2005 TAPPI PLACE Conference9/25/2005 - 9/28/2005

Caesar's PalaceLas Vegas, NV

Updated: 9/23/2005 11:10:29 AM

Plenary Session9/26/2005Session: 1

8:00:a.m. - 9:15:a.m.

Session ChairWarren Durling, Clorox Services Company

Optimization by Integrating Engineering and Business Models1 - 1 8:00 amDavid R. Roisum, Finishing Technologies Inc., SpeakerTo optimize is to find the “best” solution given certain conditions and constraints. What is meant by best and how to find it has received scant attention. To the engineer, “best” may be quickest, strongest, most reliable and so on. The engineer will have models to determine whether one solution or setpoint is better than another based on objectives such as these. “Best” in business is quite different. It means to maximize profit or minimize loss. The economist or accountant also has models. Note the obvious disconnect between the objectives of engineering and business models. This disconnect has hindered us from finding a practical best to improve profit on the plant floor. Simple questions like “what is the best tension to run” have no useful answers from a strictly engineering or business viewpoint.

This paper begins by defining best for several familiar examples. However, it quickly concludes that the only “best” that makes sense in an industrial environment is that which will minimize total costs. To find this best we must integrate engineering and business models. This technique developed here is very powerful, flexible and adaptable approach. The technique can be applied explicitly using calculus or similar numerical techniques when cost functions are well known. Even more flexible is an implicit approach which can be used when very little is known about costs. Five web handling examples are used to illustrate this problem solving technique. These examples include a variety of objectives such as optimum rejection levels, core waste, web tension, layon roller nip and water flow rate. These examples show how it is easy to combine apples and oranges, such as waste and delay, when one converts to a common denominator of cost.

Structure Optimization9/26/2005Session: 2

9:30:a.m. - 11:00:a.m.

Session ChairBob Dietrick, International Paper

Understanding Why Adhesion in Extrusion Coating Decreases with Diminishing Coating Thickness, Part I: Penetration of Porous Substrates

2 - 1 9:30 am

Barry A. Morris, DuPont Pkg. & Ind. Polymers, SpeakerIt is well known that in extrusion coating the adhesion of PE to paperboard and other porous substrates decreases with decreasing thickness. Several hypotheses are proposed for the origin of this decrease, including a reduction in time for oxidation, faster cooling in the air gap, and more rapid quenching in the nip. A model of the penetration of the molten polymer into the substrate shows that the greatest effect is cooling in the nip; thinner coatings have less time to flow into the interstices of the substrate once contact with the chill roll is made. The model results agree well with experimental adhesion data from the literature.

How Sealant Film Choice Can Affect a Laminated Structure’s Properties2 - 2 10:00 amDavid G. Timm, Charter Films, SpeakerWhen designing films for use as sealant layers, there are some functionalities that are well translated into the laminations’ properties, especially the sealant functionality that the film provides. Some properties, such as toughness, stiffness and “body” are not well understood once the films have been laminated to oriented substrates, primarily polypropylene (OPP) or oriented polyester (PET). Oriented substrates, such as OPP and PET, demonstrate orders of magnitude increases in stiffness over typical blown PE-based films. Therefore, when combining, through lamination, a soft, amorphous substrate, along with a rigid, crystalline substrate it is difficult to understand what the composite lamination’s properties will be. Packaging engineers, marketing departments, and brand managers would all desire to be able to understand, and even better, predict, these interactions.

Using Primers in Combination With Adhesive Tie-Layer Resins or Their Blends to Make Structures With Unique Performance

2 - 3 10:30 am

Richard B. Allen, Mica Corporation, SpeakerWe have blended adhesive tie-layer resins with commodity resins and made structures with excellent adhesion and water resistance. Primers were critical to success and good results were obtained even at very low extrusion temperatures. Potential benefits include improved adhesion, water resistance, processability and productivity. We also tested unblended adhesive tie-layer resins, such as those used in the co-extrusion process. Adhesion and water resistance were greatly improved by using primers.

Process Optimization9/26/2005Session: 3

9:30:a.m. - 11:00:a.m.

Session ChairKen E. Klaber, Equistar Chemicals

Inertial Measurement of Roller Parallelism - a New Approach to Solving an Old Problem3 - 1 9:30 amSebastian Busch, PRUFTECHNIK Service, Inc., SpeakerWeb handling in converting - Roller parallelism as a frequent root cause Many web handling problems can be traced back to roller alignment issues. Symptoms range from fissures and creases in the product to vibrations in the machinery and, ultimately, to unscheduled stops in production, resulting in downtime and waste material. Benefits and limits of conventional alignment techniques While roller parallelism is reasonably easy to determine and to assure with conventional alignment methods, it has traditionally been hard to determine whether a given product quality or process quality issue can be traced back to roll misalignment. This is because traditional methods of aligning rolls depend on line of sight and a certain degree of proximity between rolls.

Application of 3D Flow Simulation towards Blown Film Die Optimization3 - 2 10:00 amJohn Perdikoulias, Compuplast Canada Inc., SpeakerJiri Vlcek, Compuplast InternationalJiri Svabik, Compuplast International Inc.This paper demonstrates how a 3D Finite Element Method (FEM) flow simulation can be applied towards the analysis and optimization of a spiral mandrel type die for the production of blown (tubular) film. The paper also shows how a 3D FEM flow analysis can identify a die design flaw that would otherwise be difficult to solve.

How to Improve Cross-Machine Drying Profiles3 - 3 10:30 amWilliam R. Henry, ASI Advance Systems Inc, SpeakerBe it a flotation, roll-support, through-air or infra-red dryer, the ability to produce an even drying profile across the entire width of the web is critical for producing a consistent product and achieving high production efficiency. Existing dryers may have inherent drying deficiencies or may develop uneven drying profiles over time. The cause, effect and resolution of several profile problems are discussed with special emphasis on improvements that can be implemented in existing dryers.

Building Better BarrierThe session includes three papers on non-traditional high barrier solutions, including high oxygen barrier primers and specialty polyethylene resins providing imrpoved water and flavor barrier

9/26/2005Session: 4

9:30:a.m. - 11:00:a.m.

Session ChairJose M. Torradas, E. I. du Pont de Nemours & Co.

A New Family of sHDPE Polymers for Enhanced Moisture Barrier Performance4 - 1 9:30 amNorman D. Aubee, Nova Chemicals, SpeakerSarah K. Marshall, Nova ChemicalsPatrick Lam, Nova ChemicalsConventional Ziegler-Natta catalyzed HDPE homopolymer is used as a moisture barrier in the production of multilayer films for packaging dry food-stuffs and other moisture sensitive products. Barrier properties for these HDPEs are improved by narrowing the MWD and decreasing the molecular weight, at the expense of melt strength and processability. NOVA Chemicals Corporation has developed a new class of sHDPE resins for moisture barrier applications utilizing Advanced SCLAIRTECH™ Technology and NOVA Chemicals’ proprietary single site catalyst. These new sHDPE resins offer superior moisture barrier properties, exceeding the barrier performance of multilayer, multiple HDPE component films, without compromising processability.

TOPAS® Cyclic Olefin Copolymers in Food Packaging - High Aroma Barrier Combined with Low Extractables

4 - 2 10:00 am

Randy D. Jester, Ticona, SpeakerFilms of LLDPE, cyclic olefin copolymer (COC) and blends of the two were subjected to extraction testing under conditions of 10% ethanol in water at 60oC for 24 hours. Extractables were examined by GC/MS. Total extractables in ng/cubic cm. were 35 for the LLDPE and 6.6 for COC. Films were also evaluated for aroma/odor barrier using d-limonene, onion, and sardine. A 80% COC / 20% LLDPE blend film was found to have ~ 7 times the barrier of a 100% LLDPE film for d-Limonene and 5X and 3X better barrier to onion and sardine odors respectively. Scalping propensity of COC for d-limonene, a major flavor component in orange juice was evaluated and found to be similar to that of LLDPE. Placing a layer of COC as the food/beverage contact surface in a package will reduce off-taste in container contents and reduce aroma loss / odor.

Adding Oxygen Barrier to Adhesive Laminations4 - 3 10:30 amJessica C. Bodine, Mica Corporation, SpeakerIt has been previously reported that barrier primers contribute adhesion and oxygen barrier to extrusion coatings and extrusion laminations. The same technology allows barrier primers to contribute these properties to a different market: adhesive laminations. Coating of a barrier primer, oxygen transmission rates, adhesion and adhesive lamination will be discussed.

New Technology Showcase9/26/2005Session: 5

11:30:a.m. - 1:00:p.m.

Session ChairLaurie Beth T. Pestle, Marketing Management Center

Improved UV Stability of Urethane Adhesives5 - 1 11:30 amDavid Horst, Ciba Specialty Chemicals, SpeakerMaintaining low color upon UV aging is very challenging with urethanes. Ciba Specialty Chemicals has developed UV stabilization packages that allow urethane adhesives to pass stringent footwear UV tests.

Thin Barrier Layers - More with Less5 - 2 11:35 amBeth M. Wells, Black Clawson., SpeakerThinner multiple barrier layers create a lower cost, superior product. The Black Clawson Microlayer Feedblock is able to make layers as thin as 1% with the possibility of thinner yet.

