Table of Contents - i

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Rosamond Riley
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1 Table of Contents Section I: Introduction... 1 A. Study background... 1 B. Specific materials selected for the study... 2 Table 1 Oxygen Transmission Rates of Flexible Packaging Materials... 3 Table 2 Oxygen Transmission Rates of Flexible Packaging Materials... 4 C. Definitions and terms... 5 D. Study methodology and organization... 9 Section II: Executive Summary A. Today s barrier mainstays B. New or emerging barrier options C. Potential barrier players Table 3 Barrier Material Growth Summary Section III: Barrier Materials and Technologies A. Resins (films from resins) Temperature dependence Figure 1 EVOH Oxygen Permeation vs. Temperature Humidity Figure 2 EVOH Oxygen Permeation vs. Humidity Film thickness Figure 3 BOPP Oxygen Permeation vs. Thickness Coatings Figure 4 OTR of PET and BOPP, Metallized vs. Un-metallized Figure 5 MVTR of PET and BOPP, Metallized vs. Un-metallized B. Aluminum foil Laminations Coatings Capabilities summary Table 4 Aluminum Foil Oxygen and Moisture Transmission Rates Table 5 Creased Aluminum Foil Moisture Transmission Rates Table of Contents - i

2 4. Supplier profiles C. PVOH resins Films Coatings Table 6 PVOH, PVDC, EVOH OT at Moderate Humidity Levels Capabilities summary Table 7 PVOH Oxygen and Moisture Transmission Rates Supplier profiles Converter Profiles D. EVOH extrusion resins Extrusion resins Coatings Capabilities summary Table 8 EVOH Oxygen and Moisture Transmission Rates Figure 6 EVOH Oxygen Permeation Versus Relative Humidity Supplier profiles Converter profiles E. Silica- and alumina-coatings Silica Alumina Extrusion resins Coatings Figure 7 State-of-the-Art Glass-coating Equipment Capabilities summary Table 9 SiO x -and Al 2 O 3 -Coated Films OTR and MTR Figure 8 OT of SiO x -and Al 2 O 3 -Coated PET Films after Elongation Equipment suppliers Supplier profiles Converter profiles F. PVDC extrusion resins and coatings Extrusion resins Coatings Capabilities summary Table 10 PVDC Oxygen and Moisture Transmission Rates Supplier profiles Converter profiles G. Metallized films Extrusion resins Coatings Capabilities summary Table 11 Metallized Films Oxygen and Moisture Transmission Rates 61 Figure 9 Oxygen Transmission of Metallized PET Film after Elongation Supplier profiles Table of Contents - ii

3 H. Polyacrylonitrile extrusion resin Extrusion resins Capabilities summary Table 12 Acrylonitrile Oxygen and Moisture Transmission Rates Supplier profiles Converter profiles I. Nylon extrusion resin Extrusion resins Figure 10 Amorphous Nylon OTR versus Humidity Level Capabilities summary Table 13 Nylon Oxygen and Moisture Transmission Rates Supplier profiles Converter profiles J. Polyester extrusion resin and films Extrusion resins Coatings Capabilities summary Table 14 Polyester Oxygen and Moisture Transmission Rates Supplier profiles Converter profiles K. Polychlorotrifluoroethylene (PCTFE) extrusion resin Extrusion resins Capabilities summary Table 15 PCTFE Oxygen and Moisture Transmission Rates Supplier profiles Converter profiles Section IV: New and Emerging Barrier Technologies and Processes A. Cyclic olefin copolymer resins B. Liquid crystal polymers Table 16 Liquid Crystal Polymer OTR and MTR C. Polyethylene naphthalate film D. Heat treating/orientation of EVOH Figure: 11 Heat Treatment and Orientation Effects on the OTR of EVOH 83 E. Substrate surface design F. Continuous coating G. Non-vacuum coatings H. Polysilicate barrier coatings...86 Table 17 SilGuard Coated PET Oxygen Transmission Rate I. Silane coatings Table of Contents - iii

