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PACKAGING (VAI 226)

Week-6: Plastic for Food Packaging

INTRODUCTION

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PLASTIC: BASIC POLYMER

1. Polyolefins LDPE, LLDPE, HDPE, PP 2. Copolymers of ethylene EVA, EVOH

3. Substituted olefins
PS, PVC, PVdC 4. Polyesters PET 5. Polyamide (PA) 6. Regenerated cellulose film

PLASTICS: POLYOLEFINS
Polyethylene (PE) HDPE 940 kg/m3 LDPE < 915-939 kg/m3 Polypropylene (PP) 900 kg/m3 Permeability of polyolefins

High O2-permeability
Low H2O-permeability

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GAS BARRIER PROPERTIES

PLASTIC:POLYOLEFINS
LDPE (Low Density PolyEthylene) Excellent chemical resistance (e.g. acids) Sensitive to oils and greases Films and bottles (squeeze-bottles) Suitable for deep-freezing applications Excellent sealing properties: often used as outer layer of multi-layer films

50% cristallinity

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PLASTIC:POLYOLEFINS
HDPE (High Density PolyEthylene) 90% cristallinity (more linear structure than LDPE)

=> higher density than LDPE

=> less transparant than LDPE Better resistance to oils and greases than LDPE Films and bottles LLDPE (Low Linear Density Polyethylene) Similar molecular structure to HDPE More crystalline than LDPE (more linear)

PLASTIC:POLYOLEFINS
PP Good resistance to greases and chemicals High temperature stability Suitable for heat processes (e.g. microwave applications, sterilisation) Good gloss & high clarity => ideal for reverse printing Trays, closures, films (cast oriented form) Seal layer in retortable pouches, hot filled bottles and microwaveable packaging

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PLASTICS: COPOLYMERS OF ETHYLENE

Ethylene Vinyl Acetate (EVA) VA => crystallinity => permeability and clarity

Mostly used in multi-layer applications

Three advantage over LDPE Heat sealing temperature is lower Barrier properties are better Excellent stretch properties Applications Stretch wrapping: replacing PVC Heat sealing layer for PET and BOPP films

PLASTICS: COPOLYMERS OF ETHYLENE

Ethylene Vinyl Alcohol (EVOH) Excellent processability on machines Superior barriers to gasses, odors and solvents Multi-layer applications (in many cases surrounded by polyolefins)!!! Hydrophilic => moisture absorption => barrier properties Ethylene => barrier properties and moisture barrier

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EVOH
Gambar struktur

PLASTICS: SUBSTITUTED OLEFINS

Polystyrene (PS) Amorphous structure different types Examples 1. High Impact Polystyrene (HIPS) Adding synthetic rubbers during polymerization => brittleness of PS Thermoforming applications (cups for cream) 2. Expanded Polystyrene (EPS) PS foam Disposable packages (e.g. trays for meat and produce)

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PLASTICS: SUBSTITUTED OLEFINS

PolyVinylChloride (PVC) Largely amorphous polymer Permeability properties Water vapour barrier lower than polyolefins Gas barrier higher than polyolefins Applications 1. Film: e.g. stretch wrapping (+ stabilizers and plasticizers) Excellent gloss and transparency 2. Trays Environmental issues!

PLASTICS: SUBSTITUTED OLEFINS

PolyVinylidene Chloride (PVdC) Unique combination of low permeability to water vapournd gasses, odours, greases and alcohols Suitable for hot filling applications and retorting Component in multilayer barrier containers or films

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PLASTICS: POLYESTERS
Carbon-oxygen-carbon links 1. Poly(Ethylene Terephtalate) (PET) Bottles, films, trays Largely amorphous => excellent transparency Capacity to crystallize under certain controlled conditions (CPET) Preventing deformation during cooking and serving PET bottles Stretching: in biaxial orientation => good gas barrier => minimize bottle weights

PLASTICS: POLYAMIDE
Polyamide (PA) Also called nylons Mechanical strength (BOPA!) Good gas barrier properties (when dry!) Highly permeable to water vapor Excellent thermal stability

Applications
In combination with LDPE or EVA

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PLASTICS:REGENERATED CELLULOSE FILMS

Regenerated Cellulose Film (RCF) Also called cellophane Cellulose from wood, cotton, hemp Good gas barrier properties (when dry!) Often used in multi-layer film Recently: replaced by BOPP in many cases Twist wrapping of sweets

PLASTIC: MOST USED MATERIAL

Rigid sheets for thermoforming HIPS, HDPE, PP for bulk layers Flexible films LDPE, LLDPE Bottles PET, HDPE

Barrier layers
EVOH, PVdC

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PLASTIC: PERMEABILITY OF PLASTICS

Permeable to: Gases Water vapour Organic vapors Other low molecular weight compounds Permeability depends on: Packaging material itself Integrity of packages (including seals and closures!!!)

PLASTIC: MODIFICATION
Adding additives in plastics Co-extrusion, lamination, coating Orientation Metallization

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PLASTIC:MODIFICATION
Aim: improve different properties of the basic polymers to comply with the demands related to food packaging Example Orientation / crystallization Increase interaction between molecular strains => increase barrier properties Filling agents Decrease interaction between molecular strains => decrease barrier properties Also when H2O is absorbed (e.g. in O2-barrier in EVOH decreases due to absorption of H2O)

PLASTICS: ADDING ADDITIVES

Additive: an auxiliary ingredient enhancing the properties of the parent polymer without appreciably altering its chemical structure Food legislation: positive list! Types: Processing additives Flexibilizers Antiaging additives: for ex: UV stabiliser Surface property modifiers: antistatic and antifoaming agents Optical property modifiers: give colour Foaming agents: Active packaging technology

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CO-EXTRUSION, LAMINATION, COATING

Three methods to produce multilayer structures Co-extrusion: simultaneously extrude two or more different polymers, which fuse into one film/sheet Lamination: combining two or more different films/sheets (plastics or nonplastics) by means of adhesives and curing systems Coating: applying one or more layers of a fluid or melt to the surface of a material

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