New Styrenic Block Copolymers in Blends and Coextrusions with Polyolefins for Film Applications

5 - 4 11:45 am

Richard P. Schmidt, Kraton Polymers, SpeakerPresentation will showcase an innovative use of styrenic block copolymer, SBC's, materials in flexible packaging applications. A combination of these SBC's in monolayer film structures in blends with polyolefins produce unique film properties. Further innovative films are produced by combining these SBC's with polyolefins and other materials in coextruded film structures.

Michem®Prime 2960 - the Latest Innovation in the Series5 - 5 11:50 amMartin A. Cohen, Michelman, Inc., SpeakerMichem®Prime specialty dispersions are uniquely suited to today’s flexible packaging needs. Michem®Prime provides a clear, flexible, FDA-compliant barrier to water, grease, and solvents in addition to low heat-seal temperatures and high hot-tack. Commercial applications include film, paper and foil laminating, metallized paper, extrusion coating, nonwovens, textiles, and more.

Airflex® EF9100: A Novel Barrier Coating for Grease Resistant Packaging5 - 6 11:55 amRonald B. Jones, Air Products Polymers L.P., SpeakerPaper substrates used in food packaging typically are coated and / or treated to prevent penetration of oleophobic materials such as grease, oils and fats. In Europe this is typically accomplished by applying either polyethylene or polyester in an off-machine extrusion process. In North America, fluorochemicals are typically used in these applications. Fluorochemicals, however, are not viewed favorably in either Europe or North America due to bioaccumulation issues, and have recently come under close scrutiny when used in food packaging grades. The paper and packaging industries are searching for alternatives that not only provides comparable performance but can also be applied on the paper machine.

This paper will discuss the recent development of an aqueous barrier coating that imparts oleophobic properties to paper. This non-fluorochemical coating is non-blocking yet flexible enough to protect fold areas making it ideal for packaging applications. This novel technology is safe for use with US and German food packaging clearances. The coatings are inherently solvent resistant and potentially heat sealable. Furthermore, paper coated with these developmental coatings is repulpable and readily recyclable.

New Patented Winder Technology for Inline Slitting and Winding Large Diameter Rolls on Small Diameter Cores

5 - 7 12:00 pm

R. Duane Smith, Black Clawson Converting Machinery, SpeakerBlack Clawson Converting Machinery Inc., Fulton, New York, introduces their recently patented winding technology for high speed in-line slitting and winding of large diameter rolls on small diameter cores. The Advanced Technology SurfaStartTM (ATS) winder eliminates the shaft critical speed and deflection challenges that are posed by in-line slitting and winding large diameter rolls on 3"ID cores. The ATS winder winds materials that can be surface wound, such as films, non-wovens, papers, paperboards, and composites. These materials can be wound up to 62" diameter at speeds up to 2500 fpm on 3"ID cores.

A Novel Approach for Coextruded High Modulus Clarity Shrink Film5 - 8 12:05 pmLawrence Szmutko, Chevron Chemical Company, SpeakermPACT™ Polyethylene D350 & D449 can be used to produce unique films with outstanding “sparkle”, clarity, gloss, modulus, and shrink for use in point-of-sale packaging. They are unique to the industry in that a film structure using mPACT™ polyethylene can combine traditionally conflicting properties into one coextruded film.

Zincometal5 - 9 12:10 pmDominique G. Gallou, Dienes Corporation, Speaker

Generation IV Oxygen Barrier-Primer5 - 10 12:15 pmBruce W. Foster, Mica Corporation, SpeakerMica Corporations's efforts to develop a robust oxygen barrier-primer have recentlyresulted in a significant improvement in the utility of this exciting technology. MICA M-2802, our Generation IV product, combines the excellent processing,adhesion, and oxygen barrier performance of the Generation III material (M-2345)with significantly enhanced performance under exposure to high humidity.

New Burner Design Eliminates Laning5 - 11 12:20 pmJoseph D. DiGiacomo, Flynn Burner Corporation, SpeakerFor coating, laminating or printing lines operating at high line speeds (in excess of 2500 fpm (760 m/min) using flame surface treatment, laning (or non uniform treatment) is a problem.

Conventional ribbon burners as well as drilled port burners have not been able to solve this problem.

This burner eliminates laning.

SURPASS FPs016: Fractional Melt SSC LLDPE5 - 12 12:25 pmTodd E. Maples, NOVA Chemicals, SpeakerNova Chemicals' latest film product introduction from their proprietary Advanced SCLAIRTECH™ technology, is a fractional melt SSC LLDPE being marketed under the SURPASS® brand. FPs016 boasts the highest melt strength in the industry. With incredible toughness, this resin provides strong value drivers for converters, brand owners and consumers in markets such as food packaging, consumer packaing, medical packaging and many others that consistently seek the latest and greatest technology.

Additives; Understandings and Applications9/27/2005Session: 6

8:00:a.m. - 10:00:a.m.

Session ChairAmy B. Hitchcock, Voridian Div Eastman Chemical

Polymer Processing Additives and Melt Fracture in Blown Film: Die Geometry Considerations6 - 1 8:00 amPaul Neumann, Dyneon - a 3M Company, SpeakerThe die geometry was investigated to gain a better understanding of the polymer processing additive (PPA) coating mechanism in a blown film extrusion process. In particular, the land length of the die, the extrusion throughput rate, the width of the die gap, and the apparent shear rate at the die wall were systematically varied to identify optimal processing conditions and die geometry configurations for rapid PPA conditioning. The results show that PPA efficiency improves as the length-to-gap ratio of the die increases, particularly at low shear rates. This is consistent with a coating mechanism based on PPA migration from the melt to the die surface.

The Influence of Process Aids on Zig-Zag Type of Interfacial Instabilities in Film Blowing Multi-Layer Flows

6 - 2 8:30 am

Martin Zatloukal, Tomas Bata University, SpeakerThe effect of process aids on the zig-zag type of interfacial instabilities in film blowing multi-layer flows has been investigated experimentally as well as theoretically. For deeper understanding of the PPA role in these types of the flows, new slip model based on 'effective continuum methods' for the description of the slip was developed and used.

The Use of Calcium Carbonate in Polyolefins Offers Significant Improvement in Productivity6 - 3 9:00 amJames E. Cara, OMYA Inc.Lane G. Shaw, OMYA Inc.Mike Roussel, OMYA Inc., SpeakerAllen R. Guy, OMYA Inc.The thermal conductivity, specific heat, and thermal expansion characteristics of calcium carbonate offer the ability to improve fabrication productivity and performance of physical properties. This paper will present case studies of plastics processing applications including blown films, extrusion coating, sheet extrusion / thermoforming, and extrusion blow molding. It is the attempt of these studies to show that the proper selection of calcium carbonate in conjunction with an optimized masterbatch carrier resin is required to achieve the desired productivity improvement. It is the unique selection of calcium carbonate and carrier resin that maintains or improves the physical properties for these respective applications.

Discoloration Resistant Polyolefins: Part IV; Gamma Irradiated LLDPE Film6 - 4 9:30 amDavid Horst, Ciba Specialty Chemicals, SpeakerRoswell E. King, III, Ciba Specialty ChemicalsThe preservation of physical properties and aesthetics are two important aspects of the film industry. As such, forethought and care need to be taken in terms of the type of polymer and stabilization systems that are used to derive robust and attractive film products. For most applications, a combination of a phenolic antioxidant and a phosphite melt processing stabilizer can provide the base stabilization that is necessary to provide the retention of physical properties, good processability, and long term thermal stability without compromising the overall aesthetic appearance of the film product. However, in selected end-use applications, it is particularly desirable to have film products that do not discolor during initial processing or while the product is kept in storage. Under a selected set of circumstances, certain types of phenolics have been shown to be susceptible to discoloration, due to inadequate stabilization, harsh processing, film storage with oxides of nitrogen (pollution), and various types of ionizing radiation. In particular, gamma irradiated polyolefins films are finding a variety of end use applications in areas such as medical packaging as well as hygiene related articles where sterilization plays a key role in the life cycle of the plastic product. There is also significant potential with food packaging. While this sterilization technique is valued by end users, the stress on the plastic article is quite significant in terms of not only maintaining the original physical properties of the product, but also it’s aesthetic appearance. The study described below was carried out in a film grade linear low density polyethylene where “phenol” and “phenol free” stabilization systems were compared in regard to their ability to maintain physical and aesthetic (discoloration) properties of the polymer. The results of this study demonstrate that “phenol free” systems were better than the phenol based systems.

Productivity Developments-Machinery Designs to Improve EfficiencyThe ten papers that will be presented in this session (and the continuation in session 10) will include recent developments in Extrusion Dies and Control Systems, Servo Air Knife Systems, Benefits of Automatic Slitter Positioning Systems, Advancements in Melt Fracture and Static Elimination Systems, Advancements in Automatic Splicing Systems, New Developments in Gearless Press Technology, Implementation of On-line Web Inspection Systems, Advancements in Melt Fracture Elimination Technology and Non-nuclear Gauging Systems.

This information packed Session promises to provide many useful new technologies that you can take back to help improve the Productivity and Profitability of your Web Production and Converting Operation.

9/27/2005Session: 7

8:00:a.m. - 10:00:a.m.

