adhesive biopolmer film lamination hb fuller workshop
TRANSCRIPT
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Adhesives and KeyEssentials for LaminatingBiopolymer Films intoFlexible Packaging
Lowell Lindquist
Wayne Eklund
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H.B. Fuller Company 125 years of success as a manufacturer of specialty chemical products
Headquartered in St. Paul , Minnesota
Recognized for quality adhesives, sealants, coatings, and paints
Global with direct presence in 36 countries, 3300 employees, andcustomers in more than 100 nations
2010 sales of $1.4 billion
Public company listed on NYSE (FUL)
Component stock of the Standard & Poors Small Cap Index (S&P 600)
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Organization
Asia Pacific
H.B. Fuller Company is organizedgeographically:
Latin America
North America Europe
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Focus Market Areas Packaging
Case and Carton Container Labeling
Flexible Packaging
Packaging Reinforcement
General Assemble
Building and Construction
Personal Hygiene and Nonwovens
Paper Converting
Consumer Product Adhesives
Paper Converting Polymers
Woodworking
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Outline Flexible Packaging Review
Bio-Films that can be Laminated
Flexible Packaging Applications for Bio-Films
Lamination Processes
Dry Bond
Solvent Free
Bio-Film Surface Treatments
Adhesive Chemistry and Interactions with Bio-Films
Solvent Free
Solvent Based Water Based
Examples of Bio-Film Laminations
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Complete adhesive coverageacross entire film
Bonding a combination of films,foils, or paper
Often reverse printed inkbetween layers
Adhesive thickness ~ 1 lb/ream
Flexible Packaging Structure
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Flexible Packaging Film Cross SectionOuter layerPrinting inkAdhesive
Inner layers / Sealant film, barriers,..
Adhesive
Printing InkPrinting Ink
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Flexible Packaging Structure Substrate Surface
Not perfectly regular
Gaps and irregularities in ink
Adhesive
Must overcome surface irregularity
Typical coat weight 1.0 pounds /ream
Range coat weight 0.8-4.0 pounds/ ream
Thickness 1-5m
~2-6% of a lamination volume isadhesive
Scanning Electron Microscopy (SEM)
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Outer Layers
Reverse printed via flexo orgravure
Provide barrier properties
Carry brand image
Typical films
Cellophane PLA Paper Aliphatic-Aromatic Polyesters Blends of bio-esters Polypropylene (OPP) and Metalized
Oriented Polypropylene (MOPP)
Aclar
Polyester (PET) and MetalizedPolyester (METPET)
Nylon
Foil
Inner Layers
Primary purpose is to sealpackage
Direct contact with fill goods
Typical Films
Bio - Polyethylene (PE) PLA PHA Starch Based TPUs Aliphatic-Aromatic Polyesters PGA Blends of bio-esters Polypropylene (CPP or OPP) Polyethylene (LDPE, LLDPE,
metallocene, EVA, etc.)
Typical Package Construction
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Flexible Packaging Market Adhesives Perspective
Solvent Free Water-based Solvent-based
Market Volume
High Performance (Foil)
RetortDifficult Foil
Mid Performance (Film)
Barrier to BarrierChemical Resistance
Heat Resistance
General Purpose (Film)
Dry GoodsConfectionery SnackLid Stock
Cellophane with Barrier
Biodegradable Polyesters (PLA,PHA,etc.)
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Potential Applications-Bio-Films Frozen Foods
Fresh Cut Produce
Room Temp Confectionary
Snack
Hot Fill
Condiment
Lid Stock
Overwraps
Pasta Package
Some industrial and consumer
Not currently used above hot filltemperature
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Application of AdhesivesComparison of Lamination Processes
Solvent Free
Dry Bond
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Flexible Packaging AdhesivesDry Bond Laminating Process
In-line corona treatment
Coat weight controlled by gravure
Coat weights of 0.8 -3.0 pound/ream
Line speed limited by drying process
Liquid carrier must be removed for healthand adhesive quality
Nip temperature and pressure as high as
possible limited by film properties Typical pot life is 8 hours
Smoothing bar is required for WBA
Drying related to temperature, air flow, andinlet humidity
Laminate Slit Pouch Fill
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Dry Bond Laminator
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Flexible Packaging AdhesivesDry Bond Laminating Process
Treatment level of films Adsorbed water on films due to hydroscopic nature may affect
adhesion
Speed ramp-up-rate is a critical due to tear propagation, many bio-filmsdo not like mechanical shock
Conventional coat weights (0.8 to 3.0 lbs/ream)
Smoothing bar critical for optimum appearance water-base only
Oven temperature limitations due to yield and shrink of some bio-films-(may limit line speed due to slower drying at low temp)
Bio-Film Considerations During Dry Bond LaminationLaminate Slit Pouch Fill
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Flexible Packaging AdhesivesDry Bond Laminating Process
High nip temperature is desirable limited by film stability High nip pressure is desirable limited by film stability
Rewind tensions less critical due to high green strength
Must be aware of film relaxation (elasticity will cause corrugation andcrushed cores)
Sensitive to roll damage like nicks and bruises
Potential for film solvent sensitivity
Modified coat weight testing
Laminate Slit Pouch Fill
