New Design-Enabling TechnologiesDr. Giancarlo Caimmi, Dr. Guido KollbachAimcal R2R, Phoenix, October 2018
For Flexible Packaging
2
Market Applications for Metallized Films
Food Packaging Decoration Industrial
Snacks, Chips Bakery products Candy, Confectionary Coffee, …
Gift and Flower Wrapping Labels Hot Stamping Foils Holograms, …
Solar Window Films Anti-Counterfeiting Films Road Signs, …
October 25, 2018New Design – Enabling Technologies for Flexible Packaging for Flexible Packaging
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Market for Metallized and AlOx-Coated FilmsStrong Growth in India and Asia
Estimated Market Growth1)
October 25, 2018New Design – Enabling Technologies for Flexible Packaging1) Market estimates based on information from Henkel, Nordmeccanica, and several market studies
2.54.0
13.3
8.96.7
2.94.5
15.1
10.17.6
Europe North America
AsiaIndia & Middle
East
South America
AI Ox-coated FilmsMetalized Films
4
Market Applications for Functional Coatings
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Coating Functionalities
Sealability
Better anchorage
Improved barrier
Protection
Optical effects (gloss, matte, …)
Slip modification
Henk
el’s
Coa
ting
Tech
nolo
gies
& M
arke
ts
Trend: Multifunctional Coatings
Markets: Food, Medical
Markets: Food, Medical
Market: Food
Market: Food
HS
CS
PR
OPV
Markets: Food,MedicalBC
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Novel Metallization Primers Metallizing on top of
multifunctional metallization primers
Integration and Interaction of Product LinesFreedom of Design – Case Studies
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Traditional Lamination of metallized
films with printed stock
High Performance Protective Top-Coatings Top-coating fragile layers
like AlOx with protective coatings
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Metal DepositionPrinciple & Key Technical Data
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Aluminum layer deposited to films and paper in vacuum
Thickness: 0.005 – 0.07 micron
Optical Density: 0.2 – 4
Electrical Resistance: 0.5 – 10 Ω/m2
P (chamber pressure)= 5E-4 mbar
7
System LayoutSchematic Representations
October 25, 2018
RootsPumps
-Vacuum5 X 10-2
mbar
Diffusionspumps
-Vacuum
2-5 X 10-4mbar
Process drumchill roller
Al evaporators
Unwind Rewind
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System LayoutProduct Pictures
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Vacuumchamber
AI evaporationsystem
Winder
9October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Process SchematicMetallization Process
High vacuumchamber
Al evaporators
Boat
10
Coater TechnologyProduct Pictures
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
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Innovation Through Collaboration of Industry Leaders
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Safe and highly focused innovation process created fast results!
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Case Study AlOx-Coated FilmsNew High-Performance Protective Coating Technology
AlOx-coated films
Very good oxygen and moisture barrier
Very fragile
Converting leads to dimished barrier performance
Current top-coating technologies provide mechanical protection
New top-coating technology
Mechanical protection
Significant barrier improvement
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Substrate(e.g. PET, OPP)
AlOx-layer
High-performanceTop-coating Technology
Protected AlOx-coated Film
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Case Study AlOx-Coated FilmsProcess Flow-Chart
Top-Coating LaminationPrinting
Optimal anchorage
Superior barrier performance
Best clarity
Fragile AlOx-layer unprotected
Additional functionality for very high performance
01 02 03
AlOx-Coating
04 Protection of AlOx-
layer
Ink anchorage
High mechanical and thermal stress
Good anchorage of ink on AlOx during lamination
Keeps top barrier performance throughout process
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
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Case Study AlOx-Coated FilmsTesting Mechanical Protection
Strongly improved robustness
Barrier performance not reduced by stretching or abrasion
Gelboflex testing
Significantly more robust than traditional top-coat
13.1
21.2
47.4
14.7
2.6 4.5
11.66.2
0.1 0.1 0.1 0.2
BeforeTreatment
Stretching Abrasion Test Gelboflex-50
OTR
(cm
3 /m
2 .24h
.bar
)
No Top-Coat Traditional Top-Coat
Henkel's Top-Coat
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
(2%)
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Case Study AlOx-Coated FilmsProduction Scale Testing
Strong barrier improvement by AlOx-coating
Significant boost in oxygen barrier performance by Henkel’s new top-coating technology
Moisture barrier stabilized or improved
Very good stability throughout entire process
4.9 4.9
3.74.0
4.9
0.1 0.1 0.1AlOx-Coating Top-Coating Printing Laminating
OTR
(cm
3 /m
2 .24h
.bar
)
No Top-Coat Henkel's Top-Coat
October 25, 2018New Design – Enabling Technologies
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Case Study Metallized FilmsNovel Metallization Primer Technology
Metallization is state of the art
Improvement of anchorage of metal layer to plastic substrate
Henkel’s novel coating technology provides additional improvement in oxygen barrier
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Substrate(e.g. PET, OPP)
Novel MetallizationPrimer Technogoly
Metallization
Improve Barrier of Metallized Film
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Case Study Metallized FilmsProcess Flow-Chart
Primer Application LaminationMetallization
Full coverage and smooth laydown
Strong anchorage to film
Optical density determines barrier
Primer holding both materials in place
Good anchorage of metal-layer to substrate
Withstand mechanical and thermal stress
01 02 03
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
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Case Study Metallized FilmsBarrier Performance Development on PET Film
Very strong improvement of barrier performance by Henkel’s new coating technology
Significant barrier improvement by metallization
Very good stability throughout entire process
2.0
0.5 0.5
1.51.0
Coating Metallizing Laminating
OTR
(cm
3 /m
2 .24h
.bar
)
Henkel's High Performance Technology
Traditional Primer
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
120
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SummaryEnabling new designs for flexible packaging
Synergy of metallizing technology and multifunctional coating
High barrier metallized films
More sustainable transparent barrier films
Layer reduction
Access to high barrier recyclable structures (Circular Economy)
October 25, 2018New Design – Enabling Technologies for Flexible Packaging
Metallization
Coatings
Films
Inks
Adhesives
Processes
New packaging
design
Enabled by BarrEnhanceTech Allianceby Nordmeccanica and Henkel.Two industry leaders working in perfect collaboration
Thank you!