plastics in the microwave oven ce 435 presented by:daniel fulcher christopher hunter martin schaefer...
TRANSCRIPT
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Plastics in the Microwave Oven
CE 435
Presented by: Daniel Fulcher
Christopher Hunter
Martin Schaefer
April 17, 2001
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Introduction• U.S. households owning a microwave oven increased
from 15% in 1980 to 78% by 1989
• Gorman’s New Product News reported the number of new microwave product introductions increased from 278 in 1986 to almost 1000 in 1988
• Microwave frequency of ~2.45 GHz ensures effective penetration into the food and even food heating
• Annual revenues of 3 billion dollars
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Scope
• Max temperatures of 230oF for microwave ovens and 400oF for dual oven applications
• Containers should be sturdy, rigid in shape and capable of supporting its contents
• Limited migration of additives, colorants, or fillers
• Federal Food and Drug Administrative approval
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Home Meal Replacement Packaging
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HMR Packaging
• Crystallized polyethylene terephthalate (CPET)
• Polyphenylene oxide, high impact polystyrene blend (PPO/HIPS)
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CPET Morphology
• Heterochain, modified homopolymer with ~30% Crystallinity
• Step growth condensation polymerization reaction of terephthalic acid and ethylene glycol
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CPET Properties
• Crystallization of PET increases the upper temperature resistance from 230°F to 400°F
• Balance between strength properties and temperature resistance
• Crystallinity of 28%-32% and an intrinsic viscosity of .85 to .95
• Two-layer structure of CPET and APET
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CPET Properties
• Good O2 and CO2 barrier properties
• Acceptable water barrier properties
• Easily colored with black carbon
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CPET Processing
• In 2000, 84 million pounds produced at ~.52 $/lb
• Eastman Chemical Company produces CPET resin under the product name of VersaTray®
• Thermoformed
• Vacuum Snap-Back Thermoforming
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CPET Processing
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PPO/HIPS Morphology
• Fully miscible blended amorphous polymer
• Noryl® manufactured by General Electric Plastics
• Noryl® PPO/HIPS blend is approximately 25% PPO and 75% HIPS by weight
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PPO Morphology • Heterochain homopolymer
• Created by a free-radical, step-growth, oxidative-coupling polymerization
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HIPS Morphology • Grafted copolymer of cis-1,4-poly(1,3-butadiene) and
styrene monomer • Polystyrene chains are atactic • 2% to 15% by weight of polybutadiene
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HIPS Morphology • Polystyrene (PS) and polybutadiene phase separate
creating compartmentalized regions• Polybutadiene forms small, dispersed globules within
the polymer structure
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PPO/HIPS Properties
• Improvements in final blend properties are in direct proportion to the amount of PPO added
• PPO is added to HIPS to increase temperature resistance from approximately 180°F to 230°F
• Blending with HIPS improves PPO’s low resin flow characteristics
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PPO/HIPS Properties
• Small, dispersed globules of polybutadiene elastomer within the PS improves the blend impact strength
• PPO improves the poor gaseous and water vapor barrier properties of HIPS
• Easily colored with black carbon
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PPO/HIPS Processing
• High intensity mixer required to ensure accurate blending during extrusion
• Thermoforming on equipment designed for PS• Thermoform-Fill-Seal process
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HMR Covers
• Heat-seal the food containers
• Most widely used film is multi-layer polypropylene
• Adhesives cause complications in migration testing
• PP is a low cost packaging film ~.53$/lb
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Food Storage Containers
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Polypropylene (PP) Morphology• Zieglar-Natta polymerization• Isotactic is crystalline, atactic is amorphous
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PP Chain Structure• PP is a blend of atactic and isotactic
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PP Properties • Properties and processability determined by isotacticity
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PP Processing• 1550 million pounds produced in 2000 at ~ .53 $/lb. • Injected or blow molded• INSPIRE® PP produced by Dow Plastics
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Regulations
• The code of federal regulations provides guidance on polymers allowed in the direct contact of food.
• Article 177 presents data specific to each polymer
• Composition specifications, allowable coatings,
modifiers, emulsifiers, and testing criteria
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CPET Regulations
• Article 177.1630
• Emulsifier < 2.0 percent of the dry weight
• Additional substances allowed must be generally recognized as safe by the FDA
• < 0.02 mg/in2 of chloroform-soluble extractives for heptane and distilled water migration tests
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PPO/HIPS Regulations
• Articles 177.1810 and 177.2460
• PS: molecular weight > 29,000 and soluble in toluene
• Maximum extractable fractions of chloroform in distilled water and 50% ethanol are 0.0039 mg/cm2
• PPO: intrinsic viscosity > 0.30 deciliter/gram
• < 0.02 weight percent extractable with n-heptane
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PP Regulations
• Article 177.1520
• Density of 0.880 -0.913 and m.p. 160 C - 180 C
• Maximum extractable fraction of n-hexane is 6.4%
• Maximum soluble fraction of xylene is 9.8%
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Testing and Health Issues
• No specific requirements for microwave food containers
• FDA provides guidance for proper microwave migration testing protocols
• Migration tests using food simulants (e.g. cooking oil)
• Migration testing at the highest cooking temperature
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Testing and Health Issues
• Size and type of food, cooking time, and food geometry play part in the maximum temperature
• Consult with FDA before deciding on a migration testing protocol for microwave only containers
• Plasticizers have been linked to endocrine disorders
• Further study needed to determine possible health risks due to migration of polymer additives
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Conclusion
• Primary polymer materials: CPET, PPO/HIPS, PP
• Applications ranging from single use HMR to repeated use food storage containers
• Essentially no health risks
• Cost effective containers
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Questions?
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References annotated in the Polymers in the Microwave written report.
1. Rubbright, H.A., Davis N.O., The Microwave Decade, Packaging Strategies, West Chester, PA, 1989. 2. Becker, R. “As a Matter of Fact.” Chem Matters April 2000: Volume 18 Number 2. Online. Available HTTP: www.acs.org/education/curriculum/chemmatt.html 3. Dow Plastics, Polypropylene Resins Molding Guide. The Dow Chemical Company, 1998. 4. Brady, A.L., Marsh, K.S., The Wiley Encyclopedia of Packaging Technology. New York: John Wiley and Sons, Inc., 1997. 5. Hanlon, J.F., Kelsey, R.J., Forcinio, H.E., Handbook of Package Engineering. Technomic Publishing Company, Inc., 1998. 6. Selke, S.E., Understanding Plastics Packaging Technology. Cincinnati: Hanser/Gardner Publications, Inc., 1997. 7. 1999 CFR Title 21 Food and Drugs, Volume 3. Part 177 Indirect Food Additives: Polymers. Online. Available HTTP: www.access.gpo.gov/nara/cfr/waisidx_99/21cfr177_99.html 8. Eastman Chemical Company. Online. Available HTTP: www.eastman.com/productfiles/prod0018.html 9. General Electric Company. Plastics Division. Online. Available HTTP: www.geplastics.com/resins/techsolution/technifacts.html 10. Department of Polymer Science, University of Southern Mississippi, Macrogalleria, 1996. Online. Available HTTP: www.psrc.usm.edu/macrog/floor2.html 11. Modern Plastics Encyclopedia. New York: McGraw-Hill Companies, Inc., 2001. 12. U.S. Food and Drug Administration. Online. Available HTTP: vm.cfsan.fda.gov/~dms/opa-pmnc.html 13. U.S. Food and Drug Administration. FDA Consumer Magazine, Volume 97, Number 11. Maryland; FDA, 1998.