4 J. Ormocer Table 18 ORMOCER Coated Films OTR and MTR K. Vacuum deposited silane coating L. Nanoparticles Figure: 12 Flex Modulus of Melt Compounded Additives in Nylon Figure: 13 Oxygen Barrier of Nylon 6 with Nanoclay M. Polymerization versus melt compounding Figure: 14 Melt Compounded Nanoparticles in Nylon Figure: 15 In Situ Polymerized Nanoparticles in Nylon N. Active Packaging Figure: 16 Global Oxygen Absorber Consumption Figure: 17 Film Containing Oxygen Scavenger Section V: End-use Applications and Markets for Barrier Packaging A. Meat, poultry, and fish Barrier shrink bags Table 19 N America Value-added Flexible Packaging by End-Use Chubs Laminations & Coextrusions Summary B. Medical Suture packaging Syringes Ostomy bags C. Pharmaceutical Blister packs Table 20 Formable Webs for Blister Packs D. Baked Goods Hard goods Soft goods E. Snacks Figure Snack Food Volume by Type Potato chips Corn chips F. Fresh produce G. Dairy foods Cheese Yogurt H. Confectionery I. Health & beauty Table of Contents - iv

5 J. Frozen food K. Pet food L. Prepared drinks M. Tobacco N. Breakfast food O. Dry mixes P. Condiments Q. Dried foods & pasta Section VI: Economic Cost Comparisons and Case Studies A. Case 1: Film/polyethylene/foil/polyethylene Introduction Operating parameters Discussion of results Table 21 Assumptions Case Table 22 Results Case B. Case 2: Blister pack thermoforming films Introduction Operating parameters Discussion of results Table 23 Assumptions Case Table 24 Results Case C. Case 3: Lid stock with oxygen scavenging Introduction Operating parameters Discussion of results Table 25 Assumptions Case Table 26 Results Case D. Case 4: An inexpensive glass-coated film Introduction Operating parameters Discussion of results Table 27 Assumptions Case Table 28 Results Case E. Case 5: Glass-coated film vs. laminate for retort applications Introduction Operating parameters Discussion of results Table 29 Assumptions Case Table 30 Results Case Table of Contents - v

6 Section VII: Market Trends and Projections Table 31 Global Consumption of Barrier Materials in Flexible Packaging A. Trends B. Market demand for barrier packaging C. Environmental factors D. Economics E. Aluminum foil Figure 19 Global Aluminum Foil Consumption in Packaging Figure 20 Global Aluminum Foil Consumption by End-use Projection Table 32 Global Aluminum Foil Projections by End-use Table 33 Aluminum Foil Projections by Geographic Area F. PET film Figure 21 Global Oriented PET Film Consumption by Product Type Figure 22 Global PET Film Consumption by End-use Projection Table 34 Global PET Film Projections by End-use Table 35 PET Film Projections by Geographic Area G. Nylon extrusion resin Figure 23 Global Nylon Resin Utilization for Flexible Packaging Figure 24 Global Nylon Films Consumption by End-use Projection Table 36 Global Nylon Projections by End-use Table 37 Nylon Projections by Geographic Area H. Metallized films Figure 25 Global Metallized Film Manufactured by Substrate Type Figure 26 Global Consumption of Metallized Film by End-use Market Projection Table 38 Global Nylon Projections by End-use Table 39 Metallized Film Projections by Geographic Area I. PVDC extrusion resin and coatings Figure 27 Global PVDC Consumption by Application Type Figure 28 Global PVDC Resin Consumption by End-use Projection Table 40 Global PVDC Projections by End-use Table 41 PVDC Projections by Geographic Area J. EVOH resins Figure 29 Global EVOH Consumption in Packaging by Product Type 172 Figure 30 Global EVOH Resin Consumption by End-use Projection Table of Contents - vi

7 Table 42 Global EVOH Projections by End-use Table 43 EVOH Projections by Geographic Area K. PAN resins Figure 31 Global PAN Consumption by Product Type Figure 32 Global PAN Resin Consumption by End-use Projection Table 44 Global PAN Projections by End-use Table 45 PAN Resin Projections by Geographic Area L. Alumina- and silica-coated films Figure 33 Al 2 O 3 - and SiO x -coated Film Consumption by Product Type Figure 34 Al 2 O 3 - and SiO x -coated Film Consumption by End-use Projection Table 46 Al 2 O 3 - and SiO x -coated Film Projections by End-use Table 47 Al 2 O 3 - and SiO x -coated Film Projections by Geographic 181 M. PCTFE resins Projection N. PVOH resins Projection Section VIII: Supplier, Converter Profiles Table of Contents - vii

PVDC New Developments, New Opportunities

PVDC New Developments, New Opportunities Kirk Paisley SolVin, a division of Solvay Advanced Polymers, L.L.C. Alpharetta, Georgia Introduction The information in this presentation will provide basic background