Advances in Food Packaging Design for
Shelf life enhancement and
integrity of Quality and Food Safety
Dec, 2014
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Agenda
• Emerging technologies
• Defining “Convenience”
• Easy Peel Open Challenges, Sealing Concepts & Applications
• Functional pouches - Reclosable
• Functional pouches – Two compartment
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Some Emerging Technologies in Packaging
• Active packaging
– Antimicrobial
– Fresh produce
• Enhanced consumer experience
– Freshness and safety indicators
– Consumer delight
• Convenience & functionality
– New Packaging Designs and formats
• Packaging materials
– Nanocomposites
– Safety aspects and regulations
• Addressing Environmental concerns
– Life cycle assessment (LCA)
– Biobased or compostable resins
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DuPont Packaging Survey Results: Packaging breakthroughs
Invention 1 – Re-Closeable Invention 2 – Microwaveable Invention 3 – Recycled ContentInvention 4 – Retort and AsepticInvention 6 – Hot FillInvention 6 – Case Ready/MAP/Value Add
Recloseable packaging and microwaveable plastic tra ys top the list of packaging breakthroughs that cha nged our lives, according to the nearly 300 people who visited this site from April 9 through May 10, 2013 and voted.
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Convenience & functionality
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Consumer Convenience - Products in the market place
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What is “Consumer Convenience”?
The convenience of packaging includes all of the various aspects
that make the use of a product easier for consumers”
…for instance,
Easy to open
Easy to tear
Enabling accurate dosage
Providing a good grip
Clear instructions that are easy to read, etc.
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• Convenience to consumer is the key driver:
– product convenience (value added meats)• UHT milk
• microwaveable (ready-to-eat)
• meal kits
– package convenience • easy open - peelable
• easy open, reclosable – zipper and others
• single serving packs
• On-To-Go
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Convenience & Seal Integrity – will they go together…?
Packaging Challenges:
• Seal through contamination(oil, powdered product)
• Capillary leakers
• Handling Conditions(external pressure and temperature)
• Sealing Temperature variations (pressure, temperature, time)
• Delamination(poor interlayer adhesion, chemical resistance)
• Package treatment (pasteurization, retort, etc.)
How do you produce a peelable ?
…peel strength, reclosable, etc.
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Pouch Peelable Seals
• Interfacial
seals fail at interface
seal temperature determines strength
• Delamination
seals fail at internal interface
thickness and adhesion to internal layers determine strength
• Cohesive
seals fail within seal layer
internal strength determines heat seal strength
tamper evident, stress whitening
PE
sealant
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Cohesive failure
Lidding
Sealant
Tray/Forming Web
Interfacial failure
Lidding PeelableSeals
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Appeel® Peelable Lidding ResinFormulated resins that provide controlled adhesion in easy open packaging applications
�Appeel® resins provide Easy to open, strong, secure seals to prevent tearing and splitting providing peace of mind that the package will not o pen until the consumer is ready .
�Used in blown film, cast film, extrusion coating and coextrusion processes on equipment designed for processing PE.
�A proven, out of the bag technology enabling easier entry into the lidding market
�Many grades are versatile and bond to multiple surfaces resulting in SKU reduction
�Security of a hermetically sealed package that resists punctures and tears to deliver tamper resistant or tamper-evident peels for greater consumer protection
Sustainable Contributions
•Solvent Free system does not contribute VOC emissions to the atmosphere•Reduces Energy required as solvent recovery is energy intensive•Reduces Energy in that lower seal initiation temperature reduces seal bar temperature required
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Food & Beverage
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Steamed Rice Package
High temperature Sterilization applications
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Functional
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•Key Features
• Reference in Cereals and Snacks
• Higher line productivity
– From low Seal temp.,
– high hot tack,
– Seal through powder
– Surface hardness…
• Transport safety
– Burst strength
• Better seal strength control
– Initial opening = thickness of Surlyn layer
– Continuation peel = interply bond strength
• No ageing of Peel force
Burst Peel Concept
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Burst PeelPe
el f
orce
Time
Initiation peel
Continuation Peel
PE-HD / Surlyn Blend
Peel force as a function of time and
distance
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Functional pouches – Reclosable
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Why Recloseable Packages ?
On the Go
Snacking
Convenience
Food Safety
Sustainability
Aging Population
• Maintain Food Freshness
• Allow several consumption ocassions
• Easy Open and Reclose
• Material Reduction
• Don´t need to transfer product to another container
• Maintain package integrity
Consumer TrendsHow reclosesable packages address consumer trends ?