Session ChairR. Duane Smith, Black Clawson Conv. Mach. Inc.

Automatic Servo Positioned Air Knife Systems for Optimal Cast Film Quenching7 - 1 8:00 amBeth M. Wells, Black Clawson Conv. Mach. Inc.Fred Suppon, Black Clawcon Conv. Mach. Inc., SpeakerIt could very well be that the days of cast film manufacturers running the same product day after day without changeover are fast becoming a thing of the past. With demands increasing for more custom blends, bringing new products to market and shorter runs, the film industry has seen a need for quicker changeover between products, less down time, less set up time and the ability to obtain spec on a product in less time from start up. One response to this demand is an innovative new servo positioned air knife system with enhanced manual features as well, that has been developed to help address these issues by providing multiple axis position repeatability, stable air pressure and velocity, consistent air temperature control and more user friendly set up. These features have all been combined into one system that provides optimal cast film quenching as well as gentle pressure to lay the film smoothly on the chill roll and minimize the entrapped air layer between the film and the chill roll with superior repeatability over traditional air knives. This paper will examine these and other features and list expected benefits.

Improving Productivity with Automated Slitter Positioning7 - 2 8:30 amQuino Lorente, Tidland Corporation, SpeakerAutomated slitter positioning technology offers many opportunities to improve productivity. Fast and accurate slitter setups increase production capability and flexibility. Automation improves product consistency, minimizes tool wear, and reduces worker exposure to production hazards. Automation also enables synergistic integration of the automated slitting system with other management and production systems. Achieving the benefits of automated slitter positioning depends upon installing slitting system hardware and controls that are appropriate for the application. Many types of automated slitting systems are available and numerous factors must be considered when choosing an automated slitting system to achieve maximum productivity improvements.

Benefits of Automatic Computer Positioning Systems7 - 3 8:45 amDavid A. Rumson, Dienes Corporation, SpeakerThis paper and information is based upon direct feedback from end users who have enjoyed the benefits of modern Automatic Slitter Positioning Systems. A questionnaire was sent asking for general information comparing relative production improvement realized from installation of an automatic slitter positioning system that replaced a manual system. Although this is not a scientific survey it does identify key finishing and converting improvement potential for end users weighing the purchase of an automatic slitter positioning system.

Benefits of New Technology Ionizers for Web Handling7 - 4 9:00 amScott Shelton, Simco Company Inc., SpeakerIonizers are critical to the web handling process, controlling electrostatic charges to enhance product quality and throughput. In solvent coating and printing processes, they are critical to safety, reducing the chance of fires and explosions. All ionizers require periodic cleaning and performance verification, but this is rarely done due to lack of understanding of the importance and little knowledge of the ionizers and how to evaluate and service them. New technology ionizers solve these problems, offering constant monitoring of system operating status and performance. Local display or remote computer display indicates when maintenance is required.

Fully-Integrated Mulit-Station Static Control System With Web Charge Verification7 - 5 9:15 amMark Blitshteyn, ION Systems Industrial, SpeakerStatic neutralizers on web coating lines have traditionally been add-on devices, installed and often forgotten until static would cause quality or safety problems. The paper describes an advanced static control system with long-range neutralizing capabilities which measures the ion current flowing to the charged material and calculates charge on the web before and after neutralization. Functions of this system can be integrated with the line’s controls to communicate diagnostics and performance information over industrial networks.

Improving Production Efficiency of Flexible Film Printing Lines by the Print Control and Changeover Benefits of Gearless C.I. Presses

7 - 6 9:30 am

Mick Karchinski, Paper Converting Machine Company, SpeakerThomas J. Jacques, Paper Converting Machine CompanyMajor global forces are changing the structure and focus of the global packaging industry. As a result of the so-called “Wal-Mart Effect” – the drive to drastically reduce costs through economies of scale and increased production efficiencies – flexible packaging suppliers are responding in two major ways: • Consolidate market share worldwide to increased size/scale • Improve internal production efficiency of converting lines The goal of this paper is to give some insight into the industry as a whole, review the actions of some major players, and then, delve into the fine details of improving production efficiency of flexible film printing Lines by the print control and quick changeover benefits of gearless central impression (or C.I.) drum flexopresses.

Advancements in Retort PackagingFlexible retort packaging is becoming an increasingly attractive alternative to cans in the marketplace. However, many industry professionals are unsure of what contitutes "typical" retort conditions, how to effectively test these during the product development cycle, and what the latest technologies are in flexible retort packaging. This session presents a comprehensive overview of the latest technology in flexible retort packaging from may different viewpoints. Presentations to be made by a Clemson University professor, a retorot packaging co-packer, an adhesive supplier, a clear barrier film supplier and a high performance additive supplier.

9/26/2005Session: 8

8:00:a.m. - 10:00:a.m.

Session ChairDante F. Ferrari, Celplast Metallized Prod. Ltd.

Introduction to Retort Pouch Technology8 - 1 8:00 amScott Whiteside, Clemson University, SpeakerRetort pouches have been in existence for several decades with the only major market being MRE’s for the military. Since the late 1990’s, retail food products in retort pouches have experienced substantial growth. Much is known about processing shelf stable food products in rigid, metal cans, but the processing technology for retort pouches is different. This presentation will present an overview of current processing technology for retort pouches.

Retort Flexible Pouches: Selecting a Co-Packer8 - 2 8:30 amWinson Kutte, Palmetto Food Packaging LLC, SpeakerThe food industry continues to evolve and become ever creative in its approach to food production, food packaging, food marketing, and food delivery (both at the retail and food service levels). This combined effort at all levels of the food delivery chain is aimed at increasing sales and market share, of course, by giving the consumer a sense that they are not only purchasing a product, but more importantly, making a lifestyle decision that represents them. These lifestyle decisions can be based on the convenience and/or value a product offers, the tastes and variety a product offers, and even the perception that a chosen product or brand conveys a premium “lifestyle” over other brands (example, Starbucks versus other coffees). Every industry has its share of products and product marketing that aims to sell not just a product but to sell a “brand”, a definition of a lifestyle and an image as created by that product (witness bottled water in its many different packages and now, flavors, which consumers drink to suggest that they are health conscious and care about their well-being or drink to suggest their choice of a premium lifestyle by preferring bottled water over tap water or other bottled water brands). The rest of the food industry is no different, and increasingly in the last few years, has become more creative in marketing to consumers, as a result of competition both locally (on a national level) and globally, as more ethnic food products make their way onto the shelf and as more products continue to break the stereotype of typical packaging solutions. To this end, food products prepared, packaged, and marketed in flexible retort pouches are no different. They have been around in this country for many years (on the fringe) as military MREs and available in other countries as “normal” food solutions in areas where refrigeration, shelf-space, and disposal space are at a premium.

The Effects of Retort Conditions on Clear High Barrier Laminated Structures8 - 3 9:00 amThomas R. Mueller, Rohm and Haas Company, SpeakerRetort packaging is rapidly developing as a flexible alternative to cans. The ability to offer packaging with see through qualities has spurred the growth of high barrier laminate films. The clear retort package also offers the advantage of microwaveability right in the pouch, offering consumers extra convenience. This paper will examine the barrier and interlaminate bond qualities before and after retort of several different clear, high barrier film laminates, as compared to conventional foil structures.

PVDC Barrier Concepts for Demanding Coextrusion and Lamination Applications8 - 4 9:30 amValerie Renard, Dow Deutschland GmbH & Co OHGSteve Jenkins, The Dow Chemical Co., SpeakerCopolymers of polyvinylidene chloride (PVDC), are-well known for their use in demanding barrier packaging applications to minimize the permeation of oxygen, water vapor, and odors. New die designs incorporating patented early encapsulation technology (US Patent 6,685,872, International Publication Number WO 02/06047, US Patent 4,643,927), coupled with temperature isolation technology developed by equipment suppliers, have eliminated degradation problems existing in the typical spiral mandrel dies used in the blown film process. These new die designs, coupled with new resin offerings; enable PVDC resins to be processed on large multilayer blown film dies. Multilayer films incorporating PVDC resins with higher temperature polymers such as Nylon, PP, and LLDPE in the skins are now possible.

Additivies-Understandings and ApplicationsManufactures have developed resin additives to enhance specific resin properties, improve resin performance during processing and improve handling in the final product. This session will discuss how various additives interact with different resins to provide the improved performance. Various topics that will be discussed in the session include: elimination of sharkskin in LLDPE, application of controlled architecture materials, discoloration of PE film due to gas-fading, engineered resins used to extend PP performance, and improvements in barrier properties with high clarity technology.

9/27/2005Session: 9

10:30:a.m. - 1:00:p.m.

Session ChairAmy B. Rode, Voridian Div Eastman Chemical

Polymeric Nanocomposites Enabled by Controlled Architecture Materials9 - 1 10:30 amJames Nelson, 3M Dyneon, Speaker Controlled architecture materials (CAMs) (i.e. block copolymers) are being explored as specialty additives for the formation of polymer nanocomposites under melt-processing conditions. These block-copolymer-based additives provide interesting exfoliation solutions for clays of differing hydrophobicity in a variety of polymers. In this paper we demonstrate the ability of CAMs to exfoliate both organically modified and unmodified natural clays in polystyrene (PS) and polypropylene (PP) resins. Complementary characterization techniques of Transmission Electron Microscopy (TEM), x-ray diffraction (XRD), and rheology are used to identify exfoliation. Additionally, we demonstrate the efficiency of CAMs to exfoliate clay at low additive levels.

