Flexible Packaging

Design & Selection

Bhupendra Singh
PACKAGING FUNCTIONS
Package is the means of providing
CONTAINMENT
PROTECTION

IDENTIFICATION/
PRESENTATION INFORMATION

CONVENIENCE

BRAND PROTECTION
PACKAGING FUNCTIONS
• “Packaging must protect
what it sells, and sell
what it protects”
 Flexible Packaging
Flexible Packaging is defined as
construction made from flexible
substrates.
E.g. Paper, plastic films, aluminum foil
and other laminates.
These materials can be coated or
laminated.
Applications
A Flexible Pack Offers the Following
Advantages: -
• Variety, reduction in size.
• Convenience of storage resulting in
space saving.
• Ease of opening and reclosing.
• Light weight.
• Disposability.
Components used :-
• Paper, Metallic Foil, Cellophane, LDPE, HDPE,
Polypropylene, Polyester, Nylon, and Oriented
Polypropylene etc.

Substrate combination selected On the

Basis of:-
• Strength, printability, heat salability, opacity,
barrier to moisture & oxygen and similar type
of characteristic.

E.g Paper - Stiffness & printability

Foil - Barrier properties & aesthetic appeal
HDPE - Stiffness& low WVTR
 Factors influencing Flexible
Packaging Design & Selection

0 . Spoilage of Product
1 . Factors Influencing
Pack Design
2 . Factors Influencing Package
Material Selection
 Spoilage of
Product

0. Spoilage of product results from

- Chemical Incompatibility between the

ingredients of the product / packaging material

-Moisture,

-Oxygen,

-Light &

-Temperature changes
 Spoilage of
Product

0 .1 Effects of Moisture
Ψ Crystalline substances absorb moisture, e.g.

CaCO3, Na-Sulphate

Ψ Aspirin can be hydrolyzed by water absorption

Ψ Vitamins are also susceptible to moisture

Ψ Suitable packaging material should be used to

prevent / reduce the effect of water / moisture.

 Spoilage of
Product

0 .2 Effects of Light & Oxygen

Ψ Light has a catalyzing effect on degradation by
oxygen.
Ψ The degradation products may be toxic.
Ψ It is essential that light does not affect the
product.
Ψ Suitable packaging material should be used (e.g.
Amber colour glass Bottle) to prevent / reduce
the effect of light or the product should be
modified if possible.
 Spoilage of
Product

0 .3 Effects of Heat
Ψ Heat can cause product to loose the water of
crystallization & convert the product into amorphous
state.
Ψ The rate of vaporization of some products are
affected by changes in heat (liquid products).
Ψ Many medications are deactivated / degraded by heat
& exposure to light further accelerate the heating
effect.
Ψ Suitable packaging material with adequate protection
from heat should be used. Insulation may also be used
along with coolant for long term transport & storage.
 Spoilage of
Product

0 .4 Effects of Other Factors

Distribution Hazards
• Mechanical Hazards of transportation
• Climatic Hazards of distribution
• Biological hazards of distribution
• Compatibility
 Spoilage of
Product
0 .4.1Mechanical Hazards of transport
• Hazards of loading & Unloading
• Drops, Height of drop

• Hazards of Movements
– Rail : (Shunting Shocks, Vibration, Acceleration /
Deceleration hazards )

– Road : (Vibration, Bouncing of load, Acceleration /

Deceleration hazards )
– Water : (Staking, Vibration hazards )
– Air : (Low pressure, High frequency Vibration hazards )
– Multi-modal Transport
– Hazards of warehousing
 Spoilage of
Product
0 .4.2 Climatic Hazards of distribution
• Exposure to liquids/ water
• Exposure to vapour/ humidity
• Temperature Change (Low / High)
• Pressure Changes (Low / High)
• Dust storms
 Spoilage of
Product
0 .4.3 Biological Hazards of distribution
• Biological Hazards
– Microorganisms
• Fungi
• Moulds
• Bacteria
– Insects
• Beetle, Ants, Termites
– Mites
– Rodents
 Package Design - Bulk Packaging

• Metal Containers
• Fiber / Plywood
• Drums
• Multi-wall
• Heavy-duty Plastics Sacks
FLEXIBLE PACKAGING –
Manufacturing
(CO-EXTRUSION AND
LAMINATES)
 Manufacturing processes of
Flexible Composites
i. Lamination
ii. Extrusion coating
iii. Co-extrusion
 LAMINATION
FLEXIBLE LAMINATES FOR
PACKAGING
It consists of superimposed layers of plastics,
paper or foil bonded together by heat or adhesive
or polymer melt to form a composite film of
uniform thickness and flexibility.

