Post on 04-Jun-2018
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2nd International Conference Ljubljana, Slovenia – 17th & 18th September 2012
“New approaches for sustainable food packaging concepts”
Recent research activities regarding sustainable food packaging materials
Biopolymers in flexible packaging materials for sensitive food products
Nano-scale surface modifications on paper for optimized barrier properties
Markus Schmid
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Content
Introduction Fraunhofer IVV
Introduction to food packaging
Protection as the primary function of packages
Sustainability of packaging materials
Classification of Biopolymers – What do you really need?
Project examples
FutureBioPack
Flexpakrenew
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Institute Director Prof. Dr. Horst-Christian Langowski Giggenhauser Straße 35 85354 Freising Germany www.ivv.fraunhofer.de
Introduction Fraunhofer IVV
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Core Competence Materials Development and Business Field Functional Materials
Introduction Fraunhofer IVV
Polymer processing Polymer coating Materials testing
Vacuum web coating via e-beam evaporation
Lacquering and lamination of films, papers and composites
Manufacturing of barrier film composites by combining vacuum coating and lacquering
Compounding of polymers
Production of single or multi-layer flat films
Extrusion coating and extrusion lamination
Permeability of packaging materials to water vapour and oxygen
Optical and surface properties
Mechanical properties of packaging and packaging materials
Lab and pilot scale
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Introduction to Food Packaging
Containment Protection
Convenience Communication
Functions of Food
Packaging
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Protection as the primary function of packages
Deterioration of foodstuffs by….
microbial processes
aerobic process: oxygen
Anae-robic
process: absence
of oxygen
chemical / biochemical
processes
lipid oxida-tion: light,
oxygen
Enzy-matic brow-ning:
oxygen
physical processes
loss of water, uptake
of water
off- flavours
loss of flavours
Water, water vapour
Oxygen
Light
Flavours and off-flavours
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Protection as the primary function of packages
Requirements to packaging materials for sensitive food, pharmaceutical and technical products
Source: Langowski, H.-C. (2008): Permeation durch Lebensmittelverpackungen – Anwendungsbeispiele. Seminar: Permeation durch Packstoffe, Fraunhofer IVV
0,01
0,1
1
10
100
1000
0,01 0,1 1 10 100
Water vapour permeability [g / m² d] 85% 0% RH
Oxyg
en
perm
eab
ilit
y [
cm
³ (S
TP
)/ m
² d
bar]
meat/MAP
ketchup, sauces
nuts, snacks
Edible oil
UHT milk
Vacuum coffee
beer Special food, infusions, baby food
Instant coffee
vacuum isolation panels, flexible displays
tablets (blister)
Fresh fruit, vegetables, …
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Protection as the primary function of packages
Permeability for water vapour and oxygen at 23°C and 100 µm film thickness of commonly used thermoplastics and special packaging type polymers
Source: IRIS
d
PQ
...1111
321
QQQP
d
Q ii
i
tot
100100
dQQ
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Sustainability of packaging materials
1EUROPEN (Europäische Organisation für Verpackung und Umwelt) in: EUWID Verpackung 6.2011
Protection and safety of the product has highest priority
The packed food product uses significantly more resources than its packaging
Insufficient protection leads to spoilage of food
Spoilage of food causes much higher CO2 emissions and usage of resources than any change of packaging material could save
Packaging must sufficiently protect the product
Material reduction by optimized material properties
Material substitution only if product safety is guaranteed
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Sustainability of packaging materials
Source: Diers, A., Langowski, H.-C., Pannkoke, K., Hop, R.: Produkt-Ökobilanz vakuumverpackter Röstkaffee.
LCA Documents, Vol. 3. ecomed-Verlag, Landsberg, 1999
LCA of vacuum packed coffee, prepared at the consumer, product vs. packaging, relative figures
packaging
coffee
renewable energy
non renewable energy
pesticides, fertilizers
total energy
minerals
water
municipal waste
hazardous waste
radioactive waste
eutrophication
acidification
global warming
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Sustainability of packaging materials
Source: Pascal Gréverath, Nestlé AG, IVLV-Workshop Sustainability, Freising,
04.12.2008
Packaging can help to minimize food losses!
Losses in the Food Chain
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Sustainability of packaging materials – Facts!
Source: H.-C. Langowski, Fraunhofer IVV, The different aspects of sustainability –
introduction and overview, ICE Conference 2011, Munich.