Improving the Gas-Fading Performance of Polyethylene Film Resins by Addressing the Over-Oxidation of Phenolic Antioxidants

9 - 2 11:00 am

Tony Tikuisis, Nova Chemicals Ltd., SpeakerDiscoloration of polyethylene due to “gas-fading” is an ongoing nuisance in the film packaging industry and can result in significant product claims and potential loss of business. It is well known that gas-fading can be attributed to the over-oxidation of phenolic antioxidants. There is a correlation between the changes in color that can occur during processing and the subsequent discoloration due to gas-fading. NOVA Chemicals has recently introduced gas-fade resistant polyethylene film resins into the marketplace. Data comparing the melt flow and color stability, physical property performance, long-term thermal stability and improved gas-fading resistance of these resins to conventionally stabilized formulations are presented. The new resins have been designed to tolerate the addition of moderate levels of phenolic antioxidant (from blending with other film resins) without a significant effect on color performance.

Proprietary Engineering Resins as Additives to Polypropylene9 - 3 11:30 amBob McKay, GE Advanced Materials, SpeakerKen Rudolph, GE Advanced MaterialsTodd Washburn, GE Advanced MaterialsTo extend the performance of polypropylene, additives manufacturers have developed a variety of products (light stabilizers, antioxidants, nucleating agents, etc.) to enhance specific material properties. However, to bridge the gap between polypropylene and engineering resins, converters must improve its impact resistance and also its elevated temperature dimensional stability, and do so economically. PPO* resin, a proprietary polymer of poly(2,6-dimethyl-1,4-phenylene ether) available from GE Plastics, is a unique product which may be utilized as a low level additive in polypropylene to achieve such property enhancements.

High Clarity Masterbatch: A New Technology for Improving the Clarity and Gloss of PE Films9 - 4 12:00 pmPrakash R. Patel, Ampacet Corporation, SpeakerA lot of advances have been made to improve the barrier properties of the PE films. The clarity has also improved with the advent of mLLDPE and cleaner polymers. But all films need to be modified to accomodate easy handling during packaging and dispensation. Commonly slip and antiblocks are added to the film to modify the surface. While these additives provide the necessary surface properties, they adversely affect the clarity and gloss of the film. A new masterbatch has been developed to address these issues. The following paper discusses the virtues of this patented technology.

Advances in Polymer Processing Additives (PPA)9 - 5 12:30 pmClaude Lavallee, 3M Canada Inc., SpeakerIn previous work1,2, flow visualization was used to understand how polymer processing additives (PPA) eliminate sharkskin in linear low-density polyethylene (LLDPE). The PPA migrates to and coats the die wall, induces slippage, and eliminates sharkskin. In this work, the interface between the PPA and LLDPE was further characterized using reflection light microscopy, scanning electron microscopy, energy dispersive X-ray, and profilometry. The coating is characterized by long stripes in the flow direction. The coating density obtained from different technologies was characterized on gold and nickel. The coating thickness was also measured.

Productivity Developments-Machinery Designs to Improve EfficiencyContinued from session 6

9/27/2005Session: 10

10:30:a.m. - 1:00:p.m.

Session ChairR. Duane Smith, Black Clawson Conv. Mach. Inc.

More Than Defect Detection - The Real Value of Web Inspection10 - 1 10:30 amBrian Heil, ISRA Surface Vision, SpeakerThis article explores opportunities to maximize the value of automated on-line film inspection. Examples are presented of implemented inspection systems that provide critical real time process and converting information to maximize yield, improve raw material quality, and strengthen customer relationships. A solution for automated re-wind control for defect removal that increases converting throughput is discussed. The implementation of this technology offers its users a variety of methods to achieve value. The user realizes the maximum value when all of the possible methods are implemented.

Non-Nuclear Gauging Alternatives Offer Enhanced Performance with Simplified Use10 - 2 11:00 amHector E. Marchand, NDC Infrared Engineering, SpeakerThis paper considers the role non-nuclear Infrared backscatter and X-Ray transmission sensors can play in the measurement of coatings and laminate layers online. For a long time, Beta transmission sensors and gamma backscatter sensors have been the preferred choice, due to their design simplicity, and ability to be used on a wide range of materials and applications with fairly predictable results. However, radioactive source regulations and disposal requirements are getting increasingly tougher, and many countries and companies are adopting “green” initiatives to reduce or eliminate the use of hazardous materials in the workplace. In this new environment, the possibilities and advantages that Infrared and X-Ray sensor technologies can deliver are starting to be realized in a number of applications including the converting industry, particularly where high performance is demanded, such as extrusion coating and lamination. The acceptance of Infrared and X-Ray sensors for the use in measurement of converted materials has come about due to a change in attitudes and philosophies while the advancement of the hardware technology has also promoted its use. Some of these advances have been made at the sensor level, and some at the system level, where use of such tools as same spot measurement, more robust calibration techniques, and improved sensor management have resulted in significant performance gains.

New Die Designs and Advancements in Automatic Die Controls for Improved Efficiencies in Film Production

10 - 3 11:30 am

James F. Foederer, Extrusion Dies Industries LLC, SpeakerFrequent product changes has driven die designers to develop new technologies. This paper will focus on new die designs targeted toward the thin film producer. Features and benefits of these dies include uniform deflection, streamlined polymer flow, reduced die start up time and reduced scrap resulting in increased productivity. Automatic die lip control will be discuss as well as additional die features and coatings, all relating the increased extruder uptime and complementary to the “Lean Manufacturer”.

Challenges of High Speed Splicing10 - 4 12:00 pmDonald L. Teich, Black Clawson Conv. Mach. Inc., SpeakerRichard S. Tetro, Black Clawson Conv. Mach. Inc.Reliability is a key objective of any continuous web splicing operation, as web speeds increase and parent roll diameters are reduced; the challenge to increase reliability becomes much more difficult. Accuracy and repeatability of splicing systems become critical when splicing at high web speeds, and failure to consider and solve the obstacles will result in decreased splicing reliability and increased downtime. The goal of this paper “The challenges of high speed splicing” is to explain what the obstacles are and the solutions required in overcoming these obstacles.

Advancements in Melt Fracture Elimination Technology10 - 5 12:30 pmRafael J. Castillo, Dual Spiral Systems, Inc., SpeakerIn extrusion, melt fracture or sharkskin is a phenomenon attributed to the stick/slip behavior of molten plastic flowing through a melt channel. If unaddressed, melt fracture causes the extrudate surface to appear rough with diminished physical and optical properties. Typically, melt fracture occurs when polymer melt is forced to flow through narrow die chambers at elevated shear stress levels. Traditionally the onset of melt fracture has been delayed through the application of polymer processing aides that have acted as a lubricant between the melt and the wall of the channel in which they are flowing. Dual Spiral Systems has recently completed field trials of a new low coefficient of friction coating that is showing promise in reducing melt fracture in high output extrusion lines. The melt fracture reducing die coating compound, called K05, has been tested at several blown film extrusion plants processing various LLDPE and HDPE resin grades. Previously the concentration of polymer processing aide (PPA) to eliminate melt fracture these companies were using was between 500-1200 ppm. So far the coating has been applied on blown film and tubing dies. Some preliminary data has been collected on film extrusion processes. This paper will detail the results of our preliminary data and analysis to date on the K05 trials and introduce the notion of using low friction coatings as an alternative to addressing melt fracture elimination.

Select Topics9/27/2005Session: 11

10:30:a.m. - 1:00:p.m.

Session ChairBrice T. Hunnicutt, Westlake Polymers LP

Viscoelastic Coextrusion Flow Modeling by Advanced Constitutive Equations: The Influence of the Die Design on Interfacial Instabilities

11 - 1 10:30 am

Jiri Vlcek, Compuplast InternationalMartin Zatloukal, Tomas Bata University, SpeakerPetra Saha, Tomas Bata University in ZlinMichael T. Martyn, University of BradfordFully viscoelastic FEM together with flow visualization technique are employed to quantify the effect of the die design on the wave type of interfacial instabilities in coextrusion. It has been shown experimentally that the minor channel geometry has a strong impact on the wave type of interfacial instabilities and the results can be correlated through novel criteria called as Total Stress Difference (TSN), which takes in to account the bulk change of the total stress in normal as well as tangential direction with respect to the interface. It has also been shown that specific type of high stress area occurs around the interface at the end of the converging section. This total stress has been found to be non-monotonic and discontinues along the interface and related for the onset of zig-zag type of interfacial instabilities.

Flame Plasma Surface Treating System Applied to a High Speed Coating Line11 - 2 11:00 amDom Medina, Flynn Burner CorporationJoseph D. DiGiacomo, Flynn Burner Corporation, SpeakerThis paper describes a flame plasma surface treating system successfully applied to a coating line operating from 100m/min (328 fpm) to 1000m/min (3280 fpm). The line coats a variety of polymer and paper substrates. This is one of the fastest coating lines operating in a manufacturing environment. The issues in applying a flame treating system to this range of line speeds and how they were addressed will be presented. The results obtained with flame plasma treatment at line speeds of 800m/min (2624 fpm) – 1000m/min (3280 fpm) will be compared with the results using corona treatment at significantly lower line speeds.

