VACUUM COATINGS FOR CLEAR BARRIER PERFORMANCE

Transcription

1 VACUUM COATINGS FOR CLEAR BARRIER PERFORMANCE Professor Nadir A.G. Ahmed Idvac Ltd. Greenheys, Manchester Science Park Pencroft Way, Manchester M15 6JJ, England Tel: +44(0)

2 Name: Professor Nadir Ahmed Title: Managing Director Company: Idvac Ltd. Presentation title: Vacuum Coatings for Clear Barrier Performance Company Profile : Idvac Ltd., Private Company Headquarter(s): Manchester, UK. Key Operation(s): America, Middle East Number of employees: 3 Western & Eastern Europe, Asia, North & South Products / Services: Process Development & Retrofits; Films & Papers, Web Metalliser & Advanced Materials Consultants. Application markets: Packaging, Holography & Solar Window Films

3 Product Innovation Advanced Materials Development University Links Advanced Vacuum Coating Processes Advanced Laser Technology New Functional Products

4 Risk Product Development Strategy Idea Consideration Market Assessment Viability Concept & Business Plan Optimise Concept & Specifications Exclusive Licence Non-Exclusive Licence Develop Prototype & Samples Samples Evaluation by customer Product launch Time

5 Development of Value Added Products Economic High Competition in aluminium metallisation: Low profit margin. Losing opportunity to meet demand for new high added value coatings. New Business Opportunity. Lack of Budget to Buy New Special Metalliser. Technical Flexibility for wide product range. Latest technology. Technical lead ahead of competition. Exploring new markets for unique products.

6 Vacuum Web Metallizing Process Unwind Rewind Plasma pre-treatment mbar Process Drum Optical probe Winding zone Evaporation zone mbar Aluminium evaporation

7 VALUE ADDED PRODUCTS ON STANDARD METALLISER Gold Colour Cryolite SiOx ZnS Colour Shift Metal Oxides Chrome AlOx Copper Oxide Chrome Alloy Silver Silver Alloy Copper

8 Transparent Barrier Films Global demand for functional additives and barrier coatings for plastic packaging is forecast to grow by 4.3% in the five years from 2009 to reach US$752m by Ref: Pira 2009 Report: The Future of Functional Additives and Barrier Coatings for Plastic Packaging to 2014

9 Clear Barrier For Various Requirements

10 Advantages of Clear Barrier Films Product visibility Retortability Metal detectability Quality control visual inspection Microwaveability Safety Long shelf life Fresher image Convenience Marketing

11 Main Requirements for Clear Barrier Films Visible Transparency > 75% Transparent to Microwave. Good Barrier Properties; Good Quality. Environmentally Friendly; Easy to Recycle. Health & Safety: Safe for consumer; No interaction with food content. Selling Price: Competitive to Standard Aluminium Metallisation.

12 Global Market for Transparent Barrier Films 2008 Source: Flexible & Plastic Packaging Innovation, Vol.2, Issue2, 2008

13 Films Used for Transparent Barrier Coatings *Others include: OPP, PVOH and COEX OPA: Mainly Japan

14 Global Market for Transparent Barrier Films 1. In 2009 Japan exported million sq m of Transparent Films (mainly AlOx & SiOx) to Europe. 2. Annual Growth: 5-10% 3. In UK: mainly for Fresh meat and Rice. Sources: Allied Development Corp.,USA. Barrier Films and Coatings PCI Film Consultants, UK. Private Communication Private Communication with UK Converting Companies

15 Barrier Requirements For Packaging Product Primary Secondary Tertiary Fresh Meat Oxygen Moisture Light,aroma Dairy products Oxygen, light Moisture Condiments Oxygen Flavour Moisture Coffee Oxygen Moisture, light Potato chips Moisture Light Oxygen Bakery goods Moisture Flavour

16 Clear Barrier Production Technologies Transparent Barrier Coating SiO x, SiO 2, Al 2 O 3, Metal Oxide, Others Thermal Evaporation & Electron Beam) Sputtering PECVD Fast, Cost effective Slow, expensive Medium line speed Good Oxygen & Water Barrier High quality Clear, Good Oxygen and Water barrier Good quality Light colour/transparent Not very transparent Stand alone no lamination required Lamination may or may not required Good properties when laminated

17 Vacuum Deposited Clear Barrier Coatings PVD RESISTANCE HEATED Non- Reactive SiOx ; Melamine Reactive SiO +O2 Reactive Al + O2 ELECTRON BEAM HEATED Reactive Reactive Mixed Reactive Mixed Non-Reactive Low cost reactive SiO + O2 Al + O2 SiO + Al + O2 SiO2 + Al2O3 SiO + O2 PECVD Medium frequency, RF, Micro-wave. Micro-wave. Silicon based coatings Carbon based coatings

18 Thermal Evaporation SiOx Non Reactive low productivity low investment long cycle time High material cost AlOx Reactive high productivity High investment in control system low material cost layer sensitive to elongation Metal Oxide Non Reactive Medium productivity Low investment Medium-Low material cost No static build up

19 Electron Beam Evaporation AlOx Reactive high productivity high investment low material costs layer sensitive to elongation SiOx/SiO2 Reactive high productivity high investment low material costs high mechanical resistance

20 Chemical Vapour Deposition SiO2 Reactive low productivity high investment low material costs Carbon Reactive low productivity high investment low material costs

21 Properties of Vacuum Deposited Transparent Barrier Coatings on 12µ PET Film Property Process OTR * WVTR ** Retortability AlOx SiOx Reactive Evaporation Thermal Evaporation Good Good Metal oxide SiOx Thermal Evaporation Chemical Vapour Deposition Good Good *cc/m2 /day at 23 o C, 0% RH. ASTM D3985 ** g/m2/day at 38 o C, 90% RH. ASTM F1249

22 Oxygen Transmission Rates of Coated 12 µ PET & BOPET Films 100cc/m2/da 140cc/m2/day

23 Barrier Test of Metal Oxide Without Lamination

24 OTR vs Metal Oxide Thickness for 23 micron PET

25 Comparison Between Metal Oxide & Other Coatings

26 Transparency of Metal Oxide Coating on 12µ PET At Different Line Speeds

27 Applications of SiOx for Food Packaging Packs for Cheese & Dairy Products: OPA-SiOx/PE Packs for Ground Coffee: PET-SiOx/PE Packs for Processed Meat Snacks: PET/PET-SiOx/PP Packs in Pouches for Dry Pet Food: PETP/SiOx/Adhesive/PE or PP Packs for Clear Cosmetic Pouches: PET/SiOx/Adhesive/Sealant Film Packs for Collapsible Tubes: PET/SiOx/Adhesive/Sealant Film Packs for Chocolate Bars: OPP/Adhesive/SiOx/OPP

28 AFM Picture of SiOx on 12 µ PET Film

29 Lamination of Clear Oxide Films

30 Approximate Market Price of Clear Barrier Films Anticipated future market price Anticipated future market price Low Quality SiOx High Quality SiOx

31 Conclusions The market for clear barrier is growing. New metal oxide coating can offer good cost effective alternative to SiOx. The process can be retrofit on standard metalliser with minimum modification. Environmentally friendly product.

32 Thank you for your attention Any Question?