Real-Time Detection of Organic and Inorganic Contamination in Packaging

Transcription

1 Real-Time Detection of Organic and Inorganic Contamination in Packaging Keith Vorst, Jeffrey Danes, Bradley Goodlaxson, Greg Curtzwiler, Nathan Davis Polymer and Food Protection Consortium Iowa State University Ames, IA United States of America

2 Agenda Who we are Applied Science and Technology Quality & Safety of Packaging Baseline Contamination Analysis Fingerprint Technology Results What s NEXT 2

3 Polymer and Food Protection Consortium Acquistapace Farms Inc. 3

4 Customer Questions Media Answers Does my salad bowl contain BPA? What is flaking off my microwave EPS (Styrofoam) tray" Did using recycled plastics give my 3-year old autism? Did Sheryl Crow really get cancer from water bottles? Grocery Chain What are we sending to the landfill

5 Recycling and Contamination 5

6 Global Characterization Since 2006 Working with Brand-Owners, Retailers, Converters, Manufactures (~10 yrs). Pre and post converted resin, sheet, bottle data from around the globe. 20,000 ft 2 - Retained samples, supplier history, supplier resin and final article. 6

7 Global Characterization since

8 Baseline Contamination Analysis Multiple methods to evaluate contamination levels in packaging. Contaminants in flexibles and rigids. Reflux and solvent extractions coupled with GC or TGA-IR-MS. Polymer digestion and ICP. 8

9 Typical Bench Top Analysis Prop 65 analysis for EG, AA, benzene and others. Heavy metals analysis (EDXRF and ICP). Total extractable organics per CFR, FDA, Etc All of this is necessary but costly and consumers want to know what is in the packaging! CONTAMINATION ANALYSIS 9

10 Research Observations Total extractables vary by supplier and process. Retailer/QSR interest in PCR claim validation. Microwave/elevated temp packaging. Packaging with greater than 200 ppm of Pb and extractable more than 3x U.S. CFR levels. 10

11 Antimony Content in ppm or mg/kg Results vary by lab, preparation method Antimony (Sb) Levels by Method and Percent Recycled Content Method A 210 Method B Method C Method D Virgin PET 20% PCR PET 40% PCR PET 60% PCR PET 80% PCR PET 100% PCR PET *Error bars represent the standard error associated with the analysis of the three methods 11

12 What s Next Digital DNA of Packaging Yes, it is time! 12

13 Pattern Signatures Organic Contamination Inorganic Contamination Percentage of Recycled Material, %PCR 13

14 Non Destructive Detection 14

15 Mix of Sensor Inputs Inorganic contamination (e.g.,toxic Metals) X-Ray fluorescence ED-X-Ray Fluorescence Organic contamination (e.g., VOCs) Near Infrared (NIR) spectroscopy Semiconducting metal oxide sensors Ultraviolet visible spectroscopy (UV-Vis) Photoionization (PID) High Resolution Raman Polymer degradation (in addition to those above) Conversion Process Controls (torque, melt pressure etc.) Melt Flow Index Mechanical Properties (tensile and impact strength) 15

16 Real-Time Detection of Toxic Elements 16

17 Real-time Process Monitoring Detection/Identification of total volatile exchange/heavy metals. Ability to quantify contamination during production. Adaptable to injection molding resin systems. 17

18 Real-time Monitoring Injection 18

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20 Fingerprint Technology Training Distribution and Predicted Output (Lee 2001, Lee 2002) Danes, J. and Vorst, K. Detection in Thermoplastics (US PTO Application No.: 12/893,305) 20

21 Post Consumer Recycled Content Previous work show variations with different blends of PCR to virgin resins (Bernardo et al. 1996). Our research has shown thermal, IR, optical and other properties can be used to determine blends ratios (Curtzwiler, Vorst, et al.,). 21

22 Separation in Real-Time 22

23 UV Signatures by Blend Example UV percent transmittance signature captured by array for polyethylene terephthalate polymer. 23

24 Increased Freshness/Shelf-life Effects of light wavelength, filtering, haze, gloss, color and contaminant load Bottled water, salad kits and juice utilizing RPET blends currently being evaluated 2016 Vorst, K., Brown, J.W., Danes J. and Curtwiler, G. Methods for Optimizing Plastics Composition to Increase Shelf-Life of Perishable Products and System Thereof (Application No.: (04335). 24

25 Detecting, Storing, and Retrieving Thermoplastic Contamination Signatures Selection of virgin and recycled thermoplastic materials to be used in a finished products. Real-time assessment of organic (e.g., volatile organic compounds) and inorganic contamination (e.g., metallic content). Thermoplastic pattern signatures created, stored, and retrieved by advanced neural network and pattern recognition techniques. Validation of the entire process with digitally stored thermoplastic pattern signatures. 25

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32 PFPC OUR GOAL Develop global packaging technologies that are cost effective, protect the brand and ultimately the consumer while maintaining a positive environmental image. Data driven and safety feel good packaging Backed by Academic and 3 rd Party Institutions Traceable Packaging. Embrace consumer awareness and concerns with data driven policies on packaging - Honest Packaging that is PackedSAFE. ADD VALUE to recycled waste streams INCREASED Freshness. We have Honest Products NOW it is time for HONEST PACKAGING! 32

33 Polymer and Food Protection Consortium Acquistapace Farms Inc. 33