A Laminate is defined flexible, when

substantially parts of it can be folded to 180°
without cracking and without the need of pre-
crease.

Any desired properties can obtained by

different combination.
 TECHNIQUES OF
LAMINATION
• Extrusion coating
• Extrusion lamination
• Adhesive lamination
• Heat lamination
• Wax lamination
• Hot melt coating
 1. Extrusion Coating
• Involves the
application of
molten polymer
from an extruder
to the surface of
flexible
substrate
• Polymer used is
LDPE, EVA,
HDPE, PP etc.
2) Extrusion lamination :-
Hot extruded film is trapped between two other
webs and cooled.
3) Adhesive lamination: -
Applying adhesive to one ply then combining with
another
4) Heat Lamination :–
Heat sealable performed film like polyethylene is
laminated to the backing substrate
5) Wax lamination :–
Molten wax is applied to one ply of material then
combined with second ply.
 APPLICATION

1) Cellophane/ Polyethylene/ Foil/ Polyethylene

Excellent gas barrier,sandwich printing wv resistance

Pharmaceutical tablets, chocolates.

2) Foil/ Adhesive/ Paper/ Polyethylene

WVbarrier, good machnability, good appearance.

Soup mixes, drink powder and dry milk solids.

 APPLICATION
3) Foil/ Polyethylene
Excellent barrier to gas, Water vapors and
light
Hygroscopic products in strip packaging
4) Polyamide/ Polyethylene
Good gas barrier, Good W V resistance, and
Aroma retention.
Meat packing, cheese, boil in a bag pouches,
heavy machinery parts.
 Aluminum foil bearing laminates
(food packaging)

• Waxed rappers:-foil /paper/wax

• Toffee rappers;-foil/ adhesive/paper/wax
• Food overwrapes:-foil/ adhesive/ paper
• Boil in bag pouch:-PET/foil/LDPE
• Instant coffee:- paper/ foil/ PE
• Soft drink conc. :- glassine/foil/LDPE
(withstands product sterilization in package)
• Retort pouch:- polyester/foil/HDPE
• M.R.E package (meal ready to eat):- PET/ foil /PP
 CO-EXTRUSION

Co-extruded film is defined as a

multiplayer film in each distinct layer is
formed by simultaneous extrusion process
through a single die.

Co-extrusion allows one to prepare a

multifunctional packaging material in one
manufacturing step as opposed to traditional
multistep process of coating and lamination.
 TECHNOLOGY OF CO-EXTRUSION

• Extrusion of different polymers through

different extruders.
• Combining them at a common die as different
layers.
• Then blown by compressed air,which forms
bubble between the die head and nip rollers
• The nip rollers make the tabular film in lay
flats, passed on, to the winding and slitting
unit.
• The compressed air settles the bubbles is
important to create uniform width
 Co-extrusion could be considered depending
upon application and number as: -
• Two Layers
• Three Layers
• Five Layers or more
 Extruder

Fig : Schematic illustration of a typical extruder for plastics, elastomers, and composite materials.
 Sheet Extruder

Fig : Die geometry (coat-hanger) for extruding sheet.

 Film Extruder

Fig : Schematic illustration of the production of

thin film and plastic bags from tube first
produced by an extruder and then blown
by air.
Principle Processes utilizing
Co-extrusion Technology
1. Cast Film Co-extrusion.
2. Blown film Co-extrusion.
3. Co-extrusion Coating.
4. Co-extrusion Lamination
5. Cast-sheet Co-extrusion.
Cast Film Co-extrusion:-

Main Focal Point of Technology in the

Cast Film Process is a Design of Die.