Bio-Film Considerations During Dry Bond Lamination
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Flexible Packaging AdhesivesSolvent Free Laminating Process
In-line corona treatment
Two part reactive system (meter-mixaccuracy is critical)
Pot life 30 to 60 minutes
Typical line speed > 1000 fpm
Typical coat weight 1.0 lbs/ream
Heat used to adjust viscosity
Very little green strength
Rewind tension is critical due to lack of green strength
Laminate Slit Pouch Fill
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Typical Solvent Free Laminator
Adhesive pumpedinto the machine
Primary filmnipped to thesecondary film
Adhesive applied
to the primary film
Lamination wound
onto a core
Secondary filmintroduced
Primary film introduced
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Typical Solvent Free Meter-Mix
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Flexible Packaging AdhesivesSolvent Free Laminating Process
Check film dyne level treatment level of films (no solvent to help cleanfilm surface)
Adsorbed water on films due to hydroscopic nature may affectadhesion
Controlled speed ramp-up-rate is critical due to tear propagation, many
bio-films do not like mechanical shock Rewind tensions critical due to low adhesive green strength
Less aggressive nip but air must be excluded
Laminate Slit Pouch Fill
Bio-Film Considerations During Solventfree Lamination
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Flexible Packaging AdhesivesSolvent Free Laminating Process
Must be aware of film relaxation (elasticity will cause corrugation,crushed cores, curl, ink smearing, and telescoping)
Sensitive to roll damage like nicks and bruises
Potential isocyanate reaction with film and ink components (glycol)
Conventional coat-weights (0.8-1.5 pounds / ream)
Yield and elasticity of some bio-films can create web handlingchallenges
Laminate Slit Pouch Fill
Bio-Film Considerations During Solvent FreeLamination
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Comparison of Lamination ProcessesShift toward Solvent Free AdhesivesDry Bond High Green Tack High Strength Adhesives
- High Energy Demand
- Emissions
- Footprint
- Speed Limited by Oven Size
olvent Free High Speed
No Emissions
Low Energy Demand
Small Footprint
- Need for accurate metering
- Little Green Tack
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Bio-Film Surface Modification Surface treatments- (Initial treatment critical followed with in-line treatment)
Corona
Plasma
Chemical / Primers
Coatings
PVdC
Acrylic
PVOH
Urethane
Vapor Deposition
Metallization
Ceramic
Why do we treat the films? Remove contamination
Modify the polarity of film surface
Increase the surface roughness on film
Add or enhance chemical functionality of film surface
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Corona Treatment vs. Adhesion
100
200
300
400
500
600
700
0 0.5 1 1.5 2
BondStrength W-minutes/sq.ft.
Corona Treatment StudyPrinted Cello - Clear high slip LDPE
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Corona Treatment: Adds polarity to film increasing adhesion
Removes contaminants
Increases surface roughness
Corona Treatment Adds Polarity to Film
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Lamination AdhesivesSolvent Free Composition- Typical Example
No Solvent
Reactive chemistry Two-components
60%40%
Isocyanate Functional Prepolymer
Polyol Curative
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Lamination AdhesivesSolvent Free Naming and CompositionCommon Names Chemical Representation
PolyolB-side
CurativeHydroxylIsocyanate
A-SideNCO
AdhesivePrepolymer
OH
OHOH
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Laminate Slit Pouch Fill
The two components are mixed and applied to the film but have notreacted
The ratio of the two components is important for polymer creation Low viscosity to allow application to film
Very little green strength to hold films together
Water is supplied from the environment and films
OHOH
OH
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Laminate Slit Pouch Fill
Partial polymerization after 3-12 hours creates enough adhesivestrength to allow film slitting
Curative and water are reacting to begin formation of ideal polymerstructure
Heat will accelerate polymer formation time and decrease time-to-slit.
OHOH
OHOH
OH
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Laminate Slit Pouch Fill
Significant polymerization in 12-48 hours to provide heat resistance forseal making
Bond strength is very high
Water is used in reaction to increase stiffness of polymer by creating aurea group
OH
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Laminate Slit Pouch Fill
Polymerization complete, food can be safely added
Full adhesive strength is produced
Product resistance is developed
This polymer is significantly different from the starting materials
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SF Lamination AdhesivesBio-Film Interactions Hydroscopic films may provide excessive water which will alter the
polymer that is formed
More polyurea (harder, more heat and chemical resistance)
Excessive water can cause CO2 generation (gassing)
Plasticizers can be difficult for SF adhesives to displace for optimum
adhesive strength Glycols and other reactive film components will likely react into the
adhesive which will alter the polymer that is formed
Because of the low molecular weight starting materials SF adhesivescan smear ink when film tensions are not matched. A film that is over
stretched during laminating will relax in the roll with a potential to smearink.
