Ljubljana, Slovenia 17th & 18th September 2012 · a.o. Barrier is depending on grafting density...

© Fraunhofer

1

© Fraunhofer

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

© Fraunhofer

2

© Fraunhofer

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

© Fraunhofer

3

© Fraunhofer

Institute Director Prof. Dr. Horst-Christian Langowski Giggenhauser Straße 35 85354 Freising Germany www.ivv.fraunhofer.de


© Fraunhofer

4

© Fraunhofer

Business fields


© Fraunhofer

5

© Fraunhofer

Core Competence Materials Development and Business Field Functional Materials


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

© Fraunhofer

6

© Fraunhofer

Introduction to Food Packaging

Containment Protection

Convenience Communication

Functions of Food

Packaging

© Fraunhofer

7

© Fraunhofer


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

© Fraunhofer

8

© Fraunhofer


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, …

© Fraunhofer

9

© Fraunhofer


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

© Fraunhofer

10

© Fraunhofer


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

© Fraunhofer

11

© Fraunhofer


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

© Fraunhofer

12

© Fraunhofer


Source: Pascal Gréverath, Nestlé AG, IVLV-Workshop Sustainability, Freising,

04.12.2008

Packaging can help to minimize food losses!

Losses in the Food Chain

© Fraunhofer

13

© Fraunhofer

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

© Fraunhofer

14

© Fraunhofer

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!

© Fraunhofer

15

© Fraunhofer

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.


© Fraunhofer

16

© Fraunhofer

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

© Fraunhofer

17

© Fraunhofer

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

© Fraunhofer

18

© Fraunhofer

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

© Fraunhofer

19

© Fraunhofer


Barrier targets and approach of the project FlexPakRenew

© Fraunhofer

20

© Fraunhofer


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

© Fraunhofer

21

© Fraunhofer

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

© Fraunhofer

22

© Fraunhofer

a.o. Barrier is depending on grafting density

Water Oil

PVOH-Layer

Grafted fatty acids

Barrier effect

Project: FlexPakRenew - Chemical Grafting

© Fraunhofer

23

© Fraunhofer

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


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.

© Fraunhofer

24

© Fraunhofer

Ungrafted Contact angle < 90° hydrophilic

Grafted Contact angle > 100° hydrophobic


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.

© Fraunhofer

25

© Fraunhofer

46,6

74,9 72,3

101,4 104,1 106,1

0

20

40

60

80

100

120


Co

nta

ct

an

gle

[°]

Ungrafted

Grafted


„… wetability determination by contact angle measurement…“


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.

© Fraunhofer

26

© Fraunhofer

6921017 1046

9254 60

1

10

100

1000

10000


WV

TR

[g

*m

^2*d

]

ungrafted

grafted


8 19 17

Barrier

Improvement

Factor


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.

© Fraunhofer

27

© Fraunhofer

Paper

+

Precoating

+

Problems: Defects and cracks in the inorganic layer

Decreased barrier properties after vacuum coating

Project: FlexPackRenew - Inorganic nanolayers to

improve barrier properties

© Fraunhofer

28

© Fraunhofer

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



© Fraunhofer

29

© Fraunhofer

Back side (BS), magnification of 1000 Front side (FS) (mineral coated side), magnification of 3000



© Fraunhofer

30

© Fraunhofer

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



© Fraunhofer

31

© Fraunhofer

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



© Fraunhofer

32

© Fraunhofer

Results:

OTR and WVTR:

Positive effect of

preconditioning and

remoistening was

proven

Improved barrier

properties after

vacuum coating were

observed



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.

© Fraunhofer

33

© Fraunhofer

Contact Person

Fraunhofer IVV

Materials Development

Giggenhauser Str. 35

85354 Freising

Germany

Markus Schmid, M.Sc.

+49(0)8161/491-526

[email protected]

Thank you for your attention!

Ljubljana, Slovenia 17th & 18th September 2012 · a.o. Barrier is depending on grafting density...

Documents

Transcript of Ljubljana, Slovenia 17th & 18th September 2012 · a.o. Barrier is depending on grafting density...