Advances in Food PackagingDesign for Shelf life enhancement and integrity of Quality and Food Safety. Dec, 2014

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1 Advances in Food PackagingDesign for Shelf life enhancement and integrity of Quality and Food Safety Dec, 2014

2 Agenda Emerging technologies Defining Convenience Easy Peel Open Challenges, Sealing Concepts & Applications Functional pouches - Reclosable Functional pouches Two compartment 2

3 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 3

4 DuPont Packaging Survey Results: Packaging breakthroughs Recloseable packaging and microwaveable plastic trays top the list of packaging breakthroughs that changed our lives, according to the nearly 300 people who visited this site from April 9 through May 10, 2013 and voted. Invention 1 Re-Closeable Invention 2 Microwaveable Invention 3 Recycled Content Invention 4 Retort and Aseptic Invention 6 Hot Fill Invention 6 Case Ready/MAP/Value Add 4

5 Convenience & functionality 5

6 Consumer Convenience - Products in the market place 6

7 What is Consumer Convenience? The convenience of packaging includes all of the various aspects that make the use of a producteasier 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. 7

8 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 8

9 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. 9

10 Pouch Peelable Seals PE Interfacial seals fail at interface seal temperature determines strength sealant 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 10

11 Lidding Peelable Seals Interfacial failure Lidding Sealant Tray/Forming Web Cohesive failure 11

12 Appeel Peelable Lidding Resin Formulated 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 open 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 Energyin that lower seal initiation temperature reduces seal bar temperature required 12 12

13 Food & Beverage 13

14 High temperature Sterilization applications Steamed Rice Package 14

15 Functional 15

16 Burst Peel Concept 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 16

17 Burst Peel Initiation peel Peel force Continuation Peel PE-HD / Surlyn Blend Peel force as a function of time and distance Time 17

18 Functional pouches Reclosable 18

19 Why Recloseable Packages? Consumer Trends Food Safety On the Go Snacking Convenience Sustainability How reclosesable packages address consumer trends? 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 Aging Population 19

20 Voice of Customers 98% Retailers said that reclose packaging positively changes products. 67% Consumerssaid thatreclosepackagingisveryimportantin their purchasing decisions 31% Consumersalwaysbuyproductsthathaveabilityto be reclosed 20

21 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 21

22 Reclosable - Mechanism Zippers Sliders Labels Strips Velcro Pre Made Pouches Zip-Pak Fresh-Lock Zip Grip Slide-Rite Fresh-Lock Reseal it Label Macfarlane FreshPak Sealstrip Pres Lok Velcro/Amcor Pre Zippered Rolls Inno-Lock Hudson-Sharp Prime Label Inc. Peel&Seal Sealstrip ZipBox Zip-Pak FFP Pack. Sol. Esterpeel Reseal It Macfarlane 22 22

23 Reclosable Structure: Back layers / PSA / Surlyn PSA =Surlyn PSA 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 23

24 Resealable with Tray 24

25 Functional pouches 2 compartments 25

26 Frangible Pouch with Surlyn 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 Commercial Product Two Compartments Liquid - Liquid Liquid - Solid Liquid - Powder Permanent Seal on Perimeter Lock-up heat seal of Surlyn Stand-up Pouch 5 layer blown-film construction plus reverse printed OPET 26

27 Technology Brief: Lock and Peel Technology Unmet Need How to make a pouch (or bag) with easy open seal on top and lock up seal every where else? Peeling and Sealing: Surlyn AD8273 Structure: OPET/Surlyn film Broad sealing plateau for both peelable and lock up seals Peel Lock N/25mm Sealing Curve - Peel-Seal to itself (30 kg force, 1 sec) Lock Peel New Functionality: Dual Mode Seal Concept: Seal Strength and Failure Mode changes as Function of Sealing Temperature Temperature Force Seal range (lock up) Peel range Temperature 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. 27

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29 Possible Applications Milk & Juice Powder Sport Drink Cosmetics Hair Dyes Etc 29

30 Copyright 2011 DuPont or its affiliates. All rights reserved. The DuPont Oval Logo, DuPont, The miracles of science and all products denoted with or are registered trademarks or trademarks of E. I. du Pont de Nemours and Company or its affiliates. Images reproduced by E. I. du Pont de Nemours and Company under license from the National Geographic Society. 30