PLASTIC PACKAGING

Prepared by : Mahalaxmi Pradhananga

Lecturer
Central Campus of Technology
 PLASTICS PACKAGING
Plastics are used as both flexible films, such as pouches, bags, laminates, etc
and as rigid containers, such as bottles, trays, etc.
 The plastic materials are the same but the thickness is
different.

•Plastics can be divided into two main subgroups:

1. thermoplastics and
2. thermosets.

Thermoplastics are those materials which can be heated and cooled

repeatedly without appreciable loss of mechanical and physical
properties. There is no cross linking and adjacent molecules are free to
flow. For e.g. HDPE, LDPE, PVC, PVDC, EVOH, Nylon, Polyester, etc.

thermosets when heated for the first time will change their shape
permanently. If heat is reapplied, they will begin to decompose
due to the cross linking of adjacent molecules. For e.g. Phenol
formaldehyde, Urea, etc.
MOST PLASTIC MATERIALS ARE DERIVED FROM
DISTILLATION OF OIL INTO LONG CHAINED
HYDROCARBONS
PLASTICS ARE USED IN 2 FORMS:
I FLEXIBLE FILM
II. RIGID CONTAINER
 i.. Flexible flim: < 250µm e.g. pouches, bag, laminates (real
packets)

 ii. Rigid container: e.g. bottle, trays, pots, etc

a) Pre- fabricated plastic packaging : bottles are well formed

already, industry just fill the bottle.

 b) F.F.S ( formed filled sealed) : fabricated at the time of

filling and sealing
 Used in food processing e.g. in small pet bottle of coke which
is transformed to big bottle.
 ADVANTAGES OF PLASTICS
1. Light weight, less bulky and cheap with respect to metal and glass
2. Versatile – easy to mould into a wide range and style packages by
different processes
3. Flexible with properties which can be tailored to suit the product
requirements
4. Recyclable – economic
5. Good appearance and available in a variety of colours
6. Printable and heat sealable
7. Pilfer-proof, tamper proof, break resistant, corrosion resistant and
leak proof
8. Quieter in use than metal or glass – noiseless unlike metals and
glass
 ADVANTAGES OF PLASTICS
9. Excellent barriers properties to moisture, odour, oxygen and other gases so
that they can maintain the desired shelf life for various products

10. Resistant to most chemicals, non-toxic in nature and absolutely safe to use
even in direct contact with food products, medicines, etc

11. Safe in use as they do not break easily and the broken pieces are not
harmful as those of glass and metal

12. Do not promote bacterial growth and can be sterilized by all conventional
methods and hence provide wide applications in food, medical and
chemical packaging

13. Single serve packs for food items such as ketchup, condiments, etc and
small unit packs such as sachets can be made available at low costs
14. Do not pose any major disposal problems or environmental hazards, since
almost all of plastics can be recycled for reuse.
 DISADVANTAGES OF PLASTICS
1. Flammable – as they are derived from petrochemicals

2. Permeable to the passage of gases, vapors, volatiles and some

solvents to varying degrees

3. Can be degraded by UV light

4. Non-biodegradable

5. Some chemicals do attack particular plastics

6. Some plastics may absorb some food constituents, such as oils and
fats
TYPES OF PLASTICS USED IN FOOD PACKAGING
1. Polyethylene (PE)
2. Polypropylene (PP)
3. Ethylene vinyl acetate (EVA)
4. Ethylene vinyl alcohol (EVAL/EVOH)
5. Polyvinyl chloride (PVC)
6. Polyvinylidene chloride (PVdC)
7. Ionomers
8. Polystyrene (PS)
9. Polyesters (PET, PETE)
10. Polyamides (PA) – Nylon
11. Polycarbonate (PC)
12. Styrene butadiene (SB)
13. Polymethyl pentene (TPX)
14. High nitrile polymers (HNP)
15. Cellulose-based materials
 SELECTION CRITERIA

a. The requirements of the product

 dry products, respiring foods, moist food like cake, liquids,
oxygen sensitive food.

b. The requirements of the packing machine

 Machine factor as they are usually used with high speed machines.

 The properties important are elasticity, dead fold properties, tear

strength, slip, friction, and melt strength.
 The material chosen must be suitable for the equipment on
which it will be used.
 It must cut properly, seal well and run smoothly or else there will be
stoppages and wastage

C. the requirements of the market

 1. POLYETHYLENE (PE)
Polyethylene (PE), commonly called polythene

Types and density (thickness in µm)

1. Ultra low density polyethylene (ULDPE): 0.880-0.890

2. Linear low density polyethylene (LLDPE): 0.912

3. Low density polyethylene (LDPE): 0.910-0.939 (scratched with

nail)

4. High density polyethylene (HDPE): 0.940-0.965 (cannot be

scratched)
 1. POLYETHYLENE (PE)
I. HDPE
 HDPE is stiffer, harder, less flexible, and waxy.