Covalent bonds to film moiety (specifically reaction with OH or COOHgroups)
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Bio-Film Construction Solvent Free
Goal Lamination of renewable films with maximum adhesion
Use 1 mil OPLA and 1mil LDPE
Unprinted films laminated with 1.0 pounds / ream of SF adhesive
Screened three adhesive systems
OPLA / LDPE and OPLA / OPLA for Snack Food
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1 Day 2 Day 5 Day 7 Day
SF Adhesive A
SF Adhesive B
SF Adhesive C
BOPP/BOPP (Reference Laminations)
All three Solvent Free Adhesives have destruct bond level on BOPP
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0
100
200
300400
500
600
700
800
900
1000
1 day2 day 5 day 7 day
SF Adhesive A
SF Adhesive B
SF Adhesive C
OPLA / OPLA
Not all the Solvent Free Adhesives were successful on these films
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0
100
200
300
400
500
600
700
800
900
1000
1 day2 day 5 day 7 day
SF Adhesive A
SF Adhesive B
SF Adhesive C
OPLA / High Slip LDPE
Not all Solvent Free Adhesives were successful on these films
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Bio-Film Construction Solvent FreeOPLA / LDPE and OPLA / OPLA for Snack Food Goal was reached by careful selection of SF adhesive system
Not all SF adhesives give high bond strength on OPLA / OPLA orOPLA / LDPE.
Recommendation: Involve the adhesive supplier early inbio-film projects
Conclusions
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Bio-Film Construction Solvent FreeExample Set #2 OPLA / Cellophane OPLA-PHA blend / Cellophane
OPLA / Met PLA
OPLA / Met PLA-PHA blend
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0
100
200
300
400
500
600
700
Adhesive 1Adhesive 2Adhesive 3
Bio-Film Constructions Solvent FreeBond Strength
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Bio-Film Construction Solvent FreeSample Set #2-ConclusionsLamination NotesOPLA / Cellophane Adhesive selection is critical, can achieve
excellent bonding.
PHA / Cellophane Adhesive selection is critical, can achieve
excellent bonding.OPLA / Met PLA These films had metal transfer to adhesive,
need to run primer study
OPLA / PHA Adhesive selection is critical, can achieveexcellent bonding.
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Flexible Packaging AdhesivesSolvent Based Composition Typical Example35%
5%
60% Prepolymer
CurativeSolvent
Long pot life
Very low viscosity at application station Very high viscosity at nipping station
Solvent must be removed in application process
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Common Names Chemical RepresentationPolyolB-side
Curative
HydroxylIsocyanate
A-SideNCO
Adhesive
SolventEthyl Acetate
OHOH
OH
Solvent
Lamination AdhesivesSolvent Based Naming and Composition
Sol ent Based Dr Bond Laminating
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The three components are in solution Very low viscosity due to solvent
Water is supplied from the environment or films
Solvent is a carrier to get the adhesive to the film
Application Drying Nipping
Solvent Based Dry Bond Laminating
OHOH
S l t B d D B d L i ti
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An in-line oven is used to evaporate the solvent
The chemical reaction is the same as for a solvent free adhesive but thestarting molecules are much larger
Reaction is not completed
Application Drying Nipping
Solvent Based Dry Bond Laminating
OHOH
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The solvent is evaporated before nipping (dry bond)
Very high viscosity due to loss of solvent = high green strength
Oven air flow and temperature adjusted to evaporate all the solvent
Chemical reaction is not complete
OHOH
Application Drying Nipping
Solvent Based Dry Bond Laminating
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Laminate Slit Pouch Fill
Solvent Based Dry Bond
High starting molecular weight allows for slitting in as quick as one hour.
Curative and water react to form ideal polymer structure Heat will accelerate polymer formation time and decrease time-to-slit.
