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... 11 A. Today s barrier mainstays... 12 B. New or emerging barrier options... 16 C. Potential barrier players... 18 Table 3 Barrier Material Growth Summary... 19 Section III: Barrier Materials and Technologies... 21 A. Resins (films from resins)... 22 1. Temperature dependence... 22 Figure 1 EVOH Oxygen Permeation vs. Temperature... 22 2. Humidity... 23 Figure 2 EVOH Oxygen Permeation vs. Humidity... 23 3. Film thickness... 23 Figure 3 BOPP Oxygen Permeation vs. Thickness... 24 4. Coatings... 24 Figure 4 OTR of PET and BOPP, Metallized vs. Un-metallized... 25 Figure 5 MVTR of PET and BOPP, Metallized vs. Un-metallized... 26 B. Aluminum foil... 27 1. Laminations... 28 2. Coatings... 29 3. Capabilities summary... 29 Table 4 Aluminum Foil Oxygen and Moisture Transmission Rates... 30 Table 5 Creased Aluminum Foil Moisture Transmission Rates... 31 Table of Contents - i
4. Supplier profiles... 31 C. PVOH resins... 32 1. Films... 33 2. Coatings... 34 Table 6 PVOH, PVDC, EVOH OT at Moderate Humidity Levels... 35 3. Capabilities summary... 36 Table 7 PVOH Oxygen and Moisture Transmission Rates... 37 4. Supplier profiles... 37 5. Converter Profiles... 37 D. EVOH extrusion resins...38 1. Extrusion resins... 39 2. Coatings... 40 3. Capabilities summary... 40 Table 8 EVOH Oxygen and Moisture Transmission Rates... 41 Figure 6 EVOH Oxygen Permeation Versus Relative Humidity... 42 4. Supplier profiles... 43 5. Converter profiles... 43 E. Silica- and alumina-coatings... 43 1. Silica... 45 2. Alumina... 45 3. Extrusion resins... 46 4. Coatings... 46 Figure 7 State-of-the-Art Glass-coating Equipment... 50 5. Capabilities summary... 50 Table 9 SiO x -and Al 2 O 3 -Coated Films OTR and MTR... 51 Figure 8 OT of SiO x -and Al 2 O 3 -Coated PET Films after Elongation... 52 6. Equipment suppliers... 53 7. Supplier profiles... 53 8. Converter profiles... 54 F. PVDC extrusion resins and coatings... 55 1. Extrusion resins... 55 2. Coatings... 56 3. Capabilities summary... 57 Table 10 PVDC Oxygen and Moisture Transmission Rates... 58 4. Supplier profiles... 58 5. Converter profiles... 59 G. Metallized films... 59 1. Extrusion resins... 59 2. Coatings... 59 3. Capabilities summary... 60 Table 11 Metallized Films Oxygen and Moisture Transmission Rates 61 Figure 9 Oxygen Transmission of Metallized PET Film after Elongation 62 4. Supplier profiles... 62 Table of Contents - ii
H. Polyacrylonitrile extrusion resin... 63 1. Extrusion resins... 64 2. Capabilities summary... 64 Table 12 Acrylonitrile Oxygen and Moisture Transmission Rates... 65 3. Supplier profiles... 65 4. Converter profiles... 65 I. Nylon extrusion resin... 65 1. Extrusion resins... 67 Figure 10 Amorphous Nylon OTR versus Humidity Level... 68 2. Capabilities summary... 69 Table 13 Nylon Oxygen and Moisture Transmission Rates... 69 3. Supplier profiles... 70 4. Converter profiles... 70 J. Polyester extrusion resin and films... 71 1. Extrusion resins... 71 2. Coatings... 72 3. Capabilities summary... 72 Table 14 Polyester Oxygen and Moisture Transmission Rates... 73 4. Supplier profiles... 73 5. Converter profiles... 73 K. Polychlorotrifluoroethylene (PCTFE) extrusion resin... 74 1. Extrusion resins... 74 2. Capabilities summary... 74 Table 15 PCTFE Oxygen and Moisture Transmission Rates... 75 3. Supplier profiles... 75 4. Converter profiles... 75 Section IV: New and Emerging Barrier Technologies and Processes... 77 A. Cyclic olefin copolymer resins... 77 B. Liquid crystal polymers... 80 Table 16 Liquid Crystal Polymer OTR and MTR... 81 C. Polyethylene naphthalate film... 81 D. Heat treating/orientation of EVOH... 82 Figure: 11 Heat Treatment and Orientation Effects on the OTR of EVOH 83 E. Substrate surface design... 84 F. Continuous coating... 85 G. Non-vacuum coatings... 86 H. Polysilicate barrier coatings...86 Table 17 SilGuard Coated PET Oxygen Transmission Rate... 87 I. Silane coatings... 87 Table of Contents - iii
J. Ormocer... 88 Table 18 ORMOCER Coated Films OTR and MTR... 89 K. Vacuum deposited silane coating... 89 L. Nanoparticles... 90 Figure: 12 Flex Modulus of Melt Compounded Additives in Nylon 6.. 91 Figure: 13 Oxygen Barrier of Nylon 6 with Nanoclay... 92 M. Polymerization versus melt compounding... 93 Figure: 14 Melt Compounded Nanoparticles in Nylon 6... 94 Figure: 15 In Situ Polymerized Nanoparticles in Nylon 6... 95 N. Active Packaging... 95 Figure: 16 Global Oxygen Absorber Consumption... 96 Figure: 17 Film Containing Oxygen Scavenger... 99 Section V: End-use Applications and Markets for Barrier Packaging... 102 A. Meat, poultry, and fish... 102 1. Barrier shrink bags... 102 Table 19 N America Value-added Flexible Packaging by End-Use. 103 2. Chubs... 105 3. Laminations & Coextrusions... 106 4. Summary... 107 B. Medical... 107 1. Suture packaging... 107 2. Syringes... 107 3. Ostomy bags... 108 C. Pharmaceutical... 109 1. Blister packs... 109 Table 20 Formable Webs for Blister Packs... 111 D. Baked Goods... 111 1. Hard goods... 112 2. Soft goods... 112 E. Snacks... 113 Figure 18 2000 Snack Food Volume by Type... 113 1. Potato chips... 114 2. Corn chips... 114 F. Fresh produce... 114 G. Dairy foods... 115 1. Cheese... 115 2. Yogurt... 117 H. Confectionery... 117 I. Health & beauty... 119 Table of Contents - iv