Two Types of Dies used:-

 Blown film Co-extrusion
Separate resins are
extruded into a Circular
die.
The molten resin
streams are blown into a
bubble, cooled by air
rings and collapsed in
the primary nip.
The tabular film is
generally slit for
specific packaging
application.
 PRINCIPLE RAW MATERIALS

• Polyolefin (polyethylene and

polypropylene)
• HDPE-LDPE resin
• Copolymers of Ethylene Vinyl Acetate
(EVA), Ethylene Acrylic Acid (EAA) and
Ethylene Methacrylic Acid (EMA)
• nylon, polyvinylidine chloride, PVDC and
ethylene-vinyl alcohol (EVOH)
 RAW MATERIALS FOR
LAMINATES

• Paper
• Aluminum foil
• Plastic film
• Rubber hydrochloride
• Regenerated cellulose
 Materials Involved
• PET -- 10, 12 micron
• BOPP -- 15 to 30 micron
• Met PET -- 10, 12 micron
• MetBOPP -- 15 to 30 micron
• Foil – 7 to 12 micron
• PE Sealant – 20 to 140 micron
• Paper – Maplitho, Glassine, Kraft
 Sealant Layer
• Polyethylene based -- LDPE, LLDPE,

• Metallocene LLDPE, Nylon PE, EVOH PE,

• MDPE, HDPE,

• Polypropelene Based -- CPP

 SPECIALITY COATINGS

PVDC Hotmelt
Acrylic Heat Resistant
PVOH Holograph Effect
LTS Release
Methyl Acrylic Nano Composite Materia
Acid
Al203
Matt
Siox
U. V. Varnish
NEW BARRIER SUBSTRATES

SIOX Coated Film

AL203 Coated Film
Methyl Acrylic Acid Coated Film
Breathable Films
PP / PE Composite Film
Susceptor Film
 MATERIAL COMBINATION
AND PURPOSES
In multilayer film specific function of each layer can be
obtained by designing a symmetrical or non-symmetrical
structure.
A/B/C/B/A –symmetrical structure
A/B/C/B/D –non-symmetrical structure
For E.g. 3-layer co extrusion process
one layer of material A, tie layer & material B.
tie layer consists of a chemically modified polymer that
possesses good bonding properties for adhesion to material
A as well as B.
 PLASMA PROCESS

Wafer

Gas

Metallizing Metallized
process Substrate

Plasma

Cathode
Uncoated Power
Combination Application Achievable Property

LDPE/LDPE Milk film Two colors

HDPE/EVA a) Blood plasma Good mechanical and
b) Food products sealing property

Nylon/Tie/EVO Ketch –up moisture & gas barrier

H/tie/ LLDPE

PP/HDPE/PA Cosmetics & Printable, scratch

pharmaceutical resistant surface
products.

PP/Tie/ Fruit juice Gas, steam & aroma

EVOH/Tie/ PP barrier
 ADVANTAGES OF CO-EXTRUSION
OVER LAMINATION
• Eliminates the extra production cost involve in
Adhesive Lamination.
• Eliminates the use of solvent-based adhesives
• Reduce the amount of expensive polymer, by
reducing film thickness

DI SADVANTAGES OF CO-EXTRUSION

Laminate with sandwich printing can not be

produced
Scraped produced can not be regranulated
Typical Structures for Typical
applications
 LAMINATE STRUCTURE

OPP
REVERSE OR
PRINTED PET
FILM PRINT
DESIGN
ADHESIVE
FOIL
BARRIER METALLISED OR
METOPP
ADHESIVE
PE, OPP
SEALING OR
CPP

PRODUCT
Developments in Flexible
Packaging
 Biscuits
• BOPP / BOPP hs
• BOPP / Met BOPP hs
• BOPP / Met PE
• PET / Met PET / PE
Biscuits
Biscuits
 Candies :
Medium Barrier :
• BOPP / CPP
• PET / PE
• PET / PP-PE

Candies – High Barrier

• BOPP / Met BOPP Hs

Candies :
Candies :
 Chocolates :
Bars :

• Cold Seal For :

1. Sealing without exposure to heat.
2. Excellent seal integrity.
3. High line speeds.
4. “Registered”
Chocolates :
Chocolates :
Chocolates :
Cakes and bakery products :
Bakery products :
 Snack Food
Gas Flushed

• PET / Met PET / PE

Snack Food
Snack Food
 Beverages

TEA COFFEE
PET / PE PET/Foil/PE
BOPP / Paper / PE PET/Met PET/PE
 Milk & Health drink
LDPE co-ex LLDPE
PET / FOIL / PE
PET / Met PET / PE
Milk & Health drink
Milk & Health drink
 Ketch – Up
PET / Foil / PET / PE
PET / Met PET / PE
PET / PE / Foil / Special Poly
 Retort Application

