© TOPPAN USA Inc.

CONFIDENTIAL

How to integrate barrier into sustainable packaging

Shukiko Tanaka / Sales Engineer

Toppan USA, Inc.
Confidential Wed. June 26, 2019
Who we are?
© TOPPAN USA Inc.

CONFIDENTIAL
Packaging Converting Clear high barrier film
Japan

China
Japan USA
Thailand

Indonesia

Packaging & converting

Clear high barrier film mfg.
 Japan, 15 sites
 Japan, 2 sites
 Indonesia
 USA (Griffin, GA) Opened in 2016
 Thailand
 China Green-colored areas
are the countries and Used in
regions using GL Film. countries and
regions

Used all over the

world for over 2
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Toppan’s clear high barrier film
© TOPPAN USA Inc.

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Transparent base layer

(48 ga PET, 60 ga OPA, etc.)

Inorganic vapor deposition layer

(AlOx, SiOx, etc.)

Patented barrier coating layer

Coffee/Granola bar/
Ready to eat meals
Meat snacks

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Confidential Puree/Juices Medical/Electronic/Industrial
 Sustainability is Hot!
© TOPPAN USA Inc.

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 The question being asked for the last seven years is

Sustainability is a _____________ in packaging decisions..?
a) VERY IMPORTANT FACTOR
b) MODERATELY IMPORTANT FACTOR
c) REALLY A FACTOR
d) NOT AN IMPORTANT FACTOR

 For the last three years, a large number of respondents say

sustainability is a “very” or “moderately” important factor
in packaging decisions.
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 Why sustainability is hot?
© TOPPAN USA Inc.

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Major brand owners stated their commitments

Unilever committed to reduce the weight of the packaging by 2020

and to use 100% recyclable plastic packaging by 2025
2020年までに包装の重量を削減し、2025年までに100％リサイクル可能なプラスチック包装にする

Nestlé is changing the current packaging to 100% recyclable or

reusable packaging by 2025
2025年までに全プラスチックパッケージをリサイクル・再利用可能な素材に切替

Starbucks announced to eliminate single-use

plastic straws globally by 2020

Coca Cola stated to collect and recycle

one bottle or can to sell it by 2030
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Benefits of flexible packaging
© TOPPAN USA Inc.

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97%
lesser weight

<Source: Flexible Packaging Association / https://www.flexpack.org/sustainable-packaging/>

Sustainability is better achieved with flexible packaging.

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Recyclability
© TOPPAN USA Inc.

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Recyclability is also a growing focus for packaging,

as more brand owners commit and pledge to be more responsible.

What is the optimum approach of recyclable packaging

for each region?

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Composition of flexible packaging in Japan
© TOPPAN USA Inc.

Multi material CONFIDENTIAL

60.0% lamination: 67%
Percentage composition by 29%
50.0%

40.0%
Mono-PE:
weight

30.0% 23%
20.0%
Mono-PP:
10.0% 6%

0.0%
Multi material Multi material Mono-material Mono-material PVdC coated
lamination lamination PE PP PP
(non foil) (with foil)

Composition of flexible packaging in residual waste by polymer structure in Japan

<Source: Investigation on the use and wastes in packaging in 2018 / Ministry of the Environment>

 Thermal recovery has been promoted rather than mechanical recovery

as the multi material lamination recycling system in Japan.

 Multi material laminations have led to the use of flexible packaging

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because of its superior function. 8
Composition of flexible packaging in the UK
© TOPPAN USA Inc.

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Mono-PE:
40%

PP: 35%

Others: Multi material lamination: 25%

Composition of flexible packaging in residual waste by polymer structure in the UK

<Source: A summary report from REFLEX project in 2016>

Nearly 80% of the flexible packaging waste was classified

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as polyolefin material (PE and PP) which is considered recyclable. 9
How to integrate barrier into
sustainable flexible packaging
© TOPPAN USA Inc.