Printing on Metalized Polymer-Paperboard Compounds: Improvement of Adhesion by Optimized Flame Plasma Pre-treatment

11 - 3 11:30 am

Werner Eckert, Arcotec GmbH, SpeakerPolymer films have low surface tension and wettability due to non-polar molecules on the surface. Therefore, to print on laminated paperboard, there is a need to pretreat the surface to get proper adhesion of the ink. The most common physical treatment methods are Corona and flame treatment. This presentation deals with results obtained from the latest flame treatment technology. Electronically controlled unit, web speed controlled burner power and automatic burner deckling for varying web width as well as with the optimized adjustment of the flaming parameters can achieve high treatment level ensuring good adhesion of the ink. Significant reduction in gas consumption makes this technique even more interesting.

Future European Regulation on Adhesives for Food Contact Articles11 - 4 12:00 pmHermann K. Onusseit, Henkel KGaA, SpeakerFood contact materials are used for the production of articles intended to come into contact with foodstuffs and shall not transfer their components into the foodstuff in unacceptable quantities. These articles are requested to not influence the food they contact, neither toxicologically i. e. no health threat for the end user, nor may they change the composition of the food or its properties like smell, taste and appearance. On the European level two authorities deal with questions of food safety. One is the Council of Europe and the other is the European Union. While the decisions of the European Union are obligatory for national legislations, those of the Council of Europe are only a recommendation. For adhesives, the European Regulations are not harmonized. As is the case with all other materials, adhesives have to fulfill the requirements of the current framework regulation. In the framework regulation (EC)1935/2004 in annex 1 adhesives are listed for the first time, along with sixteen other groups of materials or articles for which special directives or regulations are planned. Although the draft of the so-called "Super Regulation" intends to include the migration contributions of the adhesives used in multilayer constructions it does not mention a specific regulation.

High Clarity Linear Low Density Polyethelene for Packaging Applications11 - 5 12:30 pmAmy B. Hitchcock, Voridian Div Eastman Chemical, SpeakerAs packaging applications become more demanding, film extruders are searching for resins with a combination of properties, including strength, clarity and stiffness. Many conventional resins, such as high-pressure low density polyethylene are clear, but lack the overall balance of toughness and stiffness that many applications require. Linear low density polyethylenes provide increased toughness and stiffness, but most lack the high gloss and low haze required for clarity applications. To achieve better film clarity, some extruders use lower density linear polyethylenes or blend with high pressure polyethylenes, thus sacrificing stiffness and toughness. A new polyethylene that combines good stiffness, clarity and toughness is now available for these demanding applications. This polyethylene, a 0.926 g/cc density linear low density based polyethylene can be used to produce stiff, clear films that can be used in a variety of applications including shrink wrap, and form, fill and seal applications.

Surface Treating for Flexography (Sponsored by FTA)The greater the demands put on the packaging for end use the greater the demands are for the printing of the material. Corona, flame and plasma are all treating methods used to improve the adhesion of ink on film, foil and even paper. Many factors will determine which process is preferred for one application verses another. Considering each of the treatment effects on the ink adhesion as well as the effect on the substrate is important. The economical aspects of one method over another may be more convincing for one process over another based on press width and speed. Selection of proper treating process and equipment is imperative for high quality flexo printing, laminating and coating.

9/28/2005Session: 12

8:00:a.m. - 10:00:a.m.

Session ChairRick Mix, Flexographic Technical Assn.

Do All Substrates Need Surface Treatment?12 - 1 8:00 amSteven Utschig, Fox Valley Technical College, SpeakerA substrate supplier describes the requirements of their materials and what can negatively effect different substrates. Can accurately use a “dyne pen” to test chemically treated films? Find out why this is a problem.

The Right Tools for the Right Job12 - 2 8:30 amMichelle Stevens, MOCON Inc, SpeakerTest methods, procedures and equipment for proper testing of substrate properties including but not limited to surface treatment. In addition to testing an implementation plan for testing programs will be presented.

Comparison of Surface Treatment Equipment12 - 3 9:00 amRory A. Wolf, Enercon Industries, SpeakerFor a specific adhesion problem which method is best? The range of substrates, desired speeds and processes in your facility will determine the choice if you know the answers to look for. Chemical, flame, corona or plasma find out what you need to know to establish what is the best option for you?

New Printing Adhesion Improvements Using Atmospheric Plasma Glow Discharge Technology12 - 4 9:30 amRory A. Wolf, Enercon Industries, SpeakerFlexible packaging is experiencing a technological revolution aimed at increasing consumer convenience, enhancing consumer protection, and delivering new solutions for a host of challenges throughout the manufacturing and distribution chain. High performance film structures, package configurations and applications, and printing technologies continue to drive flexible packaging into existing as well as completely new markets. The Flexible Packaging Association has identified flexible packaging sales of US$12 billion within a packaging industry estimated to have total sales of about US$20.5 billion. While corona and flame surface pre-treatments have traditionally prepared finished traditional flexible packaging structures for graphic and coating enhancements, this paper presents evidence of new flexible packaging print adhesion performance benefits using atmospheric plasma treatment (APT) technology.

Cost Reduction and Efficiency Improvement9/28/2005Session: 13

8:00:a.m. - 10:00:a.m.

Session ChairJoseph D. DiGiacomo, Flynn Burner Corporation

Economic Analysis of On-Line Gauging for Coating/Laminating Process13 - 1 8:00 amMichael Cunningham, EGS Gauging IncTan Srinivasan, EGS Gauging Inc.This paper discusses in detail the economic impact of quality improvements on finished roll goods in an Extrusion Coating/ Laminating process derived from application of on-line gauging system with available sensor and process control technologies. Accurate on-line measurement of the base, coat and laminate at high production speeds, is essential to coating processors to consistently manufacture high quality rolls. Various measurement sensor technologies and their economics are compared. Available process control technologies to minimize cross direction as well as machine direction variations are reviewed. Optimization control strategies are explored. Typical economic savings that accrue to the processor in utilizing an appropriate on-line measurement and control system in the areas of material savings, scrap reduction and productivity improvements due to faster start-ups and product change-overs are discussed. Economic impact of high quality rolls on downstream processing is also reviewed An economic worksheet for ROI computation of investment in an on-line gauging system for an Extrusion Coating/Laminating Line for both “soft” and “tight” market conditions is provided. An example of a spreadsheet for Multi-station Extrusion Coater is provided.

Reducing Resin Waste in Polymer Processing and Converting Operations13 - 2 8:30 amNatti S. Rao, Plastics Solutions International, SpeakerPolymer processing and converting operations, whether they relate to extrusion coating, blown film, making sheets for thermoforming or even manufacturing finished articles by injection molding, all these processes involve some waste of resin. A total conversion of the resin into the article of desired quality is an exception rather than a rule. As the material costs constitute the bulk of the total costs required for making a product, the aim should be to keep the resin waste as low as possible. As the quality of the product depends largely on the machine and processing parameters, one of the easiest, and yet most effective methods of reducing polymer waste is to optimize the design of converting machinery at the design stage before the machines are built. By means of several examples taken from blown film, extrusion coating, flat film, blow molding and pelletization, this paper shows how by applying this strategy resin waste could be reduced.

An Optimized and Integrated Supply Chain Planning Architecture for Paper and Film Manufacturers

13 - 3 9:00 am

Bart Van De Velde, OM Partners, SpeakerOver the past years supply chain complexity for paper and film manufacturers has increased as a result of increased possibilities to produce products at different manufacturing locations (including off-shore manufacturing), supplying products from different warehouses, larger product variety, smaller and customer specific lot-sizes and frequently changing demand patterns. Additionally during the past years, film and paper companies have experienced pressure on margins, often because of competition in low wage countries like China, India… To meet the increased supply chain complexity and margin pressure an optimized and integrated supply chain planning architecture is required. An optimized and integrated supply chain planning architecture uses a total supply chain concept supported by best practice planning processes and best-of-breed software applications. It allows companies not only to avoid cost increases but also to lower the current cost of operations.

Getting Something For Nothing13 - 4 9:30 amLouis W. Piffer, Davis-Standard Corporation, SpeakerThe purchase of an extrusion coating line is often the largest single purchase a company will make. With this sort of purchase comes the added responsibility of getting the most out of the equipment. By spending money, the efficiency of the equipment can often be improved through equipment additions and upgrades. This paper will deal more with the many ways improving the line’s effectiveness can occur without significant capital investment.

Utilizing Metallized Films t Retain Package Integrity During TransportVacuum metallized films (in particular metallized oriented polypropylene, but also oriented polyester films) are increasingly used to extend the shelf-life of a variety of food products. Additionally, they continue to replace aluminum foil laminations in many applications.Their moisture and oxygen barrier are typically not as great as that of foil, but they do offer "enough" barrier in many cases. Often the barrier level measured on a flat sheet of pristine metallized film will not be maintained through a package's distribution cycle. This session will explore the mechanisms of barrier layer degradation, laboratory methods for modeling these, and actual in-use barrier performance of metallized films. Emphasis is on metallized Oriented polypropylene, but other substrates will be mentioned.

