Advances in Food Packaging Design for

Shelf life enhancement and

integrity of Quality and Food Safety

Dec, 2014

22

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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