• Environmental impacts of food production by far dominate those of the package Fact No. 1:
• Food that is lost at the consumer creates the highest environmental loads in comparison to all other factors
Fact No. 2:
• Dissatisfaction of consumers is an important reason for product losses Fact No. 3:
• For any product, the degree of fulfillment of the function determines the environmental and economic impact
Fact No. 4:
Consequence:
A truly
sustainable
package will
never
compromise
issues and
preferences of
consumers
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Classification of Biopolymers: What do you really need?
Starches
Polyhydroxy alcanoates
Polylactic acid
Cellulose
Bio-PE, Bio-PA, Bio-PP, Bio-
PVC,
Cellulose acetate,
Caoutchouc …
Polyethylene
Polypropylene
Polyvinyl chloride
…
Polycapro-lactone
Polyvinyl alcohol
Linear Polyesters…
Non
degradable
Renewable
Resources
Biodegradable
Petrochemical
Resources
Modified from: ENDRES, H.-J. & SIEBERT-RATHS, A. 2011. Engineering biopolymers : markets, manufacturing, properties, and applications, Cincinnati, Hanser Publishers.
Re-use
Recycling
Energy recovery
composting (littering)
without energy recovery!
(biogasification)
The End-of-Life Options for „Non degradable“ polymers are also applicable to „Biodegradable“ polymers!
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The Six R's of Sustainability Recent project providing a contribution to sustainability
•Wheylayer EVOH by whey-protein
•Flexpakrenew PET by functionalized paper
•BioPaperCoating PE by PLA/PHBV REMOVE •All our research projects deal with material optimization and potentials in material reduction REDUCE
•All our research projects utilize renewable recourses
•FutureBioPack Fibre molding products for MAP applications
•Thermoplastic Proteins Thermoplastic barrier materials RENEW •Wheylayer Enables the recyclability of multilayer plastic films
•Thermoplastic Protein Improved recyclability RECYCLE
•Reusable packaging We do not work on reusable packaging yet REUSE
•Flexpakrenew Barrier paper with “Self-Healing” function REPAIR
Contribution to “Sustainability”
6R´s according to: Carlson, D. et al. (2009): OCR Design & Technology for GCSE. Hodder Education, London.
Sustainability of packaging materials
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Project: FutureBioPack
Developments and application of Sustainable and Smart Bio based
packaging materials for the benefit of SMEs
Duration: 2012-2013
18 Partners from 2 EU Countries
Funded by the European Commission
Goals: Development of sprayable and biobased
coatings providing barrier properties
Spray coating process development for coating applications on fiber moulded trays
Substitution of petrochemical based plastic trays by fiber moulded products
Source: Omni-Pac
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Project: FutureBioPack
Approach:
Materials considered in research include bio-based substrates such as flat boards and specific application 3D moulding trays, bio-based coatings, laminates and bio-composites
IVV´s research tasks are:
Material screening (materials on the market and research state)
Selection of most suitable materials
Application on flat boards
Application on 3D fibre moulded trays
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Project: FlexPakRenew
Objective: Design and development of an innovative low-substrate flexible paper system for
packaging from renewable resources The technical challenge is to develop a flexible paper
based on a multilayer structure with a total grammage weight of 50 - 90 g/m²
having barrier properties competitive with those of untreated plastic films (medium barrier) or to treated plastic films (high barrier)
The flexible packaging will be almost entirely recyclable (>95%) and biodegradable and will use only environmentally friendly processes.
EU founded project (FP7)
Duration: 2008 – 2011
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Project: FlexPakRenew
Barrier targets and approach of the project FlexPakRenew
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Project: FlexPakRenew
Project Concept:
Improvement of paper substrate
Mechanical properties
Barrier properties
Development of starch a/o hemicellulose based coatings
Reinforcement with nanoparticles to obtain medium barrier
Development of nanocoatings to improve barrier performances
Chemical grafting in cooperation with CTP and CNRS
Vacuum coating
Development of anti-microbial coatings to prolong shelf life of food products
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Motivation: • Fast reaction • Material efficiency • Hydrophobic surface properties • Improved water vapour barrier
Esterification
Coating thickness : ~ µm Grafting thickness : ~ nm
O C=O C=O
O
Substrate
PVOH
Substrate
OH OH
Characteristics: • Closed layers • Biodegredable • high oxygen barrier
Project: FlexPakRenew – Chemical Grafting
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a.o. Barrier is depending on grafting density
Water Oil
PVOH-Layer
Grafted fatty acids
Barrier effect
Project: FlexPakRenew - Chemical Grafting
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Comparison Cobb60 Ungrafted - Grafted
18,0
23,023,0
0,30,61,1
-5,0
0,0
5,0
10,0
15,0
20,0
25,0
Mowiol 4-88 Mowiol 4-98 Mowiol 28-99
Co
bb
60 [
g/m
²]
Ungrafted
Grafted
PVOH A PVOH C PVOH B
Project: FlexPakRenew - Chemical Grafting
Source: Andreas Benz, Markus Schmid, Camelia Stinga, et al., “Fundamental investigations regarding barrier properties of grafted PVOH layers,” International Journal of Polymer Science, 2012, - In press.