9/28/2005Session: 14

8:00:a.m. - 10:00:a.m.

Session ChairThomas J. Dunn, Printpack Inc.

Barrier Testing and Comparison in Pouch Packaging Structures14 - 1 8:00 amBill Minnich, AET Films, SpeakerVarious methods may be used to estimate the oxygen and moisture barrier of flexible pouch packaging. A series of experiments was designed to compare the practical barrier of pouches. Foil was used as the control and compared to metallized oriented polypropylene. These experiments were intended to simulate flexing and handling that would be expected through the conversion and distribution chain. Barrier data was collected at various stages in order to estimate and compare the potential degradation of initial barrier through practical usage. In one set of experiments, Gelbo flex testing was used to simulate handling. In the second set of experiments pouches were filled with desiccant, subjected to a protocol of shipping and dropping, and weight gain measured over time.

Effects of Converting Operations on the Barrier Levels of Metallized Films14 - 2 8:30 amThomas J. Dunn, Printpack Inc., SpeakerEric Jordan, Printpack Inc.This paper presents actual production data generated in the same laboratory representing metallized base film and corresponding extrusion laminations made using those base films. Data represent a twelve month period from March 2004 to March 2005. Actual barrier values indicate that very low transmission rates are possible for metallized OPP and OPET (oriented polypropylene and polyester respectively). Extrusion laminating affects overall barrier population means and distributions. Actual composition of the base sheets greatly determined the direction and magnitude of the effects. The highest oxygen and moisture barrier OPP film design out-performed metallized OPET. In all cases, extrusion laminating the metallized base film to (printed) OPP with polyethylene extrudate lowered moisture transmission rates. Use of a converter-applied OTR enhancement improved the OTR of a moderate oxygen-barrier OPP base sheet.

Advances In Ultra High Barrier (UHB) And Enhanced Sealant (ES) Technology For Bi-Oriented Polypropylene (BOPP) Films

14 - 3 9:00 am

Sal Pellingra, ExxonMobil Chemical, SpeakerAdvances in ultra high barrier and enhanced sealant technology have been combined to provide solutions for barrier packaging including foil replacement and seal through contamination not previously available with a BOPP film. Through modifications to the extrusion and orientation process and the addition of advanced sealant and metal adhesion polymers, ExxonMobil has developed grades of Metallyte® BOPP films with on oxygen transmission rate (OTR) of 0.006 cc/100 in2/24 hr, a water vapor transmission rate (WVTR) of 0.02 g/100 in2/24 hr and seals of >2000 g/in in lamination. These new films offer excellent aroma barrier, improved flex crack resistance over foil and the ability to seal through contamination, with enough seal integrity for "over the-mountain" distribution. In addition, the films have excellent hot tack and offer robust packaging ranges on both vertical and horizontal packaging equipment.

High Barrier Advancements in Metallized Films14 - 4 9:30 amDante F. Ferrari, Celplast Metallized Prod. Ltd.Jim Lush, Celplast Metallized Prod. Ltd., SpeakerSome flexible packaging applications for dry powder, liquid packaging, lidding, and medical /pharmaceutical are highly oxygen or moisture sensitive, requiring excellent barrier properties. Many of these applications have historically used foil as the barrier layer in order to protect the product during its life cycle. Why foil? One reason is that standard metallized polyester (met PET) has not previously been able to meet the barrier needs of these high end products.

How Substrates Effect High Quality Graphics (Sponsored by FTA)The need for the graphics to drive product sale from the store shelf will continue to drive the desires of the packaging buyer to higher and higher quality graphics. Various flexible packaging applications including stand-up pouches, shrink films and form-fill packaging films have increased the requirements for multi-layer flexible packaging. Substrate requirements to provide toughness, rigidity, clarity and gloss have all contributed to complicating the process of achieving high quality printing.

Variations in substrate, whether in the form of thin films or multi-wall corrugated, have a significant effect on the printing of these substrates. Although gauge inconsistency is synonymous with “substrate variation” it is, by no means, the only variable that causes problems for achieving high quality flexographically printed material.

Presenters will address the most common negative attributes of substrates and the specific effect they have on high quality flexographic printing. Identification of the attributes through proper testing followed by discussions of processes, procedures and equipment available to avoid print defects will all be addressed.

9/28/2005Session: 15

10:30:a.m. - 12:30:p.m.

Session ChairRick Mix, Flexographic Technical Assn.

Evaluating, Monitoring and Controlling the Flexographic Printing Process15 - 1 10:30 amCordes Porcher, Bobst Group USA Inc., SpeakerThere are two groups of people in the flexographic printing industry. Group one is the press operator or button pushers. The individuals that make up this group spend many hours fighting with the system or process. They are also many times quite amazed at the result good or bad and could not tell you how they got there. The second group is just the opposite and is quite successful at what they do. Those that are successful have learned to manage and control their process from beginning to end. One of the many keys to this success is the ability to read and interpret the signs on the printed sheet. This presentation will cover some of the foundational elements (signs) to include on jobs, why the signs are needed and how to interpret them. Participants will be exposed to five key targets and examples of these targets in use.

High Quality Can Only be Achieved by Controlling Ink Volume15 - 2 11:00 amMike Huey, Harper Corporation of America, SpeakerSurface energy, surface tension and substrate thickness are important, but they are not the only attributes that can have an effect on proper ink lay down. Compensation for lamination, polyester coatings and metalized films effect the selection of the proper combination of anilox line count and volume and compatible plate material.

Detecting and Managing Print Defects, A Comparison of Quality Control Strategies and Tools15 - 3 11:30 amJohn Thome, BST Promark, SpeakerThe ability to identify issues related to the substrate before the material is on press is not always possible. The use of video web inspection can ensure that variables that occur during the press run and cause defects will be identified and resolved quickly. The improved productivity and lower waste achieved while gaining higher quality material produced is the result of using technology to examine the ink lay-down consistency, registration and dot gain at press speed. More is achieved using process control systems in flexographic printing.

The Converter's Perspective15 - 4 12:00 pmJason Scroggs, Sealed Air Corporation, SpeakerRegistration issues, ink adhesion, yellowing effect of laminations and coatings, film slip and packaging requirements are only a few of the many substrate-oriented concerns evaluated by flexo printers. Printers interest in greater press speed, reduction in waste and improved productivity all starts with the can all be achieved through and reduction in waste in their quest for high quality graphics.

Test Methods and Material Characterizations9/28/2005Session: 16

10:30:a.m. - 12:30:p.m.

Session ChairBruce W. Foster, Mica Corporation

The Effect of Resin Type and Coextrusion Film Structure on Gloss Measured at Multiple Geometries and the Correlation to Human Perception

16 - 1 10:30 am

Kathleen McCormick, NOVA Chemicals Corp., SpeakerGil Arnould, NOVA Chemcials Corp.Gloss is often used as a criterion to evaluate the quality of packaging films. Gloss is a quick and simple lab measurement made with a portable reflectometer unit, but do the values correlate with human perception? This study explores the relation between standard gloss measurement and perceived package ‘sparkle’. Clear plastic films have two specularly reflecting surfaces, that is, gloss contribution from the first surface and from the opposite film surface. Coextruded blown film structures can introduce additional layer interfaces in the bulk of a film, which contribute to specular gloss as well. This study explores the effect of resin type and coextruded film structure on gloss measured at multiple angle geometries.

Monitoring of Rheological Indicators of LDPE16 - 2 11:00 amClaes Oveby, Tetra Pak Carton Ambient AB, SpeakerPer-Ake Clevenhag, Tetra Pak Carton Ambient ABLDPE,s from high-pressure autoclave reactors for extrusion coating with Melt Flow Rates (MFR,s) from 6 to 9g/10 min., and with densities of 917-921 kg/m3, have been considered uniform commodities for a long time. However, as coating lines became faster, differences in processing performance among LDPE,s have been observed even though they met MFR and density specifications. These problems included web break and edge instabilities causing PE missing. Various LDPE,s behaved differently in the coating process due to differing rheological properties. This paper presents results of our investigation comparing several LDPE,s. Results showed significant differences in their rheological properties. These differences significantly affected performance of the LDPE,s in the extrusion coating process. A further finding was significant variation in rheological properties and resulting performance within the same grade from the same supplier.

Infrared Analysis of Single and Multilayer Films in the Production Area16 - 3 11:30 amScott T. Cobranchi, Sealed Air CorporationSandy Rintoul, Wilks Enterprise Inc, SpeakerThere are many areas in production that can benefit from a rapid onsite measurement: determining which side is which on multilayer films to be laminated, checking rolls of film in the warehouse, measuring an individual layer within a film in the production area, raw material verification, and formulation discrimination are few examples. A new concept portable infrared spectrometer enables the user to obtain infrared spectra on single layer or multiple layer films outside of the laboratory. Polymers such as nylon, EVOH, EVA, and polyethylene have characteristic absorbances in the mid infrared range that can be used for material identification or for quantitative measurements. This new spectrometer utilizes a detector array and a linear variable filter in order to produce spectral information much like an FTIR (fourier transform infrared spectrometer). Unlike the FTIR, the spectrometer is rugged, has no moving parts, fits in the palm of a hand, is a fraction of the cost and is easy to operate.