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Presence of Flexible Barrier film

Approach
packaging recycling development

No flexible packaging
To use PCR PET
recycling stream
recycled material base
Thermal recovery is promoted. barrier film

Mono-PP & Mono-PE

PP base
 Recyclable barrier film
Mono material
packaging
Mono-PE
PE base
 Recyclable barrier film
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PET recycle and PCR PET base barrier film
© TOPPAN USA Inc.

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Toppan produces PCR-PET based barrier film

Grade Applications OTR WVTR
0.019 cc/100in2/day 0.065 g/100in2/day
GL-AE-N Dry contents
0.3 cc/m2/day 1.0 g/m2/day
0.019 cc/100in2/day 0.065 g/100in2/day
GL-AR-NF Liquid, Retort
PCR content 0.3 cc/m2/day 1.0 g/m2/day
80% All numbers are typical values.
*FDA complied. [Barrier measurement]
 OTR: 86F, 70%RH (30C, 70%RH)
 Commercial applications  WVTR: 104F, 90%RH (40C, 90%RH)

Nuts Potato
salad
Boiled eggs

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Confidential Dry food Toiletry
Chilled food
 Statistics study on barrier packaging in the US
© TOPPAN USA Inc.
WVTR
Almond CONFIDENTIAL
50.0 3.2 Dry Pet Food
EVOH PE PVDC coat
Pet Dental-Bone
co-extrusion OPP
10.0 0.65 Sport Drink
Pet Treat Yogurt Sliced Cheese
Natural Cheese Pistachio Mozzarella
5.0 0.32 High-end Ham Tortilla Sunflower seeds
g/100in2/day Dried Fruit Sausage
Cookies, Crackers
g/m2/day Mix Nuts Salty Snacks
3.0 0.19 Granola Bar
Pet Treat High-end coffee
Retort Food Cream Filled Cake
Jerkies
1.0 0.065 Medical Wipe Granola flakes Pig Skin
IV Baby food
Corn Tips
0.1 6.5E-3 Stent

Organic PV
1E-2 6.5E-4 Insulation
QDEF
1E-3 6.5E-5
CIGS PV
O-LED
0
0.065 0.19 0.32 0.65 1.9 6.5 OTR cc/100in2/day
1 3 5 10 30 100 cc/m2/day
OTR WVTR
Barrier Market Size*
Market cc/100in2/day g/100in2/day
technology M lbs.
(cc/m2/day) (g/m2/day)
[Barrier measurement]
Salty snacks < 0.645 (< 10) < 0.323 (< 5) PVDC > 8M  OTR: 86F, 70%RH (30C, 70%RH)
 WVTR: 104F, 90%RH (40C, 90%RH)
Nuts, Cookies, Crackers < 0.323 (< 5) < 0.452 (< 7) PVDC, EVOH > 5M
Cheese, Ham < 0.194 (< 3) < 0.194 (< 3) PVDC, EVOH > 5M
Granola Bars, Jerkies < 0.194 (< 3) < 0.097 (< 1.5) EVOH, AlOx > 4M *Market size information is 12
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Baby food (retort, hot-fill) < 0.194 (< 3) < 0.097 (< 1.5) AlOx > 3M based in 80 ga OPP film.
Target Barrier and applications
© TOPPAN USA Inc.

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Base Barrier Tentative target barrier

Target applications
Film materials OTR WVTR

Dry Fruits < 0.19 cc/100in2/day < 0.16 g/100in2/day

Coating
Mix nuts, Cookies < 3.0 cc/m2/day < 2.5 g/m2/day
SiOx < 0.065 cc/100in2/day < 0.013 g/100in2/day
Granola bar
PP Beef jerky
+
coating < 1.0 cc/m2/day < 0.2 g/m2/day
Under development SiOx
Liquid & Hot-fill + TBD
coating

Dry Fruits < 0.19 cc/100in2/day < 0.19 g/100in2/day

Coating
Mix nuts, Cookies < 3.0 cc/m2/day < 3.0 g/m2/day
PE Granola bar
SiOx < 0.065 cc/100in2/day < 0.065 g/100in2/day
+
Beef jerky < 1.0 cc/m2/day < 1.0 g/m2/day
coating
[Barrier measurement]
 OTR: 86F, 70%RH (30C, 70%RH) 13
Confidential  WVTR: 104F, 90%RH (40C, 90%RH)
Challenging for PP and PE barrier development
© TOPPAN USA Inc.

