PA6/6.6/12:

- More amorphous

- Lower Tc

Curling reduction

CoPA FOR : CURLING

Measured on 100 microns air blown film: LDPE/Tie/PA (30 % PA)

Curling degree measurement: 100 mm round specimen – final dimensions after cutting (UEP method)

PA 6 PA 6/6.6

15%

PA 6/6.6

20 % PA 6/6.6/12

Curling = 90% Curling = 80% Curling = 45% Curling = 5%

CoPA FOR :CURLING

Melting point range

CoPA FOR : THERMAL RESISTANCE

Autoclave T = 125ºC

50 µm monolayer airblown film

CoPA FOR : RETORT

Thermoforming

PROBLEMS / CHALLENGES

Deeper packages

Functionality

Distribution

CoPA SOLUTIONS FOR

Mould: - 2x2 cavity - 91 mm diameter - variable depth

CoPA FOR : DEEPER PACKAGES

MAX thermoforming DEPTH study

Film: 50 microns monolayer air blown film

CoPA FOR : DEEPER PACKAGES

Max. thermoforming depth (Airblown)

PA6

Heating plate

110ºC 7

0 m

m CoPA

10 % 10%

Heating plate

85ºC

70

mm

CoPA

Heating plate

80ºC

85

mm

TerPA

Heating plate

80ºC

95

mm

LOW CO-MONOMER

% HIGH CO-MONOMER

% THREE

CO-MONOMER

CoPA FOR : DEEPER PACKAGES

Max. thermoforming depth (Airblown)

Heating plate

105ºC

115

mm

TerPA+

Additive

PA6

Heating plate

110ºC

70

mm

CoPA 10 % 10%

Heating plate

85ºC

70

mm

CoPA

Heating plate

80ºC

85

mm

TerPA

Heating plate

80ºC 9

5 m

m

LOW CO-MONOMER

% HIGH CO-MONOMER

% THREE

CO-MONOMER

MODIFICATION

READY-TO-USE

Higher optimum

tempertaure

CoPA FOR : BETTER DISTRIBUTION

Thermoforming THICKNESS DISTRIBUTION

study

Film: 50 microns monolayer air blown film

Mould: - 1X1 cavity - 202 mm diameter - 60 mm depth

CoPA FOR : DEEPER PACKAGES

Thickness distribution at 60 mm depth (Airblown)

--- PA6 --- CoPA (10 %) --- CoPA (20 %) --- TerPA

Thermoforming for respiring cheese with TerPA 6/6.6/12

CoPA FOR : FUNCTIONALLITY

Flexible

bottles

CoPA SOLUTIONS FOR

PROBLEMS / CHALLENGES

Flexcrack

Barrier

Puncture

Flex Crack Resistance

40

20

10105

00

10

20

30

40

50

PA6 CoPA6/6.6

CoPA6/6.6/12

Nu

mb

er

of

ho

les

(0

,04

.m

2)

23 ºC1000 cycles

5 ºC 100 cycles

CoPA FOR : FLEXCRACK

PE PE Tie CoPA EVOH CoPA Tie PE PE

PE PE PE Tie EVOH Tie PE PE PE

Co-ex films (9) = 30 microns / Each layer of CoPA = 2 microns

Puncture Resistance

CoPA FOR : PUNCTURE

PE PE Tie CoPA EVOH CoPA Tie PE PE

PE PE PE Tie EVOH Tie PE PE PE

Co-ex films (9) = 30 microns / Each layer of CoPA = 2 microns

Mechanical properties

CoPA FOR : STRENGTH

Shrink film

CoPA SOLUTIONS FOR

PROBLEMS / CHALLENGES

Shrinkage

Environment

Puncture

Very good shrinkability

CoPA FOR : SHIRNKAGE

Excellent puncture; bone-in

CoPA FOR : PUNCTURE

Request for

PVC and PVDC free solutions

Market feeling

PVC - PVDC :

Environmental concerns

Market is growing

“Pellicola senza PVC”

“PVC free film”

CoPA FOR : ENVIROMENT/LEGISLATION

Film structure

Thickness

PE/EVA/PVDC/EVA/PE

Total : 80 µm (PVDC : 10%)

PA/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 40%)

PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 20%)

PVDC based

7 layers 9 layers

CoPA/EVOH/CoPA based

0

50

100

150

200

PVDC based PA/EVOH/PA based7 layers

PA/EVOH/PA based9 layers

80

130

95

150 140 155

Tensile properties at break (MD)

Strength (MPa) Elongation (%)

0

25

50

75

100

PVDC based PA/EVOH/PA based7 layers

PA/EVOH/PA based9 layers

9 11 9

48

83

48

Puncture resistance

Deformation (mm) Energy (mJ)

CoPA FOR : CHLORINE-FREE ALTERNATIVE

Barrier package + Single hole = Barrier loss = Waste of money !

