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PolyShieldTM
The Monolayer Barrier
Martin N. GossageINVISTA Resins & Fibers GmbHPET World Congress at Drinktec
12th September, 2005
Polymer & Resins 2
Fiber, Resin & Intermediates
Polymer & Resins 3
PET & Nylon Resins
• A Fiber, Resin & Intermediates Business – Vertically integrated in nylon and polyester
– Global presence in more than 30 countries
– Combined 2 businesses on April 30, 2004• Former Hoechst Polyester Resin & Fibers
• Former DuPont Textile & Interiors (DTI)
– Subsidiary of Koch Industries• Wholly-owned subsidiary
• Independently managed
Polymer & Resins 4
Global Brand Portfolio
Success through well-known global brands
Polymer & Resins 5
Business Operations
• Operating 5 business divisions– Intermediates
– Polymer & Resins
– Performance &
Textile Fibers
– Interiors
– Apparel
Polymer & Resins 6
A Market Leader in PET
Polymer & Resins 7
A Leader in Polyester
Polymer & Polymer &
Packaging Packaging
ResinsResins
DMTDMT
Tire Tire CordCord
Staple FiberStaple Fiber
IntermediatesIntermediates
Textile FilamentTextile FilamentTechnical FilamentTechnical Filament
From raw materials to resin and fibers
Polymer & Resins 8
Packaging Products
Return - Refill
Liquor - Clarity
Juice - Hot-fill
CSD - Low Stick
Water - Low AA
Bulk Water
Beer -Barrier
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The Monolayer Barrier
Polymer & Resins 10
The Monolayer Barrier
• PolyShieldTM is a PET barrier resin which provides excellent oxygen and carbon dioxide barrier in combination with outstanding clarity for tinted bottles when blended with MXD6 at the injection machine– PET - MXD6 blend
– Monolayer bottles
– Active O2 scavenging
– Passive CO2 barrier
– Excellent clarity
Polymer & Resins 11
• Superior clarity is achieved by significantly reducing the size of the barrier platelets through applying an innovative compatibilizer
Standard PET/MXD6 Blend
(Preform)
PolyShield/MXD6 Blend
(Preform)
PolyShield/MXD6 Blend (Bottle)
hazy clear clear
The Polyshield - Clarity
Polymer & Resins 12
The Monolayer Advantage
Gravimetric Feeder
PET Dryer
Injection Machine
MonolayerPreforms
Barrier Injection MachineMXD6 Dryer
Additionally required parts in red
MXD6 Dryer
Multilayer Control Panel
MultilayerPreforms
Multilayer Mold
MonolayerMonolayer
MultilayerMultilayer
Polymer & Resins 13
• PolyShieldTM is suited for use in food packaging applications in contact with all foods
– All monomers and additives are included on the respective “positive lists” in the EU Plastics Directive
– PolyShield™ bottles meet all global and specific migration limits of the European Union Directive
– PolyShieldTM bottles are safe and suitable under the Framework Directive (Directive 2002/72/EEC)
– Migration studies for foods with more than 10% alcohol and fattyfoods are still pending
Regulatory Approval
Polymer & Resins 14
• Excellent for standard and premium beers – Preserves freshest taste
• 4 month shelf life in 500ml, 28 g bottle– Less than 1 ppm oxygen ingress in 1 year
– Less than 15 % loss of carbon dioxide in 4 months
– 6 month shelf life on taste and odor test
• Exceptional clarity– Less than 5% haze in amber and green bottles
Bottle Performance
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Performance for Beer
Polymer & Resins 16
Taste Testing at VLB
500 ml Bottle AT Filling 1 Month 3 Month 4 Months 5 Months 6 Months
Standard PET Passed Failed Failed Failed Failed Failed
Multilayer (5 layer) Passed Passed Passed Failed Failed Failed
PolyShieldTM (2% MXD6) Passed Passed Passed Failed Failed Failed
Internal Coating Passed Passed Passed Passed Failed Failed
PolyShieldTM (5% MXD6) Passed Passed Passed Passed Passed Passed
PolyShieldTM (7% MXD6) Passed Passed Passed Passed Passed Passed
Multilayer (3 layer) Passed Passed Passed Passed Passed Passed
