New Developments Environment Friendly Adhesive Systems. Shilip Kumar Business Manager Rohm and Haas (India) Pvt. Ltd.

Transcription

1 New Developments Environment Friendly Adhesive Systems Shilip Kumar Business Manager Rohm and Haas (India) Pvt. Ltd. August, 2008

2 Contents Drivers for Innovation in Adhesives Laminating Adhesives An overview New Developments : Solvent-Free Adhesives Fast Cure adhesives Retort / Boil in Bag adhesives ELM adhesives Water Based Dry Lamination adhesives

3 Drivers for Innovations in Adhesives Key Drivers Total Cost reduction Shorter order to ship cycle times Stricter regulations and increasing consumer awareness of food safety Packaging with enhanced features Environmental concerns Innovations to address these needs New generation Solvent-free adhesives: Fast Cure High Performance Retort Grade Water-based adhesives

4 Solvent-based Dry Lamination Solvents to be dried Typically 2 component polyurethane (PU) adhesives + Relatively easy to run + Versatile: General Purpose to High Performance - Residual solvent odour in laminate - Safety & Health risk - Environmental pollution - Risk of carcinogenic aromatic amine - Slower speeds versus solvent-free - Most expensive

5 Solvent-free Lamination No Solvents used 1 or 2 component Polyurethane (PU) adhesives + Most cost effective + High speeds + No residual odour/solvent - Needs skilled operators and good equipment - Handling of isocyanates, health risk - Risk of carcinogenic aromatic amines - Difficult to run rigid & polar substrates (e.g. PET/Foil)

6 Water-based Dry Lamination Water-based emulsion 1 or 2 component acrylic based adhesives + Cost effective + No residual odour + No risk of carcinogenic aromatic amines + Can be used on existing Dry Laminators at similar speeds to SB + Ease of use + Immediate slitting and processing + Environmentally safe - Drying capacity of machines - Ink compatibility - Needs Operator training

7 Adhesives Applications Liquids Retort Medium Performance -SB, SL, WB (lower end) High Performance Mainly SB, New SL Dry Products General Performance -SB, WB, SL Generally 2 layer laminates Typically 3 layer laminates 4 layer complex laminates

8 Laminating Adhesives : How They Stack Up Good Low High Fair Fair Low Low Easy Low High Fair Easy Economics Safety, Odor Risk Cure Time* Processing * - Slitting, heat sealing

9 Key Regulations : Adhesives in Food Packaging 21 CFR To cover laminates subjected to room temp applications (49 C and below). 21 CFR Laminate structures for use at temp of >121 C (retortable laminates) 21 CFR Laminate structures for use at temp between C as boilable, hot-fill. 90/128 EEC : PAA limit : 10 ppb BgVV : PAA limit : 2 ppb FDA : Compositional regulation/need for functional barrier

10 Solvent-Free Adhesives Concerns Low green bond. Minimum 24hrs cure time for slitting. Suitable only for General performance segment and some Medium performance jobs. Food Legislation - Carcinogenic Primary Aromatic Amine issues.

11 Solvent-Free New Developments Fast cure Retort / Boil in Bag Extremely Low Monomer (ELM)

12 New Fast Cure Solvent-Free adhesives Unique Fast Cure Technology RT Applied & Cured Similar pot life as current products 200 gms/25mm bond seen in 2 hrs Second pass & Slitting possible in 4 hours Ready to fill in 3 days (including liquids) Good Metal adhesion Met.PET & Foil Lower Work in Process (WIP) costs Hot fill FDA clearance ( ) 3 days with Mor-Free TM C-411 & 5 days with Mor-Free TM C Products commercialized : Morfree L C-411 (100 : 40 pbw) Morfree L C (100 : 63 pbw) To know more about our Mor-Free L Fast Cure Technology

13 Pot Life of MF /C-411 at 100:40 Mix Ratio Pot Life For Mor-Free L /C Pot life at 38 C 30mins Viscosity, cp C 38 C 43 C 49 C :00:00 0:14:24 0:28:48 0:43:12 0:57:36 1:12:00 1:26:24 Time, Hours:minutes:seconds

14 Pot Life of MF /C at 100:63 Mix Ratio Pot Life For Mor-Free L /C Pot life at 38 C 43mins Viscosity, cp C 38 C 43 C 49 C :00:00 0:14:24 0:28:48 0:43:12 0:57:36 1:12:00 1:26:24 Time, Hours:minutes:seconds

15 Comparative Bond Strength Development Bond Strength Development in PET/PE Avg.Load in gms/25mm Bonds develop rapidly in 8hrs MF403A/C-411 MFL75-164/C-411 MFL75-164/C hrs 8hrs 24hrs 48hrs 26days

16 Conclusion - New Fast Cure / Hot Fill Cure response is fast, pot life is similar to more slowly curing products Fast bond development for further processing (500 gms/25mm in 8 hours) Good metal adhesion depending on coreactant choice (Mor-Free TM C- 411) A solvent free product that can be used for hot fill applications and has FDA Room temperature application and cure.