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Ungrafted Contact angle < 90° hydrophilic
Grafted Contact angle > 100° hydrophobic
Project: FlexPakRenew - Chemical Grafting
Source: Andreas Benz, Markus Schmid, Camelia Stinga, et al., “Fundamental investigations regarding barrier properties of grafted PVOH layers,” International Journal of Polymer Science, Article submitted in 2012.
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46,6
74,9 72,3
101,4 104,1 106,1
0
20
40
60
80
100
120
Mowiol 4-88 Mowiol 4-98 Mowiol 28-99
Co
nta
ct
an
gle
[°]
Ungrafted
Grafted
PVOH A PVOH C PVOH B
„… wetability determination by contact angle measurement…“
Project: FlexPakRenew - Chemical Grafting
Source: Andreas Benz, Markus Schmid, Camelia Stinga, et al., “Fundamental investigations regarding barrier properties of grafted PVOH layers,” International Journal of Polymer Science, Article submitted in 2012.
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6921017 1046
9254 60
1
10
100
1000
10000
Mowiol 4-88 Mowiol 4-98 Mowiol 28-99
WV
TR
[g
*m
^2*d
]
ungrafted
grafted
PVOH A PVOH C PVOH B
8 19 17
Barrier
Improvement
Factor
Project: FlexPakRenew - Chemical Grafting
Source: Schmid, M. and D. Samain. Improved barrier properties for Innovative food packaging applications by nanoscale surface modification – a chemical grafting process. in BIOPOLPACK - 2nd Congress on biodegradable polymer packaging. 2012. Milan, Italy: Università degli Studi d i Parma.
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Paper
+
Precoating
+
Problems: Defects and cracks in the inorganic layer
Decreased barrier properties after vacuum coating
Project: FlexPackRenew - Inorganic nanolayers to
improve barrier properties
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Reasons:
Surface Roughness
RMS-Value > 50 nm
Evaporation of residual water (10-4 -10-5 mbar)
water cannot act as a plasticizer anymore
brittle coating
Different hygroexpansion behaviour of paper/precoating and
inorganic layer
Project: FlexPackRenew - Inorganic nanolayers to
improve barrier properties
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Back side (BS), magnification of 1000 Front side (FS) (mineral coated side), magnification of 3000
Project: FlexPackRenew - Inorganic nanolayers to
improve barrier properties
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Starch coateing on FS (12g/m2), Surface of the starch coating, magnif. of 2000
(example from Sustainpack)
Planarising layer on on FS (4-5 g/m2), Thickness of the OR.-surface, magnif. of 5000
Project: FlexPackRenew - Inorganic nanolayers to
improve barrier properties
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Improved surface roughness
• Calandering ( not sufficient)
• Coating
Improved precoating materials
• Usage of non-volatile plasticizers
Preconditioning & Remoistening
• Substrate dependent preconditioning ( Dryingkinetic)
• Substrate dependent remoistening ( Sorptionisotherms)
smooth
flexible
Preconditioning & Remoistening
Project: FlexPackRenew - Inorganic nanolayers to
improve barrier properties
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Results:
OTR and WVTR:
Positive effect of
preconditioning and
remoistening was
proven
Improved barrier
properties after
vacuum coating were
observed
Project: FlexPackRenew - Inorganic nanolayers to
improve barrier properties
Source: Noller, K., M. Schmid, and C. Schönweitz. Organic and inorganic nanolayers to improve barrier properties. in FlexPakRenew Workshop - Planet Friendly Packaging. 2011. Lyon, France.