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Issue 02/2017

  • Text
  • Bioplastics
  • Packaging
  • Biodegradable
  • Materials
  • Products
  • Biobased
  • Films
  • Plastics
  • Compostable
  • Germany
bioplasticsMAGAZINE_1702

Thermoforming / Rigid

Thermoforming / Rigid Packaging White, easy-to-peel bio-PET lidding film Toray Plastics (America), Inc., now offers a biobased version of its new LumiLid ® XL7W, a white, easy-topeel PET lidding film for use with refrigerated and frozen dairy and dairy-replacement foods that are packaged in polypropylene (PP) containers. Toray’s LumiLid portfolio of PET lidding films includes biobased and traditional films in clear, white, and metallized formats for dual-ovenable, refrigerated, fresh, wet, and dry food applications. When XL7W is sealed to a PP container, it forms a strong, consistent bond, sealing even through overfill on the rim of the tray. Other white lidding films have a thinner sealant layer and lack the superior caulkability (i.e. the ability of the sealant to flow around irregularities in the seal area) performance of XL7W. With its thicker, high-performance sealant, the new product can often replace multi-layer laminations, which are expensive. The XL7W seal is strong enough to protect product freshness and is also consumerfriendly, providing a quick, easy, clean peel that resists shredding and complements XL7W’s premium appearance and feel. In addition, the new lidding film satisfies the customer’s desire for a robust narrow matrix rewind, which allows more lids to be produced and reduces downtime and waste during production. It is available in 128, 164, and 200 gauges (32, 41 and 50 µm). “The market demand for PP containers, and compatible biobased lidding film is growing,” says Milan Moscaritolo, Senior Director, New Business Development, Toray Plastics (America). “Biobased XL7W offers the perfect solution in many areas: environment-friendliness, functionality, production efficiencies, waste reduction, seal performance during distribution, and consumer satisfaction.” Toray launched its first biobased lidding films in 2015 with the introduction of its biobased dual-ovenable films. Toray’s biobased films are manufactured with its proprietary sustainable resin blends. The thin, multilayer films consist of a structural bio-PET layer and a specialty sealant layer, which delivers specified performance and seal-strength characteristics. This sealant is an extrusion coated proprietary multilayer structure made with biobased polyethylene. Biobased LumiLid products (consisting of blends of biobased polyolefin as a sealant extrusion coated to a biobased PET film) have a total bio-content of about 35 % to 50 %, depending on the application. Biobased content is validated by a third party laboratory. Biobased LumiLid films were created to lessen the impact on the environment and to meet the needs of the environment-conscious end user and consumer. Like all LumiLid films, they are manufactured without solvents, which ensures the films are odor-free. This may alleviate end-users’ concerns about solvent retention, as well as enhance the films’ sustainability profile. LumiLid biobased films have the same superior performance qualities that are characteristic of the LumiLid brand. They have a low seal initiation (SIT), broad seal range, outstanding seal integrity, and an easy peel.MT www.toraytpa.com Magnetic for Plastics www.plasticker.com • International Trade in Raw Materials, Machinery & Products Free of Charge. • Daily News from the Industrial Sector and the Plastics Markets. • Current Market Prices for Plastics. • Buyer’s Guide for Plastics & Additives, Machinery & Equipment, Subcontractors and Services. • Job Market for Specialists and Executive Staff in the Plastics Industry. Up-to-date • Fast • Professional 12 bioplastics MAGAZINE [02/17] Vol. 12

Thermoforming / Rigid Packaging A sticky situation Creating hot filled candy molds from bioplastics DSC results for thermoformed tray Making trays for PLA or PHA based candy and chocolate packaging has been possible for a number of years, but creating a bioplastic thin-gauge thermoformed tray that can also act as a mold for hot, sticky caramel at 130°C is a new breakthrough in biopolymer science. Solegear Bioplastic Technologies Inc. (Vancouver, British Columbia, Canada) has developed a new thermoforming biopolymer that can do just that, allowing chocolatiers and confectioners to move away from conventional heat-resistant PP packaging and adopt bioplastic packaging across their full product range. Solegear’s latest biopolymer contains 80% biobased content and is eligible to be certified compostable. Testing has shown that packaging trays made from Solegear’s latest material will consistently retain dimensional stability up to 130°C, even when being filled with hot, sticky caramels or chocolates with high fat and sugar contents – ingredients that usually spell disaster for first generation bioplastics. The thermoformed tray was manufactured using conventional extrusion and thermoforming methods. In addition to the requirement to retain a high percentage of biobased content so that the resulting trays could be certified compostable, the main challenge for development of this biopolymer was to engineer a formulation that would produce packaging that could withstand the considerable chemical and mechanical stresses introduced when hot caramel was poured into the tray, including heat resistance and dimensional stability up to 130°C. Solegear’s Product Development team, deployed its expertise in manipulating high-performance biopolymers and non-hazardous, biobased additives to successfully create this new innovative formulation. The manufacturing process was also optimized to achieve a sufficient level of crystallinity of over 45% (see DSC plot) and high impact resistance of more than 75 kg·cm (Gardner drop weight impact resistance, ASTM D5420). These significant performance requirements posed numerous technical barriers during the course of production trials before a suitable high quality packaging was manufactured. Using its know-how and a design approach focused on the concurrent testing of multiple variables and criteria, Solegear succeeded in achieving the desired results in just under one year. These bioplastic trays not only act as molds for hot and sticky candies and chocolates at 130°C, but can also form the final packaging for the product, moving successfully from production, to transport and to fridge and freezer storage without cracking and without leaching any elements into the candies and chocolates. Solegear’s material formulation and the final thermoformed high heat resistant trays contain no “Chemicals of Concern” that may potentially be harmful to human health and the environment. This becomes especially important in the food industry where safety and security have become a priority concern for consumers and product manufacturers. Traceability of materials is proving to be challenging for fossil fuel-based plastics, and can be more precarious for recycled materials where the source and composition are rarely well documented. The first full-scale packaging made from Solegear’s new material is expected to be on retail shelves in 2017. Solegear is continuing further product development to meet the needs of additional food safety and security opportunities. And for those of us who are nuts about caramels and chocolates, it can now be a bit more of a guilt-free experience knowing we’re doing something better for the planet. MT www.solegear.ca bioplastics MAGAZINE [02/17] Vol. 12 13

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