Polymer & Resins 17
Aging Marks / Taste
01234567
0 50 100 150 200
time [days]
mai
n va
lue
Standard PET
PS 2%
PS 5%
PS 7%
Coating
5 Layer
3 Layer
Glass
threshold
Sensory Taste Test
500 ml bottles filled with beer and taste tested over 6 month
=> Polyshield with 5%/7% MXD6 and 3 layer technology pass the 6 month taste test
Above 3 = Failed
Below 3 = Passed
Polymer & Resins 18
Aging Marks/ Odour
0123456
0 50 100 150 200
t (d)
mai
n va
lue
Standard PET
PS 2%
PS 5%
PS 7%
Coating
5 Layer
3 Layer
Glass
threshold
Sensory Odor Test
Above 3 = Failed
Below 3 = Passed
500 ml bottles filled with beer analyzed for odor over 6 month
=> Polyshield with 5%/7% MXD6 and 3 Layer technology pass the 6 month odor test
Polymer & Resins 19
Change in CO2
500 ml bottles filled with beer and carbonation tested over 6 month
=> Polyshield with 7% MXD6, coating and 3 Layer technology have the smallest CO loss over time
-1.4-1.2-1.0-0.8-0.6-0.4-0.20.0
0 5 10 15 20Weeks
CO
2 Lo
ss (
g/l)
Standard PET
PS / 2% MXD6
PS / 5% MXD6
PS / 7% MXD6
Coating
5 Layer
3 Layer
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Sample: 500ml / 28 gram / Plain PET bottle at 23 °C
45 Days 68 Days0 Days
O2 Ingress Monitoring
Guelph Food Technology
• Oxygen ingress detection
• Bottles filled with gel indicator
• Oxygen turns the indicator blue
• Oxygen ingress can be located
• Oxygen ingress can be quantified
Polymer & Resins 21
O2 Ingress Monitoring
Some multilayer bottles show significant O2 ingress after a very short time at the base, neck and finishClosures without barrier liner are a source of significant oxygen ingress
Multilayer Bottle
Polymer & Resins 22
O2 Ingress Monitoring
30 days 120 days 154 days
After 8 months:
• No O2 Ingress
• No Leaks
PolyShieldTM 500ml 28 gram bottleStandard
PET
45 days
245 days
Polymer & Resins 23
• Better Product Performance– Passive CO2 barrier built in
– Greater oxygen barrier
– Reliable longer term oxygen scavenging and barrier
• Easier handling and processing– No empty bottle shelf life issue
– No scavenging activation from environment needed
Versus other O2 scavengers
Polymer & Resins 24
• Better Product Performance– Longer shelf life demonstrated in application testing
– More consistent and reliable barrier
– No leaks due to cracks and pinholes
• No additional coating machine required– No additional investment
– Much less hassle at the brewer or filler
– No coating machine/chemistry between bottle blowing and filling
• No additional manufacturing cost– No additional complexity
– No additional man power need to run and clean the machines
Advantages over Coating
Polymer & Resins 25
• Better Product Performance– Barrier over the entire bottle
– No barrier layer delamination
– Ability to make complex shapes
• Runs on Standard Injection machine– No investment in dedicated and expensive multilayer equipment
– Flexibility in switching between standard and barrier preforms
• Lower manufacturing cost– Less need for expensive spare parts
– Less man power needed
– Less scrap in preform production
Advantages over Multilayer
Polymer & Resins 26
Commercialized Applications
Polymer & Resins 27
• PolyShieldTM is the long awaited breakthrough for Beer and other oxygen sensitive products in monolayer PET containers– Preserves fresh taste
– Perfect for standard and premium beers
– Excellent O2 scavenging & CO2 barrier
– Monolayer barrier packaging with excellent clarity
– Runs on all injection molding machine
– Cost competitive with one–way glass
– Commercialized in Europe
Conclusion
Polymer & Resins 28
Visit INVISTA at
Drinktec - Hall 6A - Stand 116
Or contact INVISTA via: • Martin N Gossage
• Tel: +44 7785 393517
• Fax: +44 1234 709062
• E-mail: [email protected]
• Web: www.invista.com
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