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1) Heat resistant of base film

2) Rough film surface which causes problems in barrier

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Challenging for PP and PE barrier development
© TOPPAN USA Inc.

1. Heat resistance of base film CONFIDENTIAL

Density
lbs./ft.3 Melting Point
(g/cm3)

PET
81.2-83.0 482-491F Less heat resistance would cause
(1.30-1.33) (250-255℃)
film shrinkage issue
55.6-56.8 257-338F
PP
(0.89-0.91) (125-170℃) during production process.
58.7-60.6 260-284F
HDPE
(0.94-0.97) (127-140℃)

Approach
1
To find/develop heat resistant base film

Approach To develop Toppan’s new barrier coating

2  Low temperature curable material
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To find/develop heat resistant base film
© TOPPAN USA Inc.

PP & PE film: Not much difference in M.P. or Tg. among each material.
CONFIDENTIAL
Approach
1
How to check heat resistance of films..?
1) To get the letter size of sheet sample from the center of the film web.
2) Draw lines both MD and TD directions with 20 mm interval using a graph paper.
3) Measure the distance between T-X and T-X’, and M-Y and M-Y’ using a scale and a
magnification.
4) Put the sheet sample on the glass plate and place the glass plate in the oven.
5) Keep the samples in the oven for 15 - 30 minutes.
6) Take the sheet sample out and measure the distance between T-X and T-X’, and M-Y and
M-Y’ using a scale and a magnification to calculate the shrinkage.
100 mm 100 mm

◘
◘
◘
◘
◘
◘
◘
•T1 •T1’
•T2 •T2’
M7
M6
M5
M4
M3
M2
M1
•T3 •T3’
100 mm •T4 •T4’ 100 mm
•T5 •T5’
◘
◘
◘
◘
◘
◘
◘
•T6 •T6’
•T7 •T7’
M7'
M6'
M5'
M4'
M3'
M2'
M1'
MD MD

TD TD
Instruction Instruction 16
Confidential Instruction 2) 4) & 5) 3) & 6)
 To find/develop heat resistant base film
© TOPPAN USA Inc.

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Approach
1

MD direction heat shrinkage TD direction heat shrinkage

8.0 8.0
1.0 mil PE 1.0 mil PE
7.0 (Supplier A) 7.0 (Supplier A)
Shrinkage [%]

Shrinkage [%]
6.0 0.75 mil PE 6.0 0.75 mil PE
5.0 (Supplier B) 5.0 (Supplier B)
1.25 mil PE 1.25 mil PE
4.0 4.0
(Supplier C) (Supplier C)
3.0 68 ga PP 3.0 68 ga PP
2.0 2.0
1.0 48 ga PET 1.0 48 ga PET
0.0 0.0
150 175 200 225 250 275 150 175 200 225 250 275

Temperature [F] Temperature [F]

All numbers are typical values.

[Evaluation conditions]
 Period in the oven: 15 minutes for PP and PE film, 30 minutes for PET film

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New Toppan’s barrier coating development
© TOPPAN USA Inc.

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Approach
2

 Vacuum metallization material: SiOx

 Excellent barrier performance
 Lower thermal conditions at VM process than AlOx
etc.

 New Toppan’s coating material  US patent filling

 New ingredient which provides great oxygen barrier.
 Low temperature curability.
 Flexible layer for flex resistance.
 Long term stable shelf life and pot life.
etc.