Puncture risk during shrinkage process (sharp shapes, bone-in)

Puncture risk when handling the packed goods (machine, supermarket)

CoPA FOR : CHLORINE-FREE ALTERNATIVE

Film structure

Thickness

PE/EVA/PVDC/EVA/PE

Total : 80 µm (PVDC : 10%)

PA/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 40%)

PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 20%)

PVDC based

7 layers 9 layers

PA/EVOH/PA based

0

5

10

15

20

PVDC based PA/EVOH/PAbased

7 layers

PA/EVOH/PAbased

9 layers

16

7

13

Haze (%)

0

25

50

75

100

125

150

PVDC based PA/EVOH/PAbased

7 layers

PA/EVOH/PAbased

9 layers

97 121

102

Gloss (%) Angle : 60º

CoPA FOR : CHLORINE-FREE ALTERNATIVE

CoPA FOR : CHLORINE-FREE ALTERNATIVE

Film structure

Thicknesses

PE/EVA/PVDC/EVA/PE

Total : 80 µm (PVDC : 10%)

PA/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 40%)

PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 20%)

PVDC based

7 layers 9 layers

PA/EVOH/PA based

0

10

20

30

40

50

PVDC based PA/EVOH/PAbased

7 layers

PA/EVOH/PAbased

9 layers

10 4,5

15,5

OTR (cc/m2.day)

CoPA FOR : CHLORINE-FREE ALTERNATIVE

Film structure

Thickness

PE/EVA/PVDC/EVA/PE

Total : 80 µm (PVDC : 10%)

PA/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 40%)

PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 20%)

PVDC based

7 layers 9 layers

PA/EVOH/PA based

0

10

20

30

40

50

60

PVDC based PA/EVOH/PA based7 layers

PA/EVOH/PA based9 layers

50

37

48 48

39

54

Thermal shrinkage (%) Soaked @ 90ºC

MD TD

CoPA FOR : CHLORINE-FREE ALTERNATIVE

Film structure

Thickness

PE/EVA/PVDC/EVA/PE

Total : 80 µm (PVDC : 10%)

PA/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 40%)

PET/Tie/PE/Tie/PA/EVOH/PA/Tie/PE

Total : 50 µm (PA : 20%)

PVDC based

7 layers 9 layers

PA/EVOH/PA based

Tensile (MD/TD)

Strength (MPa)

Elongation (%)

Puncture Force (N)

Deformation (mm)

Energy (mJ)

80 / 70

150 / 210

13,5

9

48

130 / 135

140 / 125

20,5

11

83

95 / 105

155 / 120

13,5

9

48

Haze (%)

Gloss (%), 60º

16

97

7

121

13

102

OTR (cc/m2.day) 10,0 4,5 15,5

Shrinkage (%) MD

TD

50

48

37

39

48

54

CoPA FOR : CHLORINE-FREE ALTERNATIVE

SOLUTIONS FOR THE OF THE PACKAGE

GLASS/CAN PLASTIC

RIGID PLASTIC FLEXIBLE

Less space

Less weight

Less CO2

SOLUTIONS FOR THE OF THE PACKAGE

SOLUTIONS FOR THE OF THE PACKAGE

New Polymers

New applications

New functionallity

New technology

More combinations

Higher efficiency

SOLUTIONS FOR THE OF THE PACKAGE

CoPA

TerPA

Physical properties

High stretching

& shrinkage

Thermal stability

Design freedom

Cost reduction

Sustain-ability

CONCLUSIONS

Thank you

PRESENTED BY

Carlos Catarozzo UBE Latin América Serviços Ltda. c.catarozzo@ube.ind.br