72857953 Recyclable Coatings for Paper Food Service Packaging

8/3/2019 72857953 Recyclable Coatings for Paper Food Service Packaging

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RECYCLABLE COATINGSFOR PAPER FOODSERVICE PACKAGING:FUNCTIONAL & SUSTAINABLE BARRIERS

Islem Yezza, Technical Director



For decades, packaging was seen as nothing but waste, a nuisanceto be avoided

Packaging waste pales into insignificance compared with the losses

caused by food waste

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Source: United Nations Food and Agriculture Organization (FAO)

One-third of food in developing countries is

destroyed before it ever reaches the consumer

Worldwide food loss: 1.3 billion tons/year



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Food packaging—could now move frombeing the villain to being the hero

Three main messages came across with great importance for food packaging:

1. Packaging prevents food waste and saves resources

2. Packaging is part of the solution for an overall resource

efficient economy

3. Packaging facilitates more sustainable lifestyles



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Finding the balance between under-packaging and over-

packaging is the aim for all of our businesses

Source: Innventia



Outline

1. Sustainable Packaging: Trends and markets

2. Enhancing barrier properties of paper: Why Wax is on the Wane?

3. Extrusion coating:

Conventional resin: PE, PEHD, PP, PET and Nylon

Bioplastics: Challenges, Hurdles & Success factors

4. Water-based coating: A bright Future

5. Paper Foodservice Packaging Innovations

6. Wrap-up…

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Eco-conscious Consumer demand for more Sustainableand Convenient packaging

Retailers and manufacturers perceive a marketing

advantage. Eco-friendly, Green, Bio-based, Compostable

& Biodegradable: big selling points

Legislation & regulations pushing for innovative eco-

friendly packaging

Sustainable packaging: Win-Win-Win for the environment,

for manufacturers and suppliers, and for consumers

Sustainable Packaging Sustainability is a Shared Responsibility

World demand for green packaging—including recycled-content, reusable, and degradable

packaging is projected to rise 5.7% per year to $212 billion in 2015 (Freedonia, 2011)

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Provides versatile and responsible packaging solutions for product

manufacturers, retailers, and consumers

Paper has an excellent image as packaging material (renewable, recyclableand biodegradable)

Paper packaging accounts for nearly 3/4 of all packaging materials recovered

for recycling (The Responsible Package, 2010)

Paper-based Packaging

The Responsible Package

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Improving paper's barrier properties is seen as a crucial step in increasing itsviability as a packaging material

The missing performance and barrier properties of paper can be compensated by:

Paper-based Packaging

Improving barrier properties

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1. Wax impregnation: curtain, cascaded

2. Extrusion coating: Petro-based resin and Bioplastics

3. Water-based coating



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Petroleum-based wax has traditionally been used as a

moisture barrier to preserve the strength of a corrugatedcontainer holding iced or wet products

Waxed paper-based packaging are raising Recyclability,Sustainability and Renewability Concerns

Wax-coated Packaging Wax is on the Wane

Growers and retailers are looking for alternatives to wax



Wax-coated packaging are not recyclable: waxcoatings do not dissolve in water, so they cannot easily

be recycled

Wax-coated packaging are heavy

Paraffin based wax, a non-renewable resources isbecoming more expensive

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Why Wax is on the Wane Sustainability & Economic Concerns

Many leading retailers and grocers, including Wal-Mart and Costco have beendemanding an eco- friendly alternative to wax coated boxes from their suppliers



The future is clear – wax replacement packaging willbecome a necessity

Opportunities to sharply reduce their landfill costs,while boosting their recycling levels

In 2010, the corrugated industry shipped 6.4 billionsquare feet of boxes using recyclable waxalternative coatings. That’s over 30% more than the

4.9 billion square feet shipped in 2009 and 385%more than when first measured in 2002, dramaticallyincreasing the volume of containers that could berecycled. (Source: Corrugated Packaging Alliance)

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Wax Alternative Growing market



Inside: Products packaging requirements FDA compliant, moisture and gas barrier, water

repellence, grease and oil barrier, meatrelease…

Outside: Environmental considerations

Storage and handling conditions, Printing,glueability, scealbility, scuff resistance, water

resistance, anti-slip, anti-abrasive, heat

resistance, high gloss or matte…

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Wax replacement

Think Outside & Inside the Box



Extrusion coating allows processing a variety of polymers and board

Paper and paperboard (SBS, CCNB, Bending Chipboard, Liner)

LDPE - most widely used material for extrusion coating applications: easy to

process, provides adequate moisture barrier, has excellent sealing properties,

grease resistance and lamination layer and cost competitive

PP and HDPE

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Extrusion Coating PE, PP and HDPE



Hygroscopic resin consume more torque than the standard olefin

resin: Low shear (low speed), high torque

PET coated paperboard: Thermoformed paper-based trays,Ovenable/Microwavable paper-based trays/folding carton

Nylon coated paperboard: Corrugated box (pass through the

corrugators)

PLA coated paperboard: Compostable Paper-based bags, Take-

out box…

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Extrusion Coating Hygroscopic Resin