2020
Voice of Customers
• 98% Retailers said that reclose packaging positively changes
products.
• 67% Consumers said that reclose packaging is very important in
their purchasing decisions
• 31% Consumers always buy products that have ability to be
reclosed
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Current applications in reclosable packages
• Bakery, Cookies & Crackers• Confectionery• House Hold & Personal Care• Dry Fruits and seeds• Processed Meat and Cheese• Other Consumer Goods and Industrial
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Reclosable - Mechanism
Sliders Labels Strips VelcroZippers
Pre Zippered Rolls
Pre Made Pouches•Zip-Pak®
•Fresh-Lock®•Zip Grip®
Inno-Lock®Hudson-Sharp
ZipBox®Zip-Pak
Slide-Rite®Fresh-Lock
Reseal it® LabelMacfarlane
FreshPak®Sealstrip
Peel&Seal®Sealstrip
Pres Lok®Velcro/Amcor
Prime Label Inc.
FFP Pack. Sol.Esterpeel Reseal It®
Macfarlane
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Reclosable
• Structure: Back layers / PSA / Surlyn®
• Surlyn® is the seal layer. Structure is sealed onto itself, i.e. Surlyn® onto Surlyn®
• PSA stands for Pressure Sensitive Adhesive. This is the material providing the reclosability feature. We
have used grade M550 from Bostik
=Surlyn®
PSA PSA
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Resealable with Tray
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Functional pouches – 2 compartments
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Commercial ProductTwo
Compartments• Liquid - Liquid
• Liquid - Solid
• Liquid - Powder
Frangible Seal between
Compartments• Surlyn® “specified” resin inner
sealant layer
• Designed to “peel” at specified pressure (equivalent to child’s
hand force)
• “Force Concentrator” to provide robustness
Permanent Seal on Perimeter
• Lock-up heat seal of Surlyn®
Stand-up Pouch• 5 layer blown-film construction plus
reverse printed OPET
Frangible Pouch with Surlyn®
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Unmet Need
Peel
Lock
How to make a pouch (or bag) with “easy open” seal on topand “lock up seal” every where else?
Unmet Need
Peel
Lock
How to make a pouch (or bag) with “easy open” seal on topand “lock up seal” every where else?
New Functionality: Dual Mode SealConcept: Seal Strength and Failure Mode
changes as Function of Sealing Temperature
Force
Temperature
Peel range
Seal range (lock up)
Sealing Curve - Peel-Seal to itself (30 kg force, 1 sec)
0
10
20
30
40
50
60
70
Temperature
N/25mm
Peeling and Sealing: Surlyn ® AD8273Structure: OPET/Surlyn® film
Broad sealing plateau for both peelable and lock up seals
Peel
Lock
Unmet Need
Peel
Lock
How to make a pouch (or bag) with “easy open” seal on topand “lock up seal” every where else?
Unmet Need
Peel
Lock
How to make a pouch (or bag) with “easy open” seal on topand “lock up seal” every where else?
New Functionality: Dual Mode SealConcept: Seal Strength and Failure Mode
changes as Function of Sealing Temperature
Force
Temperature
Peel range
Seal range (lock up)
Sealing Curve - Peel-Seal to itself (30 kg force, 1 sec)
0
10
20
30
40
50
60
70
Temperature
N/25mm
Peeling and Sealing: Surlyn ® AD8273Structure: OPET/Surlyn® film
Broad sealing plateau for both peelable and lock up seals
Peel
Lock
Technology Brief: Lock and Peel Technology
The technical data contained herein are guides to the use of DuPont resins. The advice contained herein is based upon tests and information believed to be reliable, but users should not rely upon it absolutely for specific applications because performance properties will vary with processing conditions. It
is given and accepted at user's risk and confirmation of its validity and suitability in particular cases should be obtained independently. The DuPont Company makes no guarantees of results and assumes no obligations or liability in connection with its advice. This publication is not to be taken as a
license to operate under, or recommendation to infringe, any patents.
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Possible Applications• Milk & Juice Powder
• Sport Drink• Cosmetics• Hair Dyes
• Etc…
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DuPont Oval Logo, DuPont™, The miracles of science™ and all products
denoted with ™ or ® are registered trademarks or trademarks of E. I. du
Pont de Nemours and Company or its affiliates.
• Images reproduced by E. I. du Pont de Nemours and Company under
license from the National Geographic Society.
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