 Its permeability to gases is lower and it can withstand higher temperatures.

It is used for foods which are heated in the package, so called ‘boil in the
bag’ items.

 Higher temperatures are required to produce thermoplasticity (melting

point, 134°C). HDPE resists fats and oils better than LDPE.

 it does not seal easily. They are waterproof and chemically resistant.

 HDPE properties are better for “squeezability”. HDPE bottles usually have
a matt finish.

 . HDPE→↓GTR ↓WVTR
 1. POLYETHYLENE (PE)
I. HDPE
 HDPE has a higher tensile strength and stiffness than LDPE.
 It can be steam sterilized, whereas LDPE cannot.

 HDPE does not offer the transparency or clarity of PET.

 HDPE is used to prepare bottles, plates, etc because it is less

vulnerable to stress cracking.

 HDPE bottles are opaque and can be used to contain detergent

and milk. HDPE is used for making containers, e.g., crates,
bottles, bags, tubs, plastic knives and forks, etc
 1. POLYETHYLENE (PE)
II. LDPE

 the printability of LDPE is poor. However, many plastics

with poor printability can be made printable by corona
treatment, in which an ionic discharge is used to sensitize one
side of the plastic.

 The main functional properties of LDPE are its glossiness,

strength, low permeability to water vapor and it forms a very
strong heat seal.

 LDPE→↑GTR ↓WVTR

 It is not a good barrier to gases, oils or volatiles.

 1.
1. POLYETHYLENE (PE)
II. LDPE

 LDPE is used on its own in the form of pouches, bags and sacks.

 It is also used for coating papers, boards and plain regenerated

cellulose and as a component in laminates.

 It is used for wrapping fruits and vegetables because of high GTR

and low WVTR, and also for frozen foods because it toughens at
low temperature.

 It is less expensive than most films

 2. POLYPROPYLENE (PP)
 PP is the lowest density polymer and extremely versatile because of
its excellent processability, mechanical and physical properties
and high heat distortion resistance.

 It is a good barrier to water vapor but not gases.

 It is often coated with PP or PVdC/PVC copolymer to

improve its barrier properties and to make it heat-sealable.
 It is normally heat-shrinkable. It is used in coated or laminated
form to package a wide range of food products, including
biscuits, cheese, meat and coffee.

 It is stable at relatively high temperature and is used for in-

package heat processing.
2. POLYPROPYLENE (PP)
 PP is a clear glossy film with a high strength and has less waxy feel
 Higher melting point than PE, so easily stand steam sterilization
 PP is often used in oriented or biaxially oriented form, i.e.
OPP (less scratch) and BOPP(more scratch).

 Orientation is a process by which the material is stretched to

improve its characteristics.

 OPP has better mechanical properties than cast PP,

particularly at low temperature, and is used in thinner gauges.
 Better barrier properties between LDPE & HDPE, and can be
increased by orientation process
 It can be printed on and is ideal for reverse or surface printing
APPLICATIONS OF PP
 PP is used for injection-molded containers and blister packs,
laminations, carton overwraps, snack food bags, and confectionery bags,
candy twist-wraps, vegetable and fruit packing

 OPP is suitable for use in frozen storage

 Due to its resilience, it is used as a linear, coating the inside of the bottle
caps

 BOPP and OPP are coated to make them heat sealable and are
used in biscuits, bread and confectionary packaging. It can also be cold
seal coated, which can be used for chocolate bar pack and is easy to peel.

 Elongation of up to 600% makes it suitable for stretch-wrapping. It has

good resistance to creep under load so is suitable for use in crates and
boxes.
3.ETHYLENE VINYL ACETATE (EVA)
 The properties of the blend depend on the proportion of
the vinyl acetate component.
3.ETHYLENE VINYL ACETATE (EVA)
 It is more permeable to gases and water vapor. EVA has good
flexing properties so it is useful for hinged lids.
 EVA is generally used for stretch wrap, closures, liners for
bag-in-box packages and meat wrap.

 EVA with PVdC is a tough high-barrier film which is

used in vacuum packing large meat cuts and with
metalized PET for bag-in-box liners for wine.

 EVA is also a major component of hot melt adhesives,

frequently used in packaging machinery to erect and
close packs, e.g. folding cartons and corrugated packaging.
4. ETHYLENE VINYL ALCOHOL (EVAL /
EVOH)
 Due to its high gloss and low haze, it has excellent clarity.

 It has outstanding high gas barrier properties, i.e. it has very

low values of GTR an poor moisture resistance i.e. high
WVTR, and is a barrier to the transfer of odor and flavor.