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BioplasticSustainable and Functional

LDPE: Shortage and Price increase

Biopolastcis can be used as barrier coatings

The bioplastic Market in 2010 was 771 million pounds. This is expected to reach nearly

932 million pounds in 2011 and then further increase to 2.5 billion pounds in 2016, at a

CAGR of 22% for the 5-year period (BBC Research 2011)



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Bioplastic

Confusion in terminology

Biopolymers are plastics that are biodegradable/

compostable and/or have bio-based content

Biomass based plastics are not always

biodegradable

Biodegradable plastics are not always biomass-based



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Biodegradable/Compostable/BiobasedDistinctions are subtle but significant

All biodegradable material are not compostable

Biobased not necessarily compostable

Biobased: Focus is on the ―origin of life‖ or where did the

carbon come from (ASTM D6866). Uses C14 content

measurement

Compostable: Focus is on ―end of life or disposal‖.

Independent of carbon source standards (EN13432 and ASTM

D6400)

http://2.bp.blogspot.com/_XMm2OsWNvVg/TTjWoSbg33I/AAAAAAAABts/jFr1ru9AL5s/s1600/288525-USDA_launches_new_biobased_product_label.jpg



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Bioplastics Challenges & Hurdles

1. Confusion in terminology: Biobased, Compostable, biodegradable, Oxo…?

Education is needed to clarify in the minds of consumers and clients, the environmental

benefits of these new materials

2. End of life hurdles: the puzzle?

Consumers are confused when it comes to separating biodegradable, compostable andrecyclable plastics. Information about how to best dispose of it, is necessary

3. Carbon footprint: bioplastics not necessarily greener than oil based relatives?

Skeptics about LCA studies: data may not be accurate or complete and system

boundaries are not easily defined



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Bioplastics Challenges & Hurdles

4. Price: Current prices for bioplastics are significantly higher than the cost of PEPeople are environmentally conscious when it’s convenient and affordable

Higher oil prices are lowering the gap in prices of bioplastics and conventional plastics

5. Weak barrier properties: MVTR, OTR, heat resistance, microwavable…?

Barrier and physical properties may limit applications

Blends and compounding

6. Value proposition: Promoting Biobased, Biodegradable or Compostable?

Is not yet clear in the minds of most consumers and clients



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Renewability and sustainability Effect on food scarcity

(Source: London Biopackaging, Bioplastics Magazine, Cargill Dow )

At full capacity, PLA will take 0.15% of the total corn for grain production in the USA

This cannot be considered to have an effect on food scarcity, especially when

compared to bio-fuels: No impact on the food supply

The raw material for bio-plastic production is plant starch. With technologicaldevelopments, soon the starch will be taken from any biomass or crop waste and not

the crop parts used in food production: Triticale very promising

Renewability and sustainability of bioplastics are questioned? Bio-resins are madefrom crops that would otherwise be used for food



1. Compostable and/or bio-based resin

2. Good adhesion

3. Comparable barrier to PE

4. High water and oil resistance (MVTR, oil &

grease resistance…)

5. Cost-effective

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Bio-resin extrusion coating

Expectations



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Processing Challenges: Screw & Dryer

Bio-resin could not be processed at existing PE screw: Stability is poor, melt

temperature are too high, and the available torque is inadequate

1. Bio-resins consume more torque than the standard olefin

resin: Low shear (low speed), high torque → Newscrew

2. Bio-resins are very hygroscopic. Hygroscopic materialsabsorb water, even from the air: In-line drying is essential

→ Dryers



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1. Biopolymer-coating: sustainable and functional barrier

2. Bio-resin extrusion coating: dedicated screw and dryers

3. Trends: volatile oil prices; energy security concerns; environmental benefits;

favourable regulatory initiatives; and the improving performance and

competitiveness

4. The distinctions are subtle but significant: not all bioplastics are created equaland there are a lot of misleading claims out there

5. Education: has to be a combined effort from resin makers, converters and the

companies that will be selling these products to the consumer


Market education



Water-based coatings

Repulpability, an Important Route to Sustainability

With the push towards sustainability, repulpability and recyclability, water-based

technologies are gaining acceptance

The packaging combines the best aspects of two materials: environmentally

friendly paperboard and good barrier properties of water-based coatings

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Sustainable and Functional barrier : can be custom-

formulated to meet the packaging requirements of a

wide range of products - Can be recycled, repulped

and/or composted

Alternative solution to current wax, PE extrusion coating

and film lamination



Latex (as binder, other polymer can also be used)

Mica (pigment, like rocks to achieve moisture barrier)

Clay (second filler, can also be Talc, calcium carbonate)

Dispersant (for processing)

Defoamer

pH control agent

Water-based Coatings

Basic Formulation

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Talc Mica

http://www.spaceman.ca/mineral/index.php?ViewMineral=29


http://upload.wikimedia.org/wikipedia/commons/b/b9/Mica-from-alstead.jpg

http://upload.wikimedia.org/wikipedia/commons/b/b9/Mica-from-alstead.jpg




26Source: Claude Tremblay, Cascades

Water-based Coatings

SEM Image



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Water-based coatings can be custom-formulated to meet the packaging requirements

of a wide range of products

1. Barrier properties : Moisture - Oil and grease barrier 2. Physical & Chemical properties : Scuff resistance, anti-slip, non-abrasive,

stacking strength, corrosion inhibitor, heat sealing, conductive & anti-static).