PET / Foil / CPP

Retort Application
Retort Application
Retort Application
 Oil Packaging
• PET/PE
• PET/Met PET/PE
 Ice Creams
• BOPP / PE
• PEARLISED BOPP hs
Vegetables
Vegetables
Vegetables
Vegetables
Other applications
Flexible Pack
Flexible Pack
Flexible Pack
Flexible Pack
Flexible Pack
Flexible Pack
 INSPECTION / TESTS

BOND / SEAL STRENGTH OPTICAL DENSITY

DYNAMIC / STATIC COF DART IMPACT

COLD / HEAT SEAL COMPRESSION STRENGTH

BALLOON BURST BLOCKING MEASURE

SEAL LEAKAGE SCUFF RESISTANCE

BURSTING STRENGTH PIN HOLE MEASUREMENT

ORGANOLEPTIC TESTS GAS CHROMOTOGRAPHY

COLOUR SPECTROMETER OTHER RM TESTS

THICKNESS
UNIT : (mm/GAUGE/Microns)
EQUIPMENT : DIAL GAUGE MICROMETER

IMPORTANT PROPERTY - AFFECTING:

• MECHANICAL PROPERTIES
• SEALABILITY
• BARRIER PROPERTIES
• PERFORMANCE
• PRODUCT PROTECTION.
TENSILE STRENGTH / ELONGATION
ASTM D. 638

• IMPORTANT MECHANICAL
PROPERTY.
• RESPONSIBLE FOR HIGH SPEED
PACKAGING OPERATIONS.
• EQUIPMENT : INSTRON TYPE
TENSILE TESTER.
• UNIT : kg/cm2
PERCENTAGE(%).
 IMPACT RESISTANCE
IS : 2508
• DART IMPACT TEST.
• UNIT g f at 50% FAILURE
• DROP HEIGHT : 66 CMS
• DROP HEIGHT : 155 CMS.
 STATIC COEFFICIENT OF FRICTION
ASTM D.1894

• RELATED TO SLIP PROPERTIES.

• TILTING PLANE METHOD
• SLEDGE 200g.
• AGE OF FILM
• BLOOMING ACTION OF SLIP ADDITIVES.
KINETIC COEFFICIENT OF FRICTION
ASTM D.1894

• FRICTION BETWEEN STEEL

COLLAR AND FILM.
 HEAT SEAL STRENGTH
ASTM F-88
DIRECTLY RELATED TO:

1. DWELL TIME ,TEMPERATURE , PRESSURE.

2. SEAL CONTAMINATION.
3. THICKNESS VARIATION.
4. MFI.
5. TYPE OF SEALANT LAYER
• TYPE OF SEALING PROCESS (IMPULSE /
HIGH FREQUENCY / ULTRASONIC).
• UNIT : kg/15 mm.
• EQUIPMENT : TENSILE TESTER.
 BOND STRENGTH
ASTM D-904.

• RELIABILITY OF CONTINUING ADHESION DURING

PACKAGING, SEALING AND STORAGE.
• THE DEGREE OF BOND VARIES
1. THE INFLUENCE OF OILS / SOLVENTS.
2. THE ADHESIVE USED.
3. THE QUANTITY OF ADHESIVE.
4. AFFINITY TO MOISTURE.
5. EXCESS SOLVENT RETENTION.
6. CLIMATIC CONDITIONS.
UNIT : g / 15mm.
EQUIPMENT : TENSILE TESTER.
WATER VAPOUR TRANSMISSION RATE
IS 1060 –II, ASTM E-96, ASTM E-398

UNIT: (G/M2/24 HRS.) AT 38 ±1°C & 90

± 2% RH.

• MOST IMPORTANT BARRIER PROPERTY FOR

MOISTURE SENSITIVE PRODUCTS

• DECIDES SHELF LIFE OF THE PRODUCTS

• DIRECTLY PROPORTIONAL TO THICKNESS

• VARIES FROM POLYMER TO POLYMER

OXYGEN TRANSMISSION RATE
ASTM D – 3985.

1. MANOMETRIC METHOD.
2. CARRIER GAS (SENSOR).
• UNIT : cc / m2/ 24 hrs / ATM.
• MOST IMPORTANT PROPERTY FOR GAS
SENSITIVE PRODUCTS
• VACCUUM PACKAGING / GAS PACKAGING
MATERIALS
New Concepts/Materials
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