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VACUUM COATINGS FOR CLEAR
BARRIER PERFORMANCE
Professor Nadir A.G. Ahmed
Idvac Ltd.
Greenheys, Manchester Science Park
Pencroft Way, Manchester M15 6JJ, England
Tel: +44(0)161 868 0088
Email: [email protected]
www.idvac.co.uk
Name: Professor Nadir Ahmed
Title: Managing Director
Company: Idvac Ltd.
Company Profile : Idvac Ltd., Private Company
Headquarter(s): Manchester, UK .
Key Operation(s): Western & Eastern Europe, Asia, North & South
America, Middle East
Number of employees: 3
Products / Services: Process Development & Retrofits; Films & Papers,
Web Metalliser & Advanced Materials Consultants.
Application markets: Packaging, Holography & Solar Window Films
Presentation title: Vacuum Coatings for Clear Barrier Performance
Advanced Materials
Development University LinksAdvanced Vacuum
Coating Processes
New Functional Products
Advanced Laser
Technology
Product Innovation
Product Development Strategy
Idea Consideration
Market Assessment
Viability
Concept & Business
Plan
Optimise Concept &
Specifications
Develop Prototype
& Samples
Samples Evaluation by
customer
Product launch
Time
Ris
k
Exclusive Licence
Non-Exclusive Licence
Development of Value Added Products
Economic
High Competition in aluminium metallisation: Low profit
margin.
Losing opportunity to meet demand for new high added value
coatings.
New Business Opportunity.
Lack of Budget to Buy New Special Metalliser.
Technical
Flexibility for wide product range.
Latest technology.
Technical lead ahead of competition.
Exploring new markets for unique products.
Vacuum Web Metallizing Process
Evaporation zone
5 × 10-4 mbar
Winding zone
Unwind
Plasma pre-treatment
5 × 10-2 mbar
Rewind
Optical probe
Aluminium evaporation
Process Drum
VALUE ADDED PRODUCTS ON STANDARD
METALLISER
Gold Colour
Chrome Alloy
SiOx
Silver
AlOxChrome
Silver Alloy
Cryolite
Copper Oxide
ZnS
Metal Oxides
Copper
Colour Shift
Transparent Barrier Films
Global demand for functional additives
and barrier coatings for plastic packaging
is forecast to grow by 4.3% in the five
years from 2009 to reach US$752m by
2014.
Ref: Pira 2009 Report: The Future of Functional Additives and
Barrier Coatings for Plastic Packaging to 2014
Clear Barrier For Various Requirements
Advantages of Clear Barrier Films
Product visibility
Retortability
Metal detectability
Quality control –visual inspection
Microwaveability
Safety
Long shelf life
Fresher image
Convenience
Marketing
Main Requirements for Clear Barrier Films
Visible Transparency > 75%
Transparent to Microwave.
Good Barrier Properties; Good Quality.
Environmentally Friendly; Easy to Recycle.
Health & Safety: Safe for consumer; No interaction with
food content.
Selling Price: Competitive to Standard Aluminium
Metallisation.
Global Market for Transparent Barrier Films
2008
Source: Flexible & Plastic Packaging Innovation, Vol.2, Issue2, 2008
Films Used for Transparent Barrier Coatings
*Others include: OPP, PVOH and COEX
OPA: Mainly Japan
Global Market for Transparent Barrier Films
Sources:
Allied Development Corp.,USA. Barrier Films and Coatings 2000-2005
PCI Film Consultants, UK. Private Communication
Private Communication with UK Converting Companies
1. In 2009 Japan exported
80-100 million sq m of
Transparent Films (mainly
AlOx & SiOx) to Europe.
2. Annual Growth: 5-10%
3. In UK: mainly for Fresh
meat and Rice.
