Innovative Hochbarrierefolien · Innovative Hochbarrierefolien – ... Packing Lacquer mixing...
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Innovative Hochbarrierefolien –Herstellung, Design und neueste Anwendungen
Möhlin- May 17, 2017
Simone HermannProduct Development Manager Pharma
Amcor - introduction
- our approach to Innovation - Manufacturing processes
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Amcor: A leading global packaging supplier
29,000+CO-WORKERS
GLOBALLY
180+ MANUFACTURING
SITES
40+ COUNTRIES WITH
OPERATIONS
US $10 BILLION ANNUAL
SALES
1860’sSTART OF
OPERATIONS
70,000+ SHAREHOLDERS
TOTAL OUTPUT
4,000,000UNITS/MIN
In Flexible Packaging
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Innovation
Amcor is today a US$9.5 billion global business with strong exposure to the emerging markets of Asia, Latin America, Eastern Europe and Africa
Over 95% of annual sales are from consumer staples including food, beverage, healthcare, home and personal care and tobacco products
Emerging markets
32%
North America
32%
Western Europe
31%
AUS,NZ 5%
Food 33%
Beverage 32%
Specialty Folding Cartons
15%
Home and personal care
3%
Healthcare 15%
Other2%Rigid
plastics 36%
Flexibles64%
Portfolio Global Reach Segments
Note: All numbers refer to FY 2016
Amcor today
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CANADA
SOUTH AFRICA
SOUTH KOREACHINA
INDIA
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USA
MEXICO
EL SAVADOR
ECUADOR
COLUMBIA
CHILE
PERU
ARGENTINA
BRASIL
TRINADAD & TOBAGO
VENEZUELA
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DENMARK
NETHERLANDS
BELGUIM
SWITZERLAND
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AUSTRALIA
NEW ZEALAND
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THAILAND
INDONESIA
SINGAPORE
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1
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TURKEY
SPAIN
PORTUGAL
MOROCO
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Flexibles Packaging110 Plants33 Countries
Folding Cartons23 Plants20 Countries
Rigid Plastics62 Plants12 Countries
UK
IRELAND
GERMANY
FRANCE
FINLAND
RUSSIA
POLAND
UKRAINEKAZAKHSTAN
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1CZECH REPUBLIC
ITALY
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2
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4
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PUERTO RICO
DOMINICAN REPUBLIC1
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1MALAYSIA
PHILIPPINES
Amcor strategy – global, integrated, relevant
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Amcor has a full range of production technologies
Aluminium rolling SioX-coating Film extrusion (cast/blown) Lacquering Lacquer/adhesive lamination Extrusion coating Extrusion lamination Printing (solvent based, UV-curing, Digital) Slitting Bag making Die cutting
Example: Formpack® – Manufacturing process
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The Formpack® innovation is the ability to stretch an aluminium laminate ≥32% in three dimensions to produce small, deep cavities without fractures, guaranteeing the protective barrier properties
oPA 25 µm
PVC 60 µm
Aluminium 45 µmadhesive
adhesiveprimer
Formability
Stiffness
Barrier
Example: Formpack® – Manufacturing process
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a) Aluminium – from ingot to foil:
AnnealingMetal temp: 280-350°C(change form hard to
soft temper)
Cold rolling3 single rolling steps,
Last step to 45µm (double rolling)
Separating(separation of double rolled foil, trimming)
AnnealingMetal temp: 280-350°C(change from hard to
soft temper)
Pre-roll stock800-1690mm
Thickness: 700µFoil stock ex Hot Rolling Mill
Packaging
Converting (Lamination)
Hot Rolling
Example: Formpack® – Manufacturing process
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Primer on Alu
LaminationoPA/ Alu/ PVC
Curing
Slitting
Packing
LaminationClean Room Class D, ISO 8 conditions
CuringSlittingClean Room Class D, ISO 8 conditions
b) Lamination & Slitting:
Example: Lidding – Manufacturing process
© Amcor 2016 Confidential
Clean Room Class D, ISO 8 conditions
Printing
Trimming
Slitting
Packing
Lacquer mixing
Lacqueringon Alu
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Amcor has an extensive and powerful set of innovation capabilities right across the packaging spectrum
DesignOur creative and technical designs drive consumer appeal. Through innovative design, we help our customer products look amazing, feel great and perform intuitively.
Material scienceUsing our deep understanding of materials, we develop and test packaging to ensure it works the way we intended, from how the product looks, feels, works, and performs.
Manufacturing and processesWe apply advanced manufacturing and engineering to maximise efficiency across the entire supply chain from how materials are sourced, processed, converted, handled, transported and recycled.