3. Aesthetic & decorative : color coatings

Water-based coatings

Tailored solutions



Greater heat sealability = more blocking

Higher coating water retention = poorer water barrier effectiveness

Higher water barrier = poorer cold glueability

Higher oil resistance = poorer hot melt adhesion

Higher effectiveness = higher cost

Water-based Barrier

A Balancing Act

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There are always exceptions, but …



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Replace not easily Recyclable and Non Renewable EPS containers

To-Go containersGrease and Moisture Barrier

Packaging Requirements: Moisture barrier, grease barrier, heat resistance,

microwavable, Gluable. FDA compliant, Compostable/recyclable/Repulpable



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Corrugated Boxes

Produce, meat, poultry and Fish

Replace not easily recyclable waxed box and Petro-plastic filmlaminated board

Packaging Requirements: Avoid water wicking inside the linerboard, Endure both

packing house and transport conditions, FDA compliant, withstands Corrugating

process heat up to 375°F/190

°C, Recyclable/Repulpable



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Folding BoxesDry and fatty foods

Replace not easily recyclable Petro-plastic film laminated board/eliminates bags

Packaging Requirements: Prevent Caking and moisture picking, Grease-resistant

linerboard, Holds up to hot-melt glue and cold set adhesives, FDA compliant,

Recyclable and Repulpable



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Food waste bags

Functional, Repulpable and Compostable

Packaging Requirements: Leak proof, Odour proof, Grease barrier, Sealable,

Recyclable, Repulpable and Compostable

Replace Petro-plastic film laminated paper and plastic bags



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Thermoformed paper trays

Functional and sustainable

Packaging Requirements: Leak proof, Grease barrier, FDA compliant,

microwavable, Recyclable, Repulpable and Compostable

Alternative to the traditional Styrofoam trays, PET microwavable trays and others plastic

trays and plates



Italian organic products distributor Ecor, together

with Italian bioplastics maker Novamont and

agricultural group Filogea, has developed a new

100% home compostable folded tray for ready-

to-eat washed salads

Mater-Bi Coated Paperboard (Italy) Compostable folded tray

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Coextrusion coating of PE/EVOH/PE

The EVOH provides the O2 barrier properties needed for the MAP

Material printed black, which is done for aesthetic reasons

Marks & Spencer has launched sliced

meat in paper packaging

Paperlite material is paper with high

stretchability, which can be formed in

existing thermoforming lines without

requiring costly investments

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Sliced meat (UK)

Flextrus Paperlite



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Walki Lids (Sweden)

Durable & Recyclable

In 2010 growth was at 25% and this year sales are expected to increase by some 15-20%

Replace aluminum-based lids

The extrusion coated paper-based lidis durable, easy to print on and can be

cut into different sizes and shapes



Coated Tecta paperboard offers a good resistance against water, water vapour and grease

Replace plastic in many applications: Repulpable, recyclable and

compostable sandwich packaging

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Tecta Paperboard (Finland)Eco-friendly alternative to plastics

http://1.bp.blogspot.com/-HI9v_lH3A-E/TkSZUH_LDSI/AAAAAAAABzY/RnKK4LF2cos/s1600/get_img.jpg



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Boxerchips (Ireland)

Box-in-bag: Innovative Crisp Packaging

Delivers the same volume of product as a standard 40g bag of crisps, but the

compact arrangement allows for an overall reduction in size by as much as 50%

and dramatically crunches the amount of packaging materials used by 35%

The 40 grams product is currently available on 17 European airlines, with 4 millionboxes being sold last year



Major companies are beginning to take note and a few have stepped forward

to lead the ―sustainable packaging revolution‖

Market drivers: Increased focus on recyclability and Increased demand for

sustainability

Innovative paper-based packaging offers environmental, convenience, food

safety and preservation and economics benefits for both customers and

packaging actors

Both the packaging industry and consumers need to work together to develop

a unified set of standards that will end confusion and maintain

transparency in the rapidly growing sustainability sector.

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Wrap-up… Keep the Molecule in Play



Divert from landfill is sustainable, but we must keep in mind the

packaging basic functions: Protect – Inform – Contain –

Transport – Preserve – Display

Wax-coated papers are usually overkill and packaging specs are

frequently unknown

In order to offer custom-formulated wax alternatives, we need to

better understand customer specific needs and packaging

requirements (see Check List)

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Wrap-up… Functionality & Sustainability

At the end of the day: How might we help our customer make more money?



Sustainable

Biobased

Recyclable

Compostable

Quality

Green

Practical

Functional

Safety

Reliable

Smart

Performance

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Contact Information:

Islem Yezza, Technical Director Email: [email protected]

Tel: 819 352-0817

Thank you

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72857953 Recyclable Coatings for Paper Food Service Packaging