Reducing Variability in Dart Measurement Associated with Dart Head Wear16 - 4 12:00 pmMark Weber, NOVA Chemicals Corporation, SpeakerDiscrepancies in results from dart impact testing of films are a common occurrence. In order to evaluate potential explanations for these differences, a study was initiated to explore the effect of dart head wear and additive formulation on dart performance. Results from this work indicated that dart head wear can lead to variation in results after testing 1000 samples. When evaluating dart impact behavior on a variety of films using new and conditioned dart heads, it was observed that the degree of impact resistance and the formulation of the film both had a significant effect on results. Samples with relatively poor impact performance were less sensitive to dart wear, as were samples which had been formulated with antiblock and slip. The sensitivity of dart to additive formulation was found to be caused by the coefficient of friction of the film, as samples with low coefficient of friction showed minimal dependence on the condition of the dart head. Based on findings from this work, NOVA Chemicals has instituted a program address these concerns. This initiative will ensure that excessive dart wear does not generate unacceptable discrepancies in dart performance.

Materials Selection and OptimizationThis session will focus on materials, how to process them, and help the attendee understand how materials and how they are coextruded interact. A must for processors looking to address problems and concerns with LLDPE's and coextrusion.

9/28/2005Session: 17

10:30:a.m. - 12:30:p.m.

Session ChairDavid G. Timm, Charter Films

First Principles Cause of Melt Fracture in LLDPE17 - 1 10:30 amDavid J. Smith, Battenfeld Gloucester Eng. Co., SpeakerMike Andrews, Battenfeld Gloucester Eng. Co.Ever since the introduction of LLDPE, the industry has had to deal with problems caused by melt fracture in many processing situations, with the worst problems typically occurring in the production of blown film. Over the years, many mechanisms have been proposed in an attempt to explain the cause and therefore possible cures for melt fracture, but none of these mechanisms has been able to adequately explain the observed phenomena or provide sufficient insight to develop a cure for the problem. Based on experimental observations, a new mechanism based on volatile induced flow defects has been proposed that explains many of the observations that could not previously be explained. This mechanism has allowed us to predict new methods for reducing melt fracture, and tests have proven these predictions to be correct. SEM photos of film samples provide additional evidence in support of this proposed mechanism.

Blown film of LLDPE/LDPE blends: a performance based product selection17 - 2 11:00 amSarah K. Marshall, Nova Chemicals Corp, SpeakerTrevor Swabey, NOVA Chemicals Corp.Paul P. Tas, NOVA ChemicalsFor LLDPE blown film it is common to blend in LDPE for a variety of reasons. In the study presented here, four different types of LDPE, varying in melt index and polydispersity, were blended in single site catalyzed LLDPE (sLLDPE), in C8 ZN-LLDPE and in C4 ZN LLDPE. The discussion evolves around the proper choice of LDPE for each LLDPE, with respect to a balance of physical and optical performance.

Cost Reduction Using Performance Products - A Case Study17 - 3 11:30 amLan T. Nguyen, Paul P. Tas, NOVA ChemicalsDaniel R. Ward, NOVA Chemicals, SpeakerThe use of a performance product is often associated with higher cost. However, the proper use of a cost vs. benefit analysis along with blend optimization has demonstrated that a cost reduction in polyethylene films can be realized. This paper illustrates a case study on how to design alternative high performance polyethylene blends. It is demonstrated that these high performance blends have improved product characteristics and increased throughput while, at the same time, reducing overall cost. The use of high performance product therefore may well be justified if it results in reduced overall cost of polyethylene films.

The Effect of Material Selection in Feed-Block Coextrusion of a Three-Layer Film17 - 4 12:00 pmJiri Svabik, Compuplast International Inc., SpeakerWalter Kopytko, PhD, Renolit AGJohn Perdikoulias, Compuplast Canada Inc.Jiri Vlcek, Compuplast International This paper describes a case study dealing with the development of a three-layer product on a feed-block coextrusion system. The problems or phenomena that occurred during the product development experiments are explained via flow simulation and the rheological properties of the materials used. The results of the study are compared with real film samples produced during the development

UV/EB Coating and AdhesivesUV/EB Curing technology has been used in packaging applications for more than 30 years. Common applications include inks, coatings, and adhesives for labels and folding cartons. The use of UV/EB technology in flexible packaging has been limited due in part to a lack of understanding of technology as well as some important technical challenges. Papers in this session will address and provide potential solutions to some of these challenges.

9/28/2005Session: 18

2:00:p.m. - 3:30:p.m.

Session ChairStephen C. Lapin, Northwest Coatings Corp.

Applications of Novel Photo-Curing Oligomer Resins: Generation Two18 - 1 2:00 pmMichael Gould, Ashland Chemical, SpeakerA new “family” of acrylic resins that can ‘self-cure’ with exposure to UV light (i.e., requiring little or no added photoinitiator) was introduced in 2002. Since then, the science behind reducing the basic concept to commercial reality has been advanced several times over. Today, resins can be made with nearly unlimited architecture and properties. Based on head-to-head benchmarking studies against published formulations, self-initiating Michael polyacrylate resins can be designed for use on almost any substrate and for nearly any application. Cure can be accomplished with equal or less UV energy than required for standard formulated products, often with no added photoinitiator. The current capabilities of these novel resins will be discussed as they apply to coatings for flexible and rigid plastic substrates, wood, metal, and paper.

Choosing the Right Cure Mechanism for UV Curable Laminating Adhesives18 - 2 2:30 pmDeborah Smith, Sartomer Company, Speaker Ultraviolet (UV)-curable laminating adhesives are currently being used to bond clear films to various film, paper, and foil substrates. Typically, the adhesive is applied to the clear film and then nipped onto the second substrate surface. The adhesive is then cured using UV irradiation through the clear film. This paper focuses on various studies, which were designed to improve adhesion in radiation- curable (i.e., UV or EB) laminating adhesives. First, a typical laminating adhesive was cured on PET using various UV lamp sources and different types of photoinitiators to evaluate cure. Next, various oligomers were UV-cured on both polypropylene (OPP) and polyester (PET) to determine the best oligomer for each film. Various lamp sources along with energy of cure were evaluated in this study.

Optimizing Application Properties of EB Curable Laminating Adhesives for Flexible Packaging18 - 3 3:00 pmStephen C. Lapin, Northwest Coatings Corp., SpeakerThe advantages and performance properties of Electron Beam (EB) curable laminating adhesives have been previously described.1-10 The most significant advantage is that full bonding is achieved instantly upon EB irradiation. This allows immediate slitting, shipping, heat sealing, and filling of the package. One challenge with instant bonding is that the adhesive appearance is “frozen” immediately upon cure. This is in contrast to isocyanate/polyol based adhesives where the adhesive can continue to flow-out in the rewind roll as the curing process continues. Of course the risk with isocyanate/polyol adhesives is that the flow out may not meet expectations and that a significant amount of scrap may result At least with EB curable adhesives the final optical appearance of the laminate can be evaluated immediately upon production. It is known that the most effective way to improve the optical properties of an adhesive laminated structure is to improve the lay-down of the adhesive on the primary web. Some additional improvements may also be possible by adjustment of the nip conditions. The goal of this study is to investigate the factors that affect the lay-down properties of EB laminating adhesives. The factors studied were: 1) web speed, 2) adhesive flow additives, 3) adhesive temperature, 4) coater configuration, and 5) corona treatment.

Test Methods and Material Characterizations9/28/2005Session: 19

2:00:p.m. - 3:30:p.m.

Session ChairBruce W. Foster, Mica Corporation

Polyolefin Microstructure Characterization Using 3D-GPC-TREF19 - 1 2:00 pmWallace W. Yau, Lyondell Chemical Company, SpeakerGel permeation chromatography (GPC) separates polymers by size, and therefore provides a measure of polymer molecular weight distribution (MWD). Since long chain branching (LCB) adds to molecular weight more than to molecular size, adding a light scattering (LS) and a viscosity detector to GPC in the form of 3D-GPC also becomes a tool to detect polymer LCB and LCB distribution. However, GPC separation is insensitive to polymer short branching (SCB). For SCB distribution, we use the temperature rising elution fractionation (TREF) technique. TREF relies on the crystallization and dissolution process to separate polymers that have different levels of SCB. Adding a LS and a viscosity detector to TREF makes it possible to detect the molecular weight (MW) dependency across the polymer SCB distribution. Therefore, a fully automated hybrid system of 3D-GPC-TREF is a very effective tool for analyzing polymer branching architectures. Such structural information is highly useful to complement the thermal analyses and the rheological results for studying many areas of polymer interests where the understanding of polymer structure-property relationship is of central importance. The following examples of problem-solving application will be discussed: LCB differences between tubular and autoclave low density polyethylene (LDPE); LCB effect on draw down, neck-in, and heat seal of LDPE in coating application; reverse MW-SCB dependency of linear low density polyethylene (LLPDE); and “gel” versus “un-melt” issues in high density polyethylene (HDPE) films.