OH
OH
OH
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Laminate Slit Pouch Fill
Significant polymerization to provide heat resistance for seal making
Less time to get to high polymer formation because of high molecular weightstarting material
Bond strength is very high
Water is used in reaction to increase stiffness of polymer
Solvent Based Dry Bond
OH
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Laminate Slit Pouch Fill
Polymerization complete, food can be safely added
Full adhesive strength allows for freezing, boiling, microwaving, etc.Thermal resistance dependant on films and adhesive
Product resistance is developed
Chemical resistance is one of the last properties to develop
Solvent Based Dry Bond
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SB Lamination AdhesivesBio-Film Interactions Ethyl acetate in adhesive may soften bio-film resulting in poor web
handling, frosting, shrinking
Hydroscopic films may provide excessive water which will alter thepolymer that is formed
More polyurea (harder, more heat and chemical resistance)
Excessive water can cause CO2 generation (gassing)
Glycols and other reactive film components will likely react into theadhesive which will alter the polymer that is formed
Covalent bonds to film moiety (specifically reaction with OH or COOHgroups)
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40%
58%
2%
WB Polymer
water
Crosslinker - optional
Long pot life Can add cross-linker for added performance
Very low application viscosity
Water has to be removed in application process
Flexible Packaging AdhesivesWater Based Composition Typical Example
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Laminate Slit Pouch Fill
WB Adhesive isgravure applied tothe film.
Water is evaporatedin the oven, film ofadhesive is formed.
Second film is drybonded to adhesive.
Primary Film
Primary Film
Coalesced Adhesive
Primary FilmCoalesced Adhesive
Secondary Film
Water Based Dry Bond
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The polymer cures, flows, crystallizes over a short time period and hasenough bond strength to be slit
Drying conditions should be ramped to avoid skinning or bubbling
Aggressive nip to increase bond strength and improve appearance
Nip conditions specifically set to match Tg of adhesive withoutexceeding film handling limits
Pouching is possible when the polymer is near full cure and has enoughheat resistance to make heat seals.
Laminate Slit Pouch Fill
Primary FilmCoalesced Adhesive
Secondary Film
Water Based Dry Bond
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Bio-Film Construction Dry Bond WB Goal lightly printed biodegradable lid for biodegradable tray with
superior film-to-film adhesion
Use matched 1 mil oriented multilayer films for best web handling
Reverse printed with light ink coverage
Screened six adhesives and two co-reactants Both adhesive and co-reactant impact adhesion values
OPLA / OPLA for Lidstock
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0
100
200
300
400
500
600
700
800
Acrylic /CR1
Acrylic /CR2
Hybrid A /CR1
Hybrid A /CR2
Hybrid B /CR1
Hybrid B /CR2
UrethaneA / CR1
UrethaneA / CR2
UrethaneB / CR1
UrethaneB / CR2
UrethaneC / CR1
UrethaneC / CR2
Green peel
24 hr peel
2 week peel
PLA / PLA Bond StrengthDry Bond - WB
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Bio-Film Construction Dry Bond WBOPLA / OPLA for Lidstock Goal was reached
Acrylic performance is greatly influenced by co-reactant selection
Acrylic performance often approached urethane performancebased on selection
Not all urethanes are better than acrylics, selection of urethaneadhesive is important
Match the chemistry
Recommendation: Involve the adhesive supplier early in
bio-film projects
Conclusions
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Bio-Film Construction Dry Bond WBCellophane / Ecoflex+PLA blend for Compostable Pouches Goal printed biodegradable lid for biodegradable tray with superior
adhesion
Use matched 1 mil oriented multilayer films for best web handling
Reverse printed with light ink coverage
Choice of WB dry bond dictated by existing assets
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Bio-Film Construction Dry Bond WBCellophane / Ecoflex+PLA blend for Compostable Pouches
0
100
200
300
400
500
600grams / inch
Cellophane / LDPE Cellophane / Ecoflex+PLA
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Bio-Film Construction Dry Bond WBCellophane / Ecoflex+PLA blend for Compostable Pouches Goal was reached
The compostable sealant had web handling like a conventional sealant
The compostable sealant had superior adhesion properties to LDPEwith this adhesive.
Recommendation: Involve the adhesive supplier early inbio-film projects
Conclusions
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Adhesive ComparisonSolventBased Solvent Free Water Based
Coat Weight(#/Ream)
1.5-3.5 1.0-1.8 1.0-2.0
Initial Bonds 300 grams 20 grams 300 grams
Viscosity Low High Low
Pot Life 8 hours 30 minutes 8 hours
Retained Solvent Possible No Amine possible
Emissions Yes No No
Energy used High Low High
Lamination speed Oven limit 1500 Oven limit
Time to Slit 2 hours 12 hours 1 hour
Fire Hazard Yes No No
Cost (adhesive +energy)
3.5X X 2.7X
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Laminate Slit Pouch Fill
Last Example
PLA / MetPLA snack food application
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Laminate Slit Pouch Fill
Last Example
Correct adhesive gives high bondstrength
Correct adhesive gives soundreduction
Working together acceleratessuccess
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ITR Workshop SupportHB Fuller would like to thank the following supportersfor their contributions to this workshop!Taghleef Industries
Innovia
Metabolix
BioBag
Heritage Plastics/Plastimin
Imaflex
Sierra Converting
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Thank You
This presentation is for informational purposes only and does not constitute an offer by H.B. Fullerto sell or a warranty of any kind.