Films/Flexibles/Bags
Films/Flexibles/Bags Bioplastic barrier films for packaging By: Christine Schaefer Director of Marketing Sidaplax |Plastic Suppliers Ghent, Belgium | Columbus, OH, USA Two primary catalysts are contributing to barrier bioplastic adoption in flexible packaging. The first is emerging and organic brands are intentionally connecting their natural products to natural packaging. It is an integral reflection for their brand. The second is global brands and retailers are including more environmentally responsible packaging in their sustainability objectives. Currently, there is high activity in transitions from fossil fuel based packaging into those that are bio-sourced because of these objectives. As a quick introduction, EarthFirst ® barrier films are PLAbased and are substitutions for fossil based polyethylene (PE) films. EarthFirst bioplastic barrier PLA films have greater than 90 % new carbon content and are certified industrially compostable to ASTM D6400. No surprise, many packages require barrier for product protection. Advancements within bioplastic film have created a greater depth of possibility in packaging - more specifically barrier films with excellent oxygen and moisture performance. Barrier bioplastic PLA packaging film is commercial globally today. Oxygen transmission rate (OTR) is better than provided by metallized OPP (oriented polypropylene), although not to the level of metallized polyester (MetPET). Water vapor transmission rate (MVTR) is comparable to metallized OPP (MetOPP) and metallized polyester (MetPET). Clear barrier PLA films, which are Aluminum Oxide (ALOX) coated, are nearing commercial status. The barrier expectations are comparable to ALOX coated polyester. Like barrier metallized films, clear barrier ALOX coated sealant films have excellent flavor, aroma and grease barrier properties, are very high yield and create strong and airtight gusset and fin seals. While there is more depth in each category, there are three main points. 1.) Incorporating barrier bioplastic film significantly reduces packaging’s carbon footprint. This point is best illustrated in an example: A 75μm PE sealant is exchanged with a 30 μm barrier metallized sealant film for 1,000 tonnes of film in stand up pouches (SUP). This environmental calculation translates to a greenhouse gas (GHG) equivalent of 213 hectares (528 acres) of forest preserved from deforestation or 1.65 million tree seedlings being grown for 10 years. Fossil fuel savings (NREU) equivalents are electricity consumed by 1.49 million residents of Western Europe or 422,000 barrels of oil saved per year. 2.) Bioplastic barrier film can also reduce packaging and operational costs Optimizing a package is the best possibility for packaging material cost savings. More specifically, incorporating barrier PLA sealant film as a replacement for both an individual barrier and an individual sealant film. The positive source reduction in eliminating a layer of material contributes to sustainability metrics as well as Fig 1: WVTO and OTR of different 20 µm metallized barrier films 10,000 1,000 Other Companies Metallized PP W.V.T.R. (g/(100 in² · day)) 0,100 0,010 Other Companies Metallized PET Other Companies Metallized PLA Sidaplax | PSI EarthFirst Metallized PLA 0,001 0,010 0,100 1,000 10,000 O.T.R (cm³/(100 in 2 · day)) CONFIDENTIAL 16 bioplastics MAGAZINE [06/19] Vol. 14
Films/Flexibles/Bags Sealant Film Exchange Fossil Film for Biosource Barrier PLA 3-Layer to 2-Layer Package Higher Micron Barrier to Lower Micron Barrier Compostable Print Web Options to Metallized or Clear Barrier Industry Structure 12µm PET/12µm Met PET/ 75µm LLDPE More Sustainable 12µm PET/12µm Met PET/ 9µm EarthFirst Compostable 20µm OPLA/ 30µm Barrier Metallized EarthFirst Compostable (example structure) 20µm OPLA/ 20µm Barrier Metallized EarthFirst Also Compostable Cello or OPLA or Paper Print Web Metallized or Clear Barrier EarthFirst reduced packaging costs. Using the same stand up pouch example, package thickness is reduced by almost half and weight is reduced by 40 %. Importantly, while the package has less material, the product integrity remains intact and may have higher performance properties. Bioplastic barrier films exhibit high seal strength, excellent hot tack and can create peelable or fusion seals. Beyond material savings, additional operational savings are connected to the lower gauge substitutions. Typically there’s a 50 % barrier bioplastic film gauge reduction versus a heavier gauge fossil based film. This reduction results in cost reductions throughout the packaging supply chain. Now, inbound freight costs are reduced by half. In warehousing, 50 % less space is needed and 50 % fewer moves to the filler are needed. Fillers/copackers experience 50 % less downtime from fewer roll changes. 3.) Modifying packages with bioplastic film is straightforward. In fact it’s easy. A great and easy first step is in film replacement – PLA sealant for a PE sealant. Typically this replacement translates to > 25 % source reduction in packaging and an associated renewable packaging content also > 25 %. As in the earlier example, an additional incremental sustainable step is transitioning from a 3 to a 2-layer structure by incorporating a barrier PLA layer – barrier metallized or clear barrier aluminum oxide-coated. The inherent uniqueness of some bioplastic films translate to a different feel and even sound to sustainable packaging. It’s these distinct tactile and audible attributes that are indicators of more environmentally responsible packaging. Summary Consumer product goods (CPG) companies and retailers are advocating for their brands in more environmentally positive ways. Technical advancements in barrier bioplastic packaging films provide greater application to packaging and future technical projects hold promise in both increased barrier and composting options. Barrier bioplastics film sourcing is inherently and naturally renewable, decouples from fossil feedstocks and sourcing sustainably ensures inputs are optimal. Globally, commercial CPG packages are in the market. There are reductions in both carbon footprint and packaging/ operational costs and it’s easy. Future bioplastic barrier packaging films include sealant films with increased barrier and extended compostability and degradation for different environments. Incremental changes to more sustainable packaging are encouraged by industry groups, environmental non profits and consumers. So are transformative changes to fully compostable packages. Collectively we can initiate positive change. www.plasticsuppliers.com Industry Structure 48g PET / 48g MetPET / 300g PE Sealant Compostable Structure 80g PLA / 120g EarthFirst Barrier Metallized PLA Total Weight Comparison NREU [MJ] GHG [kg CO 2 eq] LLDPE [EU] 3,438,000,000 78,600,000 PLA 915,500,00 14,200,000 Cumulative improvement 2,523,000,000 64,400,000 73,4 % 82 % Table 1: This model estimates the benefits of replacing LLDPE polymer with PLA biopolymer and is not a complete life cycle assessment (LCA). Source Reduction KGS/1MM Industry Structure Compostable Structure PKGS Thickness 0 % 49 % Weight 0 % 41 % % Renewable 0 % 97 % Table 2: Comparison of conventional to compostable PLA barrier solution bioplastics MAGAZINE [06/19] Vol. 14 17