J. Frozen food... 119 K. Pet food... 120 L. Prepared drinks... 121 M. Tobacco... 122 N. Breakfast food... 123 O. Dry mixes... 123 P. Condiments... 124 Q. Dried foods & pasta... 124 Section VI: Economic Cost Comparisons and Case Studies... 126 A. Case 1: Film/polyethylene/foil/polyethylene... 128 1. Introduction... 128 2. Operating parameters... 128 3. Discussion of results... 128 Table 21 Assumptions Case 1... 130 Table 22 Results Case 1... 131 B. Case 2: Blister pack thermoforming films... 132 1. Introduction... 132 2. Operating parameters... 132 3. Discussion of results... 132 Table 23 Assumptions Case 2... 134 Table 24 Results Case 2... 135 C. Case 3: Lid stock with oxygen scavenging... 136 1. Introduction... 136 2. Operating parameters... 136 3. Discussion of results... 136 Table 25 Assumptions Case 3... 138 Table 26 Results Case 3... 139 D. Case 4: An inexpensive glass-coated film... 140 1. Introduction... 140 2. Operating parameters... 140 3. Discussion of results... 140 Table 27 Assumptions Case 4... 142 Table 28 Results Case 5... 143 E. Case 5: Glass-coated film vs. laminate for retort applications... 144 1. Introduction... 144 2. Operating parameters... 144 3. Discussion of results... 144 Table 29 Assumptions Case 5... 145 Table 30 Results Case 5... 146 Table of Contents - v
Section VII: Market Trends and Projections... 148 Table 31 Global Consumption of Barrier Materials in Flexible Packaging...148 A. Trends... 149 B. Market demand for barrier packaging... 149 C. Environmental factors... 150 D. Economics... 150 E. Aluminum foil... 151 Figure 19 Global Aluminum Foil Consumption in Packaging... 152 Figure 20 Global Aluminum Foil Consumption by End-use... 153 1. Projection... 153 Table 32 Global Aluminum Foil Projections by End-use... 155 Table 33 Aluminum Foil Projections by Geographic Area... 156 F. PET film... 157 Figure 21 Global Oriented PET Film Consumption by Product Type... 157 Figure 22 Global PET Film Consumption by End-use... 158 1. Projection... 158 Table 34 Global PET Film Projections by End-use... 160 Table 35 PET Film Projections by Geographic Area... 160 G. Nylon extrusion resin... 161 Figure 23 Global Nylon Resin Utilization for Flexible Packaging... 161 Figure 24 Global Nylon Films Consumption by End-use... 162 1. Projection... 162 Table 36 Global Nylon Projections by End-use... 163 Table 37 Nylon Projections by Geographic Area... 163 H. Metallized films...164 Figure 25 Global Metallized Film Manufactured by Substrate Type... 164 Figure 26 Global Consumption of Metallized Film by End-use Market... 165 1. Projection... 165 Table 38 Global Nylon Projections by End-use... 166 Table 39 Metallized Film Projections by Geographic Area... 166 I. PVDC extrusion resin and coatings... 167 Figure 27 Global PVDC Consumption by Application Type... 167 Figure 28 Global PVDC Resin Consumption by End-use... 168 1. Projection... 168 Table 40 Global PVDC Projections by End-use... 170 Table 41 PVDC Projections by Geographic Area... 170 J. EVOH resins... 172 Figure 29 Global EVOH Consumption in Packaging by Product Type 172 Figure 30 Global EVOH Resin Consumption by End-use... 173 1. Projection... 173 Table of Contents - vi
Table 42 Global EVOH Projections by End-use... 174 Table 43 EVOH Projections by Geographic Area... 174 K. PAN resins... 175 Figure 31 Global PAN Consumption by Product Type... 175 Figure 32 Global PAN Resin Consumption by End-use... 176 1. Projection... 176 Table 44 Global PAN Projections by End-use... 177 Table 45 PAN Resin Projections by Geographic Area... 177 L. Alumina- and silica-coated films... 178 Figure 33 Al 2 O 3 - and SiO x -coated Film Consumption by Product Type...179 Figure 34 Al 2 O 3 - and SiO x -coated Film Consumption by End-use... 180 1. Projection... 180 Table 46 Al 2 O 3 - and SiO x -coated Film Projections by End-use... 181 Table 47 Al 2 O 3 - and SiO x -coated Film Projections by Geographic 181 M. PCTFE resins... 182 1. Projection... 183 N. PVOH resins... 184 1. Projection... 184 Section VIII: Supplier, Converter Profiles... 189 Table of Contents - vii