Barrier Requirements For Packaging
Product Primary Secondary Tertiary
Fresh Meat Oxygen Moisture Light,aroma
Dairy products Oxygen, light Moisture
Condiments Oxygen Flavour Moisture
Coffee Oxygen Moisture, light
Potato chips Moisture Light Oxygen
Bakery goods Moisture Flavour
Clear Barrier Production Technologies
Transparent Barrier CoatingSiOx, SiO2, Al2O3, Metal Oxide, Others
Thermal Evaporation&
Electron Beam)
Fast, Cost effective
Good Oxygen & Water Barrier
Not very transparent
Good properties whenlaminated
Sputtering
Slow, expensive
High qualityClear, Good Oxygen
and Water barrier
Stand aloneno lamination required
PECVD
Medium line speed
Good qualityLight colour/transparent
Lamination may or may not required
Vacuum Deposited Clear Barrier Coatings
PVD
RESISTANCE HEATED
• Non- Reactive SiOx ; Melamine
•Reactive SiO +O2
•Reactive Al + O2
ELECTRON BEAM HEATED
• Reactive SiO + O2
• Reactive Al + O2
• Mixed Reactive SiO + Al + O2
• Mixed Non-Reactive SiO2 + Al2O3
• ‘Low cost’ reactive SiO + O2
PECVD
• Medium frequency, RF, Micro-wave. Silicon based coatings
• Micro-wave. Carbon based coatings
Thermal Evaporation
SiOx Non Reactive low productivity
low investment
long cycle time
High material cost
AlOx Reactive high productivity
High investment in
control system
low material cost
layer sensitive to
elongation
Metal Oxide Non Reactive Medium productivity
Low investment
Medium-Low material
cost
No static build up
Electron Beam Evaporation
AlOx Reactive high productivity
high investment
low material costs
layer sensitive to
elongation
SiOx/SiO2 Reactive high productivity
high investment
low material costs
high mechanical
resistance
Chemical Vapour Deposition
SiO2 Reactive low productivity
high investment
low material costs
Carbon Reactive low productivity
high investment
low material costs
Property Process OTR* WVTR** Retortability
AlOx Reactive
Evaporation
1-5 1-5 Good
SiOx Thermal
Evaporation
1-5 1-5 Good
Metal oxide Thermal
Evaporation
1-5 1-5 Good
SiOx Chemical
Vapour
Deposition
1-3 1-3 Good
Properties of Vacuum Deposited Transparent
Barrier Coatings on 12µ PET Film
•*cc/m2 /day at 23o C, 0% RH. ASTM D3985
•** g/m2/day at 38o C, 90% RH. ASTM F1249
Oxygen Transmission Rates of Coated 12 µ PET &
BOPET Films
100cc/m2/da
140cc/m2/day
Barrier Test of Metal Oxide Without Lamination
OTR vs Metal Oxide Thickness for 23 micron PET
Comparison Between Metal Oxide & Other Coatings
Transparency of Metal Oxide Coating on 12µ PET
At Different Line Speeds
Applications of SiOx for Food Packaging
Packs for Cheese & Dairy Products: OPA-SiOx/PE
Packs for Ground Coffee: PET-SiOx/PE
Packs for Processed Meat Snacks: PET/PET-SiOx/PP
Packs in Pouches for Dry Pet Food: PETP/SiOx/Adhesive/PE
or PP
Packs for Clear Cosmetic Pouches: PET/SiOx/Adhesive/Sealant
Film
Packs for Collapsible Tubes: PET/SiOx/Adhesive/Sealant Film
Packs for Chocolate Bars: OPP/Adhesive/SiOx/OPP
AFM Picture of SiOx on 12 µ PET Film
Lamination of Clear Oxide Films
Approximate Market Price of Clear Barrier Films
Anticipated future market price
High Quality SiOx
Low Quality SiOx
Anticipated future market price
Conclusions
The market for clear barrier is growing.
New metal oxide coating can offer good
cost effective alternative to SiOx.
The process can be retrofit on standard
metalliser with minimum modification.
Environmentally friendly product.
Thank you for your
attention
Any Question?