Multilayer Flexible Packaging: Technology and Applications for the Food, Personal Care, and Over-the-Counter Pharmaceutical Industries (Plastics Design Library)

A comprehensive and highly practical survey of the materials, hardware, processes and applications of flexible plastic films. Aimed at a wide audience of engineers, technicians, managers, purchasing agents and users, Multilayer Flexible Packaging provides a thorough introduction to the manufacturing and applications of flexible plastic films, covering: Materials Hardware and Processes Multilayer film designs and applications The materials coverage includes detailed sections on polyethylene, polypropylene and additives. The dies used to produce multilayer films are explored in the hardware section, and the process engineering of film manufacture explained, with a particular focus on meeting specifications and targets. The section includes unique coverage of the problematic area of bending technology, providing a unique explanation of the issues involved in the blending of viscoelastic non-Newtonian polymeric materials. About the author John R. Wagner, Jr. is President of Crescent Associates, Inc., a consulting firm that specializes in plastic films and flexible packaging. He graduated from the University of Notre Dame with a BS and MS in Chemical Engineering. Cover Page ......Page 1 Copyright ......Page 2 Preface ......Page 3 Acknowledgement ......Page 5 Contributors ......Page 6 Materials: A historical perspective......Page 14 Markets: A global economy......Page 16 Processes, materials, needs......Page 17 Materials and barrier......Page 19 Bringing things together......Page 21 References......Page 22 Low density polyethylene......Page 23 Melt index......Page 24 Gel permeation chromatography (GPC)......Page 25 Tube reactor......Page 27 LDPE Homopolymer......Page 28 Copolymers of PE......Page 29 Solution process......Page 30 Slurry processes......Page 31 Ziegler-Natta......Page 32 Single site catalyst (Metallocene)......Page 34 Enhanced polyethylenes (EPE)......Page 36 References......Page 38 Managerial overview......Page 39 Metallocene catalyzed polymerization ofnbsppolypropylene......Page 40 Beta crystallinity......Page 41 Processing......Page 42 Challenges of using polypropylene......Page 43 References......Page 44 Overview......Page 45 Additive handling, addition andnbspdosing......Page 46 Additive types and principal mode of action......Page 47 Influencing the substrate stability during processing or conversion......Page 48 Polyolefins (polypropylene and polyethylene)......Page 49 Influencing the antioxidant effect......Page 50 Polyester......Page 51 Polyvinylchloride......Page 52 Polyamide......Page 53 Chemistry......Page 54 Effect and principle......Page 55 Principle......Page 56 Influencing the slip effect......Page 57 Principle......Page 58 Influencing the antiblock effect......Page 59 Incorporation......Page 60 References......Page 62 Appendix 4.2......Page 63 Introduction......Page 65 Viscosity and melt flow index......Page 66 Mathematical relations......Page 68 Normal stress differences and extrudate swell......Page 71 Stress relaxation and dynamic measurements......Page 73 Constitutive equations......Page 74 Sharkskin, melt fracture and die lip build-up......Page 76 Rheological problems innbspcoextrusion......Page 77 Rheometers......Page 78 Concluding remarks......Page 79 References......Page 80 Overview......Page 81 Introduction......Page 82 The adapter......Page 83 The feedblock......Page 84 Rheological background......Page 85 Feedblock designs......Page 89 Die designs......Page 91 Coextrusion systems for flat films andnbspsheet......Page 94 Layer instabilities, causes and prevention......Page 95 Example 1......Page 98 Example 2......Page 99 Summary......Page 100 References......Page 101 Conventional coextrusion dies......Page 102 Stacked dies......Page 104 References......Page 106 Some tools of process engineers......Page 108 Conclusion......Page 110 Blown film......Page 111 Cast film......Page 113 Extrusion coating and lamination......Page 114 References......Page 116 Description of machine direction orientation hardware and technology......Page 117 The process and its effect on the film......Page 118 Properties of machine direction oriented films......Page 119 Increased tensiles......Page 120 Summary......Page 121 References......Page 122 Orienting technologies......Page 123 Films oriented biaxially......Page 129 BOPP films......Page 130 BOPET films......Page 132 BOPS films......Page 135 Other BO films......Page 136 Film oriented in machine direction......Page 137 Trends for oriented films......Page 139 References......Page 140 Why blend?......Page 141 Blending processes......Page 142 Pellet pre-mixing......Page 143 Melt blending......Page 144 Physics of blending......Page 146 Thermodynamics......Page 147 Morphology development innbspimmiscible blends......Page 150 Minor phase concentration in blend......Page 158 Draw ratio......Page 159 Dispersion of rigid particles andnbspnanocomposites......Page 160 Conclusion......Page 162 References......Page 163 Coating uniformity......Page 167 Web coating machine hardware andnbspfunctions......Page 168 Classification of applicators......Page 170 Role of substrate......Page 171 Dip coaters......Page 173 Forward roll coaters......Page 174 Mayer rod or wire-wound rod coaters......Page 175 Air knife coaters......Page 176 Knife coaters......Page 177 Blade coaters......Page 178 Extrusion coaters......Page 179 Slide coaters......Page 180 Precision curtain coaters......Page 181 Gravure coaters......Page 182 Effect of solvent......Page 183 Hot melt coaters......Page 184 Selecting a coating method......Page 185 Drying and solidification......Page 187 References......Page 188 Decorative coatings......Page 189 Gas barrier......Page 191 Functional coatings......Page 192 Security applications......Page 195 Basics of metallization......Page 196 Pattern metallization......Page 201 Trends......Page 202 References......Page 205 Introduction......Page 207 Polymer selection......Page 209 Mechanical properties......Page 210 Barrier properties......Page 211 Polymer sealability......Page 214 Adhesive polymers......Page 216 Medical packaging......Page 218 Primal meat packaging (Shrink)......Page 219 Cereal box liners......Page 220 Cheese packaging......Page 224 Frozen food......Page 225 Fresh-cut produce......Page 226 Stretch wrap......Page 227 High clarity shrink film (oriented)......Page 228 Summary......Page 229 References......Page 231 Technology for multilayer oriented films......Page 233 Structures......Page 235 Consumer Requirements......Page 238 Sustainability......Page 239 Writing guide for packaging films and other multilayer structures......Page 240 Index......Page 250