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Challenging for PP and PE barrier development
© TOPPAN USA Inc.

2. Rough film surface CONFIDENTIAL

Precipitation of these kind of agent affects

Film 1) adhesion of barrier layer
2) barrier coating thickness deviation.

Anti-blocking agent
Anti-static / Slip agent

Approach
3
To optimize agent

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Rough film surface
© TOPPAN USA Inc.

Anti-blocking agent caused unevenness in CONFIDENTIAL

coating layer thickness.

Anti-blocking
agent Coating layer

PP film
SEM: x1K

Approach
3 To optimize the agent size 20
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Challenging for PP and PE barrier development
© TOPPAN USA Inc.

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1) Heat resistant of base film
 To find/develop heat resistant base film
 To develop Toppan’s new barrier coating
 Low temperature curable material

2) Rough film surface which causes problems in barrier

 To optimize the agent size

Progress on
Confidential PP & PE barrier development 21
PP & PE barrier development
© TOPPAN USA Inc.

1. Performance as mono film CONFIDENTIAL

OTR WVTR
cc/100in2/day g/100in2/day
(cc/m2/day) (g/m2/day)
Target Results Target Results
80 ga OPP < 0.19 0.097 < 0.16 0.12
(< 3.0) (1.5) (< 2.5) (1.9)
Coating

68 ga OPP < 0.065 0.055 < 0.013 0.012

SiOx (< 1.0) (0.86) (< 0.2) (0.12)
Coating

1.25 mil
HDPE
< 0.19 0.071 < 0.19 0.063
(< 3.0) (1.1) (< 3.0) (0.98)
Coating

1.25 mil
HDPE < 0.065 0.015 < 0.065 0.032
SiOx (< 1.0) (0.24) (< 1.0) (0.49)
Coating
All numbers are typical values.
[Barrier measurement]
 OTR: 86F, 70%RH (30C, 70%RH) 22
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 WVTR: 104F, 90%RH (40C, 90%RH)
 PP & PE barrier development
© TOPPAN USA Inc.

2. Performance as lamination CONFIDENTIAL

OTR WVTR
cc/100in2/day g/100in2/day Boding strength
(cc/m2/day) (g/m2/day) N/15mm Seal
Laminated material Gelbo Gelbo strength
N/15mm
10 50 10 50 90o 180o
Initial Initial
cycles cycles cycles cycles Peel Peel

80 ga barrier coated OPP /68 ga PP 0.12 0.12 0.13 0.12 0.12 0.12 1.7 1.3 -
(1.8) (1.8) (2.0) (1.8) (1.8) (1.8)

68 ga SiOx + barrier coated OPP /1.2 mil CPP 0.055 0.090 0.10 0.0074 0.023 0.023 4.3 4.6
Material
(0.86) (1.4) (1.6) (0.12) (0.34) (0.34) break

1.25 mil barrier coated PE /2.4 mil LLDPE 0.025 0.025 0.039 0.10 0.10 0.11 1.3 2.6 20.1
(0.39) (0.39) (0.60) (1.6) (1.6) (1.8)

1.25 mil SiOx + barrier coated PE /2.4 mil LLDPE 0.015 0.038 0.060 0.032 0.041 0.061 2.3 3.8
Material
(0.23) (0.59) (0.93) (0.50) (0.64) (0.95) break
All numbers are typical values.
[Barrier measurement]
 OTR: 86F, 70%RH OTR / Gelbo flex test WVTR / Gelbo flex test
0.30 0.30

WVTR [g/100inch2/day]
OTR [cc/100inch2/day]

(30C, 70%RH) OPP+coating OPP+coating

 WVTR: 104F, 90%RH 0.25 OPP+SiOx+coating 0.25 HDPE+coating
(40C, 90%RH) HDPE+SiOx+coating HDPE+SiOx+coating
0.20 0.20
HDPE+coating OPP+SiOx+coating
0.15 0.15
0.10 0.10
0.05 0.05
0.00 0.00
-10 0 10 20 30 40 50 60 -10 0 10 20 30 40 50 60
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 Storage test at 121F  Weight loss
© TOPPAN USA Inc.

