polyolefin dispersions for paper and paperboard water barrier

Dow Coating Materials

Polyolefin Dispersions

for Paper and

Paperboard Water

Barrier

Zellcheming 2019

John Haigh – Technical Sales Manager EMEA TS&D

Roland Pelzer – Senior Marketing Manager, Coatings Europe

®™ Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow

Incumbent disposable cup performance How can disposable cups be improved?

2

Acids Fats Alcohol Sugar

Staining Heat Flexible Sealable Cost


Environmental improvements for disposable cups

3

Less raw material Lower weight Fiber recovery Less waste

Thinner, repulpable barrier

Maintain same product performance


Extruded film adhesion and coat weight

4

50 µm

25 µm

13 µm

Ad

he

sio

n

Adhesion (mechanical) linked to polymer cooling

Decouple adhesion from application thickness!*Morris, B. A.; Understanding why adhesion in extrusion coating decreases with

diminishing coating thickness; Journal of Plastic film and Sheeting 24 (2008)


Disposable cup improvement: Alternative

5

Less RM Lower weight Fiber recovery Less waste

Thinner, repulpable barrier maintain same product performance

Decouple application/thickness from performance


What are Polyolefin Dispersions (PODs)?

Polyolefin dispersions (PODs): performance of high-molecular-weight

thermo-softening material with the application advantage of high-solid

waterborne dispersion

6


Advantages of PODs

Polyolefin dispersions (PODs): performance of high-molecular-weight

thermo-softening material with the application advantage of high-solid

water-borne dispersion

7

Thin coating

performance

Ease of

applicationUnique

formulations


Ideal POD for Paper

8

Cupstock Attribute Paper POD Performance

Cure temperature < 100 oC

Coat weight < 10 gsm (5 wt. %)

Viscosity < 1000 cps

Liquid barrier < 10 g/m2

Oil and grease Kit 12 (flat/folded); no leak

Stain resistance No stain visible at all angles

Block Pass (no fiber tear)

Heat seal Pass (with fiber tear)

Mechanical integrity Foldable

Food contact Global

Adhesion Chemical and mechanical

Some properties not found in historical PODs


Case study: Designing PODs for cupstock - Additives

9

Base polymer: olefin polymers and co-polymers (functionalized) Dispersant: functionalized olefin polymer (e.g. carboxylate)

Neutralizing base: low boiling point amine or hard base

Water: particle size, percent solids, viscosity

Additives: adhesion promotors, wetting agents, wax, pigment


Case study: Designing PODs for cupstock

10

Develop multiple prototypes

Application tests


Case study: Paper POD film formation

11

Discrete

particles

< 50 oC

Particle

boundaries

blend

Particle

boundaries

disappear

Melting point for PODs controllable; optimized for paper

Above designed melting point: monolithic coating


Case study: Paper POD adhesion

12

POD designed for mechanical/chemical adhesion. Efficient release

during repulping. Coating ‘self-levels’ for uniformity.


Case study: Recyclability

PTS-RH 021/97 – Category II: Paper and board for recycling (PfR)

13

Handsheets made with recycled fiber

POD: > 99 % of total fiber

present recovered

POD: Enhanced

recyclability over

incumbent (65-80%)*

*Factors: coat weight, pre-coat, composition, repulping conditions, and others


Case study: Paper POD barrier performancePaper POD (10 gsm): similar barrier performance vs. typical PE lined cup (~ 20 gsm)

14

0

5

10

15

20

25

30

35

40

45

50

PE Lined Cup RHOBARR™ 320 Std. POD Acrylic OGR Barrier

Co

bb

Valu

e (

g/m

2)

Water (90 °C/30 mins.)

Coffee (90 °C/30 mins.)

Coffee with Cream (90 °C/30 mins.)

Orange Juice (Room Temp./30 mins.)

Diet Coke (Room Temp./30 mins.)


Environmental improvements for disposable cups

15

Less RM Lower weight Fiber recovery Less waste

Thinner, repulpable barrier

Maintain same product performance

50-70 % less 10-15 % lower ~ 100 % yield 50-70 % less


Summary and ConclusionPaper PODs meet application performance requirements for hot cupstock with improved

sustainability over incumbent Paper PODs meet application performance requirements for hot

cupstock with improved sustainability over incumbent.

Typical incumbent performance at less than half the coat weight

▪ Broad spectrum of test liquid resistance, including oil and grease

▪ Heat sealable, good block performance, foldable, resists staining

▪ Coatings can represent < 5 wt. % of finished article (monomaterial)

▪ Certified repulpable and recyclable (PTS-RH, SBS-E)

▪ Polyolefin dispersion for paper: RHOBARRTM 320

Continued Focus

▪ Sustainability and environmental impact

▪ Bio-sourced raw materials PODs, recycled polymer, compostable

▪ Dialed-in performance to meet application needs

▪ Property/cost balance addressing specific needs

16

Dow Coating Materials

Questions or comments?

Thank you

18

Handling precautions

Product stewardship

Customer notice

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