New Design-Enabling Technologies For Flexible PackagingEnabling new designs for flexible packaging...

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New Design-Enabling Technologies Dr. Giancarlo Caimmi, Dr. Guido Kollbach Aimcal R2R, Phoenix, October 2018 For Flexible Packaging

Transcript of New Design-Enabling Technologies For Flexible PackagingEnabling new designs for flexible packaging...

Page 1: New Design-Enabling Technologies For Flexible PackagingEnabling new designs for flexible packaging Synergy of metallizing technology and multifunctional coating High barrier metallized

New Design-Enabling TechnologiesDr. Giancarlo Caimmi, Dr. Guido KollbachAimcal R2R, Phoenix, October 2018

For Flexible Packaging

Page 2: New Design-Enabling Technologies For Flexible PackagingEnabling new designs for flexible packaging Synergy of metallizing technology and multifunctional coating High barrier metallized

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Market Applications for Metallized Films

Food Packaging Decoration Industrial

Snacks, Chips Bakery products Candy, Confectionary Coffee, …

Gift and Flower Wrapping Labels Hot Stamping Foils Holograms, …

Solar Window Films Anti-Counterfeiting Films Road Signs, …

October 25, 2018New Design – Enabling Technologies for Flexible Packaging for Flexible Packaging

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Market for Metallized and AlOx-Coated FilmsStrong Growth in India and Asia

Estimated Market Growth1)

October 25, 2018New Design – Enabling Technologies for Flexible Packaging1) Market estimates based on information from Henkel, Nordmeccanica, and several market studies

2.54.0

13.3

8.96.7

2.94.5

15.1

10.17.6

Europe North America

AsiaIndia & Middle

East

South America

AI Ox-coated FilmsMetalized Films

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Market Applications for Functional Coatings

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Coating Functionalities

Sealability

Better anchorage

Improved barrier

Protection

Optical effects (gloss, matte, …)

Slip modification

Henk

el’s

Coa

ting

Tech

nolo

gies

& M

arke

ts

Trend: Multifunctional Coatings

Markets: Food, Medical

Markets: Food, Medical

Market: Food

Market: Food

HS

CS

PR

OPV

Markets: Food,MedicalBC

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Novel Metallization Primers Metallizing on top of

multifunctional metallization primers

Integration and Interaction of Product LinesFreedom of Design – Case Studies

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Traditional Lamination of metallized

films with printed stock

High Performance Protective Top-Coatings Top-coating fragile layers

like AlOx with protective coatings

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Metal DepositionPrinciple & Key Technical Data

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Aluminum layer deposited to films and paper in vacuum

Thickness: 0.005 – 0.07 micron

Optical Density: 0.2 – 4

Electrical Resistance: 0.5 – 10 Ω/m2

P (chamber pressure)= 5E-4 mbar

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System LayoutSchematic Representations

October 25, 2018

RootsPumps

-Vacuum5 X 10-2

mbar

Diffusionspumps

-Vacuum

2-5 X 10-4mbar

Process drumchill roller

Al evaporators

Unwind Rewind

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System LayoutProduct Pictures

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Vacuumchamber

AI evaporationsystem

Winder

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Process SchematicMetallization Process

High vacuumchamber

Al evaporators

Boat

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Coater TechnologyProduct Pictures

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

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Innovation Through Collaboration of Industry Leaders

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Safe and highly focused innovation process created fast results!

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Case Study AlOx-Coated FilmsNew High-Performance Protective Coating Technology

AlOx-coated films

Very good oxygen and moisture barrier

Very fragile

Converting leads to dimished barrier performance

Current top-coating technologies provide mechanical protection

New top-coating technology

Mechanical protection

Significant barrier improvement

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Substrate(e.g. PET, OPP)

AlOx-layer

High-performanceTop-coating Technology

Protected AlOx-coated Film

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Case Study AlOx-Coated FilmsProcess Flow-Chart

Top-Coating LaminationPrinting

Optimal anchorage

Superior barrier performance

Best clarity

Fragile AlOx-layer unprotected

Additional functionality for very high performance

01 02 03

AlOx-Coating

04 Protection of AlOx-

layer

Ink anchorage

High mechanical and thermal stress

Good anchorage of ink on AlOx during lamination

Keeps top barrier performance throughout process

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

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Case Study AlOx-Coated FilmsTesting Mechanical Protection

Strongly improved robustness

Barrier performance not reduced by stretching or abrasion

Gelboflex testing

Significantly more robust than traditional top-coat

13.1

21.2

47.4

14.7

2.6 4.5

11.66.2

0.1 0.1 0.1 0.2

BeforeTreatment

Stretching Abrasion Test Gelboflex-50

OTR

(cm

3 /m

2 .24h

.bar

)

No Top-Coat Traditional Top-Coat

Henkel's Top-Coat

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

(2%)

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Case Study AlOx-Coated FilmsProduction Scale Testing

Strong barrier improvement by AlOx-coating

Significant boost in oxygen barrier performance by Henkel’s new top-coating technology

Moisture barrier stabilized or improved

Very good stability throughout entire process

4.9 4.9

3.74.0

4.9

0.1 0.1 0.1AlOx-Coating Top-Coating Printing Laminating

OTR

(cm

3 /m

2 .24h

.bar

)

No Top-Coat Henkel's Top-Coat

October 25, 2018New Design – Enabling Technologies

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Case Study Metallized FilmsNovel Metallization Primer Technology

Metallization is state of the art

Improvement of anchorage of metal layer to plastic substrate

Henkel’s novel coating technology provides additional improvement in oxygen barrier

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Substrate(e.g. PET, OPP)

Novel MetallizationPrimer Technogoly

Metallization

Improve Barrier of Metallized Film

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Case Study Metallized FilmsProcess Flow-Chart

Primer Application LaminationMetallization

Full coverage and smooth laydown

Strong anchorage to film

Optical density determines barrier

Primer holding both materials in place

Good anchorage of metal-layer to substrate

Withstand mechanical and thermal stress

01 02 03

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

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Case Study Metallized FilmsBarrier Performance Development on PET Film

Very strong improvement of barrier performance by Henkel’s new coating technology

Significant barrier improvement by metallization

Very good stability throughout entire process

2.0

0.5 0.5

1.51.0

Coating Metallizing Laminating

OTR

(cm

3 /m

2 .24h

.bar

)

Henkel's High Performance Technology

Traditional Primer

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SummaryEnabling new designs for flexible packaging

Synergy of metallizing technology and multifunctional coating

High barrier metallized films

More sustainable transparent barrier films

Layer reduction

Access to high barrier recyclable structures (Circular Economy)

October 25, 2018New Design – Enabling Technologies for Flexible Packaging

Metallization

Coatings

Films

Inks

Adhesives

Processes

New packaging

design

Enabled by BarrEnhanceTech Allianceby Nordmeccanica and Henkel.Two industry leaders working in perfect collaboration

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Thank you!