Thermal Analysis of Primers and Coatings as a Prediction Model19 - 2 2:30 pmRobert Hammond, Mica Corporation, SpeakerThermal characteristics of primers and coatings can be a useful prediction model on how the material will perform under heat exposure from manufacturing processes and product applications. Two chemistries, poly[vinyl alcohol] and poly[ethylenimine], have been analyzed using the techniques of Thermogravimetric Analysis (TGA), TGA coupled to a Mass Spectrometer (TG/MS), TGA coupled to a Fourier Transform Infrared Spectrometer (TG/IR), Modulated Differential Scanning Calorimetry (MDSC), Dynamic Mechanical Thermal Analysis (DMTA).

Use Process Control Valves as Rheometers to Predict and Control Polyethylene Molecular Weight and Molecular Weight Distribution

19 - 3 3:00 pm

William Todd, Lyondell Chemical Company, SpeakerIn polyethylene production, having fast reliable feedback on molecular weight (MW) and molecular weight distribution (MWD) is critical for producing high quality resins. Historically this feedback comes from the quality control (QC) lab, but feedback times are at least 30 minutes, if not longer. One-third of a railcar can be produced in a large commercial plant in 30 minutes. One alternative is to install an online melt indexer or rheometer for these measurements. The downside of these online instruments is that they are expensive and can require frequent maintenance. This article describes how pressure drops across process control valves and die plates can be used as a measure of viscosity at different shear rates, which can be used to predict MW and MWD. These predicted values are then used to control the process.

Materials Selection and OptimizationThis session will cover high performance films and materials and where they can be used. With today's rapidly changing resin technologies, this session will help you to understand how to apply these new materials and give real application results.

9/28/2005Session: 20

2:00:p.m. - 3:30:p.m.

Session ChairDavid G. Timm, Charter Films

Performance Films from Single Site Bimodal sLLDPE Resins20 - 1 2:00 pmShivendra Goyal, Nova Chemicals, SpeakerWith the advent of single site dual reactor process technologies, such as NOVA Chemicals Corporation’s Advanced SCLAIRTECHTM Technology, it is now possible to produce performance films using single site bimodal sLLDPE resins. With appropriate design of resin architecture and processing conditions, dual reactor single site bimodal sLLDPE resins can provide excellent film physical and optical properties, improved sealing characteristics and low hexane extractables while maintaining good resin processability. This paper will discuss the influence of molecular architecture and processing conditions on the film performance characteristics.

Metallocene LLDPE Films for Heavy Duty Sack Applications20 - 2 2:30 pmDavid M. Fiscus, ExxonMobil Chemical Company, SpeakerPolyethylene-based heavy-duty shipping sacks are used around the world to package and shipproducts such as soil, fertilizer, mulch, gravel, and pelletized resin. Approximately1000 kilotons (kt) of polyethylene is converted into heavy-duty sacks annually around theworld. Previously, our company analyzed a variety of heavy-duty sacks and foundsacks made from m-LLDPE blends and co-extruded films exhibit a superior balance ofmechanical, optical and sealing properties versus traditional Zeigler-Natta resins. Now, EMCChas taken this performance a step further.

Novel High Performance Collation Shrink Film20 - 3 3:00 pmRichard W. Halle, ExxonMobil Chemical Co., SpeakerDavid R. Weisinger, ExxonMobil Chemical Co.Philipp Becker, ExxonMobil Chemical EuropeDonna Davis, The global collation shrink film market is segmented depending upon the film's primary function, such as transportation, bundling display, or advertising display. The highest quality collation shrink films, classified as advertising display films, require excellent optical properties in addition to good stiffness, high abuse resistance, excellent shrink performance, good holding force, and good machineability. Metallocene LLDPE has been combined with a new high performance LDPE and a new HDPE in a coextruded blown film structure to establish new industry leading performance in advertising display shrink film applications. This unique resin formulation combines outstanding package integrity and packaging line reliability, particularly on high speed packaging lines, with superb optical properties of high clarity, gloss, and enhanced print quality.

UV/EB Coatings and AdhesivesUV/EB Curing technology has been used in packaging applications for more than 30 years. Common applications include inks, coatings, and adhesives for labels and folding cartons. The use of UV/EB technology in flexible packaging has been limited due in part to a lack of understanding of technology as well as some important technical challenges. Papers in this session will address and provide potential solutions to some of these challenges.

9/28/2005Session: 21

4:00:p.m. - 5:00:p.m.

Session ChairStephen C. Lapin, Northwest Coatings Corp.

Heat Management Methodology for Successful UV Printing on Film Substrates21 - 1 4:00 pmDavid A. Samide, Prime UVErich Midlik, Prime UV Systems, Inc., SpeakerNow in 2005, UV systems possess heat management controls that fine tune the exothermic and delivered heat in the UV curing process. This paper will explore the various methodologies and controls that allow film processors to cure UV adhesives, UV inks, and UV coatings when applied to thin film substrates.

Influence of Electron Beam on Some Polymeric Substrates Used in Flexible Packaging21 - 2 4:30 pmImtiaz J. Rangwalla, Energy Sciences Inc., SpeakerElectron beam affects some polymeric substrates used in flexible packaging. What substrates and what properties of it get affected, and how to minimize these affects so that the end product is functional will be presented. In addition physical property comparisons of two different polypropylene films manufactured by two leading OPP manufacturers after EB treatment will be discussed.

Foil Applications and AdvancementsWhile many technologies are being developed for barrier packaging applications, foil maintains a high standing for providing superior barrier to vapours, odours and gases. Although foil has been in use for quite a long time, there continues to be new exciting developments with this versatile substrate. This session will dispel some myths about the effect of pinholes on barrier properties in thin foils, provide a better understanding of corona treatment of foil (as well as other substrates), and demonstrate that foil can do so much more than provide barrier - it can be engineered to control peelability in packaging and its color can be altered to provide a unique appearance for enhanced security and brand authentication.

9/28/2005Session: 22

4:00:p.m. - 5:30:p.m.

Session ChairJanevieve A. Parks, AT Plastics Inc.

Advanced Aluminum Foil Products for Packaging Applications22 - 1 4:00 pmMel Ball, Novelis Inc, SpeakerAluminum foil is widely used in flexible packaging for food, beverage, pharmaceutical and other products because it offers outstanding barrier properties (for moisture, oxygen, carbon dioxide and other gases) and also provides protection for UV sensitive products. This paper will describe some advanced foil technologies, which offer additional benefits for the packaging industry. The use of an engineered, weakened oxide interface for controlling peelability for blister packages, or for lidding applications will be described. Using this material with a suitable heat seal lacquer or laminate material, a precisely controlled and consistent peel strength can be achieved. In addition, a novel route to the production of “color shift” foil materials will also be introduced. As well as providing an interesting decorative effect, with a range of bright pastel colors, the color change or shift which occurs when the viewing angle changes, is very difficult to replicate. Consequently, this technology has potential applications for enhanced brand authentication and security.

The Impact of Foil Pinholes and Flex Cracks on the Moisture and Oxygen Barrier of Flexible Packaging

22 - 2 4:30 pm

Lee J. Murray, Alcan Packaging, SpeakerHigh barrier packaging applications for medical, industrial and food packaging often include aluminum foil. Thinner gauges of aluminum foil contain pinholes through which moisture and oxygen from the environment can enter the package accelerating the degradation of the contents. This paper addresses the impact of foil pinholes and fractures on the oxygen and moisture barrier of multilayer flexible packaging, in theory and in practice using laser-produced pinholes. The analysis shows that the transmission through the pinholes is less that occurring through exposed sealant edges and much less than that which would take place through non-foil packaging of the same size.

Saturation Phenomena in Conjunction with Corona Treatment on Different Substrates22 - 3 5:00 pmRalf Weber, AFS GmbH, SpeakerSaturation is a phenomenon, which describes an increase of input power into a corona system which does not lead to an increase of surface energy on the substrate. This may either be due to the substrate or to the treatment system. The industry is interested in having detailed information about saturation phenomena in conjunction with corona treatment in order to achieve an efficient, secure process with the best possible surface adhesion characteristics. This presentation deals with several aspects of saturation, and sheds light on substrates (Aluminum compared with PE) and different configurations of corona treaters.

Film Property Optimization Through Orientation9/28/2005Session: 23

4:00:p.m. - 5:30:p.m.

Session ChairBob Dietrick, International Paper

Effects of Machine Direction Orientation (MDO) on the Moisture and Oxygen Barrier Properties of HMW-PE Films

23 - 1 4:00 pm

D. Ryan Breese, Equistar Chemicals L.P., SpeakerMoisture and oxygen barrier properties of machine direction oriented (MDO) polyethylene films have been studied. This paper will present the effects of density and draw ratio of the MDO film on its barrier properties. This paper will also present the structural changes occurring in the crystalline phase of the MDO film and its relationship with the barrier properties.

The Effect of Orientation on MD-Tear of HMW-HDPE Films23 - 2 4:30 pmHarry Mavridis, Equistar Chemicals L.P., SpeakerAyush Bafna, Jean Merrick-Mack, The specific Machine Direction-tear strength (MD-tear per thickness) of HMW-HDPE films generally decreases with decreasing film thickness. This is thought to be the result of increasing orientation as film thickness is decreased. Therefore, it should be possible to produce thin films of enhanced MD-tear strength, if the orientation in th