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Design & Services
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Packaging Simulation (Pharma)
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Simulation & Analysis
Prediction• Coldform cavity size• Tooling material selection• Forming forces• Thermoforming thickness
distribution• WVTR calculation• …
Physicalmodelling
• Springback and relatedstresses
• Material behaviour modelling• Heat transfer during sealing• Process simulation• Impact test (crash type)• …
Validation
• Material testing (stress-strain)• Forming strain measurement• Inverse calculations• Formability tests• Friction measurement
Packaging Simulation (Pharma)
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• Black Box Thermorforming Simulation
Thickness distribution
Permeability
Packaging Simulation (Pharma)
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• FORSIS Cold forming Simulation for Tool design
Customers’Tablet Geometry
FORSISForming Simulation
CADTool drawing
Technical application support
Analytical labPilot line & Technikum
Testing on blister line, development of test methods, prototyping
Evaluation of extractables& other analytical tests
Phi-Check (analysis of strain distribution and tool alignment)
Cross Diffusion Simulation
Calculation of permeation intoFormpack ® blister through the seal area
Cross Diffusion Simulation
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Sealing LayerLid foil
Cross diffusion
Base foil
Top layer
AluminumHeat seal lacquer
Main polymer
Aluminum
Bottom layer
Adhesive
Relevant layers for cross diffusion
Lid
Base
Diffusion distance
Permeation = solubility x diffusivity
Material properties:• Density• Diffusivity• Solubility
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FORMPACK® blister
Corner cavity,no perforation
Mid-strip cavity,perforated
Mid-strip cavity,no perforation
Mid-strip cavity,perforated & lateral offset 1.5 mm
Humidity flow
Cross Diffusion Case Study
Case study results:
Corner cavity shows 30% more cross diffusion than mid strip cavity
Perforation increases cross diffusion by 6 times for a mid strip cavity
When the sealing width changes due to variations in production process (e.g.. misalignment), it is more than 7 times worse
Cross diffusion into standard Formpack® blister is more than two decades betterthan into high barrier thermoform film (e.g. PVC/Aclar Ultrx4000)
Cross Diffusion Simulation
Innovative Solutions in Pharma
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Our Pharma flexibles product range
Ready-to-Use Formpack® Blister
• Materials feature special sealing properties with both a tightseal and easy peel (frangible seal) to allow a controlled mixingof the different components, means “on-the-spot mixing”.
• Allowing highly moisture-sensitive drugs to be instantlymixed before usage, thus enhancing drug stability and simplifying supply chain (e.g. eliminating necessity of cool storage).
• New laminates (bottom and lid foil) create a high barrier cold formed blister pack, a perfect solution for unstable and water/vapor-sensitive drugs .
Option with 2 components
TDSP0506-E & TDSP0507-E
straw
Technical description:
awarded with
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• Significantly increases protection against cross diffusion,extends pharmaceutical and medical product shelf life
• Dries tablet humidity and headspace thanks to the extra capacity available
• Water absorption capacity (guaranteed): 3.6 g/m2
DessiflexTM Blister & Sachet System- a new dimension in protection
Formpack DessiflexTM Blister System
DessiflexTM Sachet System
Formpack® Dessiflex Blister System
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• Forming like Formpack® with PVC (Teflon plugs!); FORSIS to design optimal cavity & tooling
• Lid foil with PE based coating needed (lower seal temperature than for PVC-based blister needed)
• Reels packed in Alu/plastic pouches (under vacuum)• No capacity reduction during processing on blister line (unwinding
to sealing); Processing of a reel within 120h recommended
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Cost SavingsUp to 40% less film than
4-side sealed sachets
Single-serve pack solution
Key Benefits for Customer
Key Benefits for Patient
On-the-go ConvenienceLightweight and easy to open
thanks to an easy opening system
Easy DispensingEasy dispensing directly from the pack,
avoids product waste keeps hands clean
Product DosingSingle-portion packs and controlled
dosing means no measuring is required
Brand PositioningEntire printing surface and high quality
image for premium look and increased brand recognition
Examples of Material Structure
Standard spec would be PET/Alu/PE
- PET
- Alu
- PE
Other specs available, depending on application
Single-serve pack with PolyInert
Example of Material Structure
High resistance to aggressive substances.
Low scalping & chemical interaction for Dermal or liquids where the API suffer absorption into the sealant layer.
Replacement / alternative to discontinued Barex.
Polyinert sealant layerPolyinert sealant layer
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Easy-openingEasy-opening
Pharma Segment Drivers impacting Flexible Packaging
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Amcor Key Innovation AreasMacro Trends Implications for Packaging
Changing demographics:Aging population; rapid growth of middle classes in emerging regions; global mobility
Uncertain Future:Increasing cost pressure on healthcare systems
Personal Wellbeing:Higher expecations on health, safety and efficacy of drugs
Education:Increased understanding of health issues; readiness to seek treatment
Increase usage of multi-dose drugs for aging patients
Convenient packaging for mobile patients
Packaging must be cost-effective
Sustainable and recyclable materials
Packaging used as a differentiator to appeal to patients as consumers
Ease of opening for seniors; protection for children
Increased focus on supply chain security (illegal reimports, counterfeits)
Climate Challenge:Increased interest in environmental sustainability;
Personal Economics:Variable access to health insurance; wide differences in ability to pay for medicines
PATIENT SAFETYAnti-counterfeit measures, improved Child-Resistant/Senior-Friendly packs; focus on Patient Adherence
TOTAL COST OF OWNERSHIPSmaller packs; higher operational output; reduced complexity
SUSTAINABLE PACKAGINGReduced size and weight; sustainable materials; recyclability
DIFFERENTIATIONDrug Delivery Systems; easy open packs; extended shelf life
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