 Content: Sponge cake
 Storage conditions: 122F (50C)
 Test period: 30 days
 Sample numbers: 10 pouches for each structure
CONFIDENTIAL
 Laminated film for pouch
o Toppan 48 ga AlOx PET/2.4 mil LLDPE
o 1.25 mil SiOx PE/2.4 mil LLDPE
o 1.5 mil PE/EVOH/PE
o 48 ga PVDC coated PET/2.4 mil LLDPE

Weight loss at 122F (50C)

0.0%

-2.0%  Toppan AlOx PET

-4.0%  SiOx PE
Weight loss

-6.0%

-8.0%  PE/EVOH/PE
Toppan AlOx PET
-10.0% SiOx PE
-12.0% PE/EVOH/PE
 PVDC PET
PVDC PET
-14.0%
0 5 10 15 20 25 30

Storage days 24
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All numbers are typical values.
Storage test at 121F for 30 days  Moisture contents
© TOPPAN USA Inc.

Before storage CONFIDENTIAL

Digital
moisture meter

-0% -2 % -13 % -33 %

Toppan AlOx PET SiOx PE PE/EVOH/PE PVDC PET

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 Storage test at 104F, 90%RH  Weight increase
© TOPPAN USA Inc.

 Content: Crackers
 Storage conditions: 104F, 90%RH (40C, 90%RH)
 Test period: 14 days
 Sample numbers: 10 pouches for each structure
CONFIDENTIAL
 Laminated film for pouch
o Toppan 48 ga AlOx PET/2.4 mil LLDPE
o 1.25 mil SiOx PE/2.4 mil LLDPE
o 1.5 mil PE/EVOH/PE
o 48 ga PVDC coated PET/2.4 mil LLDPE

Weight increase at 104F, 90%RH (40C, 90%RH)

6.0%
PVDC PET
5.0% PE/EVOH/PE
Weight increase SiOx PE
 PVDC PET
4.0% Toppan AlOx PET
3.0%
 PE/EVOH/PE
2.0%

1.0%  SiOx PE
 Toppan AlOx PET
0.0%
0 5 10 15
Storage days
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SPC/Trex approval in PE recycle stream
© TOPPAN USA Inc.

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1.25 mil 1.25 mil PE

HDPE
Coating

1.25 mil
HDPE 1.25 mil PE with Toppan SiOx Coating

SiOx
Coating

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Mono material packaging
© TOPPAN USA Inc.

Coating barrier SiOx + coating barrier CONFIDENTIAL

PP

Under development
Seal material
Barrier Barrier OPP OPP
Coating Coating SiOx + barrier SiOx SiOx + barrier SiOx
Heat seal OPP Barrier OPP Barrier coating coating
 coating  coating Barrier Barrier
Adhesive Adhesive  coating  coating
 ink  ink
Adhesive Adhesive
Heat seal
OPP
OPP Sealable PP Sealable PP
Seal material Seal material
OTR: 0.12 cc/100inch2/day OTR: 0.055 cc/100inch2/day
WVTR: 0.12 g/100inch2/day WVTR: 0.0074 g/100inch2/day

PE Barrier
PE
SiOx + barrier SiOx
Coating coating
Barrier Barrier
PE  coating  coating
Adhesive Adhesive

PE PE
OTR: 0.025 cc/100inch2/day OTR: 0.015 cc/100inch2/day 28
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WVTR: 0.10 g/100inch2/day WVTR: 0.032 g/100inch2/day
 © TOPPAN USA Inc.

CONFIDENTIAL

Shukiko Tanaka
Sales Engineer
Packaging and Barrier film applications

stanaka@ta.toppan.com

sales@toppan-usa.com
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