17 Solvent-Free for Retort Laminates Mor-Free TM 225 / C-33 is a new retort grade SL adhesive system Meets FDA and Better Economics due to lower coat weights as compared to SB adhesives. Is RT applied and can be RT cured, but hot room is generally recommended to speed up cure. Is more robust on all clear barrier structures. Not recommended for foil containing structures with aggressive fills

18 Physical Properties Mor-Free TM 225/C-33 Mix Ratio 100 : 100 pbw Viscosity 3500 / 2400 cps Sp. Gravity in gms/cc / Application temp C Pot life 20mins at 54 C Coat weight gsm

19 Bond Strength study Bonds - Peak Load (GLI) Pre-Retort Bond Post Retort Bonds PetSiOX/Nylon/44 0CPP DupontLBT/SiOx Nylon/440CPP PETAlOx/Nylon/44 0CPP

20 Solvent-Free ELM Sources of Primary Aromatic Amines Adhesives Inks Laminate Construction Additive composition in Films Curing conditions of laminate Storage conditions of laminate Age of structure

21 Amines may be formed as follows: Isocyanates react with water R - NCO + H 2 0 intermediate stage, carbon dioxide splits off R - NH 2 corresponding amine is formed

22 Amines may be formed as follows: Polyurethanes can hydrolyse (especially under sterilization conditions) R`- O - CO - NH - R + H 2 O intermediate stage, carbon dioxide splits off R`- OH + R - NH 2

23 Historical Developments in Solvent-Free Technology 0 % Aliphatic Aromatic NCO level 0.1 % > 10 % ELM Extremely Low Monomer Hybrid different NCO s 2 comp MDI based 1 component

24 Solvent Free ELM Adhesives - Specific Advantages Superior Properties Universal product tailored to application needs with choice of coreactant Good adhesion to films, metallized films and aluminum foil Superior chemical and heat resistance with hot fill Extremely good sealability Total Safety Dramatically reduces the risk of Primary Aromatic Amine formation Reduces the risk of anti seal effect No hazardous substances, no transport or storage restrictions Easy to use and process Ambient cure, no post curing No preheating in hot rooms Extremely easy to use, less waste, clean-up and down-time To be applied at very high application speeds without misting at low application temperatures Very stable pan life, no moisture reactivity in the pan, no waste Excellent wettability of difficult substrates ELM Products Mor-Free TM 415+CR Mor-Free TM ELM415+CR Mor-Free TM ELM415+CR87-550

25 Mor-Free ELM Solvent-free Adhesives Food Contact & Migrations µg /100 m l/4 d m ² 10,00 9,00 8,00 7,00 6,00 5,00 4,00 3,00 2,00 1,00 0,00 20 ppb 10 ppb Decay example of Primary Aromatic Amines in a OPA printed PE Laminate Old Limit /EC New limit 01/07/ Days Aliphatic Polyurethane ELM 415 A + CR Hybrid Polyurethane NCO/OH Polyurethane TREND

26 Acrylic WBDL For Flexible Packaging

27 Water Based Acrylic Adhesive Chemistry Very Different from SB/SL PU Systems An emulsion polymer made by free radical polymerisation of acrylic monomers on water. High MW polymer particles finely suspended in water. Appearance : Opaque white Particle Size : microns Molecular Weight : 500,000 1,000,000 is typical Very flexible Laminate bond strength is related to the deformation energy required to separate the laminate.

28 WB Adhesives - Benefits User Friendly Easy Mixing / No Viscosity Adjustment Cost effective No Adhesive wastage Better Optics No VOC or DG Issues Safer, Greater Regulatory Compliance Faster Processing No WIP Shorter Time to Market Performance Equivalent to Medium Performance PU Systems

29 Water Based Acrylic vs Solvent Based Urethane Water Based Acrylic Very High Molecular Weight Low Viscosity (Particles) High Application Solids Solvent Based Urethane Low Molecular Weight Viscosity increases dramatically with increasing molecular weight (Chains) Low Application Solids Polyurethane : High adhesion/ Moderate cohesion Energy propagates crack Acrylic : vs. Moderate adhesion/ High cohesion Energy deforms adhesive

30 Robond - How it works

31 Shear vs. Laminate Bond Strength Bond Strength (grams / 25mm) Shear Strength (kn/m2) Robond 1K GP Adhesive Solvent Based MP Urethane Robond 2K MP Adhesive Green Bond Cured Bond Strength Strength Green Shear Strength Cured Shear Strength

32 Factors to Consider 1. Cylinder 2. Pump 3. Dryer Air velocity, Volume of air, Exhaust 4. Nip temperature and pressure 5. Smoothing Bar 6. Ink compatibility wet-out 3 2

33 Cylinder Different Cell Geometries Pyramid Quad Channel Quad (QCH) 3 3

34 Smoothing Bar

35 Smoothing Bar

36 Pump selection Critical to minimize foaming Select pumps with minimum shear Do not use ink pumps, centrifugal or gear pumps Recommendation: peristaltic or diaphragm

37 The Robond TM L Family Robond L Acrylic Dry Bond Laminating Adhesives Robond L-90D General Purpose Robond L-208 / CR-3A Medium Performance * Robond L-168A New Development

38 Concerns with WB Ink wettability Universal Ink wet-out is an issue Wet-out problem can be resolved using an Inline corona treater. Corona Treater cleans the surface of the printed film of waxes, low molecular weight compounds,.. New Product to address this concern Robond L-168A Robond L-168A has good wettability shown promising results on a wide variety of Ink systems.

39 Robond L-168A overcomes ink and substrate wetting issues With General WB With Robond L-168A Poor wetting 100% wetting

40 Robond L-168A overcomes ink and substrate wetting issues With General WB With Robond L-168A Poor wetting 100% wetting

41 Conclusion Environment Friendly WB adhesives a viable option for GP & lower end MP applications. Newly developed product will address Ink wet-out related issues.

42 Rohm and Haas Company - Leading supplier of adhesives and coatings for the flexible packaging industry A comprehensive product portfolio for all bonding needs Adhesives for paper, film and foil lamination - General purpose through high performance. - Water-based, solvent-based, solvent-free energy curable. Heat-and cold-seal coatings - Solvent-based, water-based, barrier, dispersions. Primers Extrudable Tie Layer resins

43 Thank you for the kind attention.