 EVOH is more expensive than PVDC, so it is generally

used as a thin layer in a laminate or in a co-extrusion but it is
easier to process and is recyclable.

 it must be sandwiched between materials with good water-

barrier properties, such as PP or LDPE, to be effective.
5 POLYVINYL CHLORIDE (PVC)
 PVC has low crystallinity (so has good transparency when pure), but
higher inter-chain bonding than PE due to Cl (halogen), so is harder &
stiffer. For this reason, plasticizers (dioctyl phosphates) are added during
manufacture.

 PVC has good printability.

 It is highly inert. It is glossy and resistant to moisture, fats, and gases

 It has good barrier properties, which includes low GTR. WVTR is higher
than for the polyolefins.

 Odors and flavors are also well retained and it is an excellent barrier to the
transfer of oils and alcohols.

 It has good mechanical properties. Its permeability to water vapor,

gases and volatiles depends on the type and amount of plasticizers
APPLICATIONS OF PVC
 PVC is used in the biaxial-stressed form, e.g., for shrink
wrapping of cheese and meat.

 It is also used for thermoformed containers, e.g., for

chocolates as well as for plastic pipes and toys.

 UPVC is moulded into trays, bottles and other containers

where it provides a better barrier and clarity than PE.
 PPVC is generally used in film form.

 It is suitable for stretch-wrapping and shrink-wrapping,

where it has better transparency than PE.
6 POLYVINYLIDENE CHLORIDE
(PVDC)
 It is also known by its trade name as Saran.

 It is a very transparent, glossy and tough material, with

good impact strength except at low temperatures, and
good abrasion resistance.

 It has excellent barrier properties, with very low GTR

(especially to O2), WVTR

 PVdC cannot be reprocessed because it degrades (melting

point, 162°C). This makes co-extrusion lamination difficult
as well, although it can still be easily used in coating from
solution.
APPLICATIONS OF PVDC
 It is used in flexible packaging in several ways as monolayer films, co-
extrusions and coatings.

 Generally, it is used as a thin film or coating as it is expensive.

 Due to its elasticity, it is used for shrink and stretch wrapping, and as a
twist wrap for candy as it has excellent cling properties.
 Its main use is as a barrier layer in a laminate structure, applied as a
coating.
 As a result of the high gas and odor barrier, it is used to protect flavor and
aroma sensitive foods from both loss of flavor and ingress of volatile
contaminants.
 PVdC is a widely used component in the packaging of cured meats,
cheese, snack foods, tea, coffee and confectionery.
 It is used in hot filling, retorting, low-temperature storage and MAP
as well as ambient filling and distribution in a wide range of pack shapes.
 POLYSTYRENE (PS)
 It is a poor barrier to gas, moisture, odor and flavor. Chemical
resistance is good for acids and alkalis

 PS film is produced by extrusion. It is stiff and brittle with a

clear sparkling appearance. In this form it is not useful as a
food packaging film.

 Bi-axially oriented polystyrene (BOPS) is less brittle and has

an increased tensile strength, compared to the non-oriented
film.

 BOPS has a relatively high permeability to vapors and gases

and is greaseproof. It shrinks on heating and may be heat
sealed by impulse sealers. For this, it is coextruded with
 APPLICATIONS OF PS
 PS is widely used in the form of thermoformed semi-rigid
containers and can be easily moulded into jars, trays, containers
and screw on caps, used for dairy products, salads, etc. Due to
its high transmission rates, it is suitable for fruits, vegetables
and baked goods.

 Oriented PS (OPS) is stronger and tougher and is used as an

overwrap for meat and vegetables.

 Copolymers of PS using acrylic and rubber compounds, e.g.

butadiene are called High Impact PS (HIPS). These have better
impact strength and flexibility, but the plastic is translucent as
some clarity is lost. It is used for pots and tubs, especially for
low temperature applications such as ice-cream cups.
POLYETHYLENE TEREPHTHALATE – POLYESTERS -
PET OR PETE
 POLYETHYLENE TEREPHTHALATE –
POLYESTERS - PET OR PETE
 It has good sparkle and clarity. Impact and tensile strength and puncture
resistance are good. Due to its high softening point of 245-270oC

 it performs well over a wide range of temperature ranging from -60

to +150oC, so it can be used for boil in the bag.

 It is not good for heat sealing and if this is required, it is usually coated
with a layer of polyethylene.

 It provides a good barrier to gases and odor, and has a moderate

WVTR, which is reduced to zero at freezing temperatures. It has
good resistance to grease and oil, as it is chemically resistant to
weak acids, alkalis, alcohols, hydrocarbons, ketones and esters.
APPLICATIONS OF POLYETHYLENE
TEREPHTHALATE – POLYESTERS - PET OR PETE
 As it has high strength and can withstand the carbonation
pressure, it is used in bottle making.

 GTR may not be low enough in some bottle designs to

prevent the carbonation gases escaping.

 It is often used in laminates with PVdC and PE for coffee,

meat, etc.
 Because of the wide temperature range, it can be used for
boil in the bag, microwave and ovenable applications