A comprehensive and highly practical survey of the materials, hardware, processes and applications of flexible plastic films.

Aimed at a wide audience of engineers, technicians, managers, purchasing agents and users, Multilayer Flexible Packaging provides a thorough introduction to the manufacturing and applications of flexible plastic films, covering:

• Materials
• Hardware and Processes
• Multilayer film designs and applications

The materials coverage includes detailed sections on polyethylene, polypropylene and additives. The dies used to produce multilayer films are explored in the hardware section, and the process engineering of film manufacture explained, with a particular focus on meeting specifications and targets. The section includes unique coverage of the problematic area of bending technology, providing a unique explanation of the issues involved in the blending of viscoelastic non-Newtonian polymeric materials.

About the author

John R. Wagner, Jr. is President of Crescent Associates, Inc., a consulting firm that specializes in plastic films and flexible packaging. He graduated from the University of Notre Dame with a BS and MS in Chemical Engineering.

PE Processes Polypropylene Additives to design and improve the performance of multilayer flexible packaging Rheology of molten powders Coextrusion equipment for multilayer flat films and sheets Multilayer blown (tubular) film dies Process engineering Blown film, cast film and lamination processes Machine direction oriented film technology Oriented film technology Polymer blending for packaging applications Water- and solvent-based coating technology Vacuum metallizing for flexible packaging Multilayer Films - Descriptions, Performance Characteristics, Uses, Considerations, Properties PE based multilayer film structure Multilayer oriented films. Presents a survey of the materials, hardware, processes and applications of flexible plastic films. This book offers an introduction to the manufacturing and applications of flexible plastic films. It covers topics like: Materials; Hardware and Processes; and, Multilayer film designs and applications. It is suitable for engineers and technicians.