Flexible Packaging Innovation Process

N. Siva Shankaran Head – Technical Organization V P Business Development

Uflex Ltd.,

Product Detailing  Pack Size  Pack Format  Active Ingredients  Expected Shelf Life  Critical Barrier Requirements  Product Migration Characteristics  Oxidation Behaviors  Reaction to UV Light

Packaging Design – 1st Step

 Laminate Structure Determination   Inter Layer Bond Strength  Seal Strength  Coefficient of Friction (COF)  Tensile and Elongation Properties  Drop Test  SIT & Hot Tack

Case Study – Wet Tissues

Background:   Package was delaminating in the market within three

months   The active ingredient was migrating to the print and was

leaching ink   The customer suspected that there was alteration to the

approved spec   The Laminate is Die cut inline to provide easy access to

the product for frequent use   The packs are stored in ambient temperatures after

filling during the entire life cycle

Analysis - 1

  Comparative Microtome Images showed Laminate Structure not same with varying layer thicknesses

Analysis -2

 DSC results showed different melt curves

Testing Conditions Defined

 Freeze Thaw – 1 Month  Weight loss at 50° C  Light Fastness Test  ESCR Test  5° C – end of 1, 2, 3 Months  25° C @ 60% R/H – end of 1, 2, 3 Months  40° C @ 75% R/H – end of 1, 2, 3 Months

Design Considerations

  Special Polyester was used to ensure Excellent Ink Cross linking

  Chemical and Heat Resistant Adhesive used   Poly Formulations to ensure OTR – 64 CC and WVTR –

4.5g compared to OTR – 92 CC and WVTR – 7g in the old laminate

  SIT and Hot tack to ensure excellent Seal strength of 4.5Kgf/25mm giving high speed Machinability.

  Testing to confirm consistent performance over three months in all conditions defined

  Customer started Local Sourcing and stopped Imports once the product was established

Thank You