Assignment on Specialty Plastics

Finding suitable Polymer for drink

cups and beverage manufacturing
Mesele Sisay (Arcada)

Contents
1 Introduction:................................................................................................................ 3
2 Material Selection Guidelines...................................................................................... 3
2.1 Polyolefins and Copolymers................................................................................... 4
2.1.1. Polyethylene.................................................................................................. 4
2.1.2. Polyethylene Naphthalate.............................................................................. 4
2.1.3 Polypropylene.................................................................................................. 4
2.2 Polymethyl Pentene............................................................................................... 5
2.3 Ethylene-vinyl Acetate Copolymers....................................................................... 5
2.4 Ionomers............................................................................................................... 5
2.5 Vinyl Plastics and Vinyl Copolymers...................................................................... 5
3. Conclusion.................................................................................................................. 5
4 Reference.................................................................................................................... 6

SPECIALITY PLASTICS

Plastics selection for drinking cup and Beer bottles

Objectives:
The main objective of this literature is to find out the most suitable plastic
polymer used to manufacture drinking cups either water or other liquid
products and beer bottle productions. The search will compare and analyse
different kinds of polymers depending on their chemical

constituents, their

thermal behavior, physical and other properties to be considered from health

safety points of view.

1 Introduction:
Plastics are now being used on a large scale for the packaging of fatty and
aqueous

foodstuffs and beverages, both alcoholic and non-alcoholic. This is

evident for all to see on the supermarket shelves, namely margarine packed in
polystyrene tubs, wine and beer in PVC bottles and meats and bacon in shrinkwrap film. As well as at the point of sale, foods are increasingly being shipped
in bulk in plastic containers. Additionally, there is the area of use of plastics
utensils, containers and processing equipment in the home and during bulk
preparation of food in producing factories,
at home and in restaurants and canteens. Contact between plastics packaged
commodities also occurs in the products of the pharmaceutical and cosmetics
industries and similar considerations apply to these where direct contact occurs
between the packed commodity and the container, this
is likely that some transfer will occur of polymer additives, adventitious
impurities such as monomers, oligomers, catalyst remnants and residual
polymerisation solvents and of low molecular weight polymer fractions from the
plastic into the packaged material with the consequent risk of a toxic hazard to
the consumer. This would result during the service time of the material, i.e
during packaging operations and during the shelf life of the packaged
commodity [1].

2 Material Selection Guidelines

To select the best material for an application, first, compare the different
properties and processing characteristics of several plastic resins that may
meet the application requirements. Product designers must make their resin
selection based on other important characteristics of the application such as
product design geometry effects caused by weld lines; stress concentrations, fi
berglass orientation, temperature, humidity and creep; problems caused by

mold design, construction, quality, and plastic material property variations; and
molding process problems [2].
Generally, most resins have different performance characteristics that could
create molding problems and/or part failures.. The economics involved in
plastic resin selection are complex, because the resin price is not usually the
most important factor. When a plastic resin is used for injection molding a close
dimensional tolerance end product, the following engineering requirements are
essential in reducing manufacturing costs: Part geometry needs to be designed
to produce molded components with maximum productivity.
This literarature asses the best polymer materials that can be used to produce
drinking cups and possible beer bottle manufacturing , based on chemical
inertness and safety from health issues

perspectives.

In this Analysis, the types of plastics that are being used in these applications
are
briefly reviewed. The variants of these polymers such as copolymers and
blends are
discussed together with a brief general discussion of the properties of the
polymers
which are most relevant from the point of view of their use in applications
involving
contact with food.

2.1 Polyolefins and Copolymers

2.1.1. Polyethylene

There are two distinct forms of polyethylene, namely low-density (high pressure
synthesis) and high-density (low pressure synthesis, e.g., the Ziegler route).
Also available are a range of copolymers of intermediate density made by

either blending or by the copolymerisation of ethylene with other olefins such

as propene, butane or hexane [6].
The density range for polymers produced by the low pressure route is about
0.945 to 0.965 g/cm3, whereas the high pressure process produces material
with densities between 0.918 and 0.935 g/cm3. Crystallinities are also different
for the two types of polyethylene. The high-density polyethylene (HDPE) with
its linear structure favours parallel configuration of the chains and hence a high
degree of crystallinity (75-90%). The low-density polyethylene (LDPE) has
appreciable
chain branching which disturbs the regularity of the arrangement of atoms and
hence produces a low degree of crystallinity (55-70%) [7].
The greater linearity of HDPE also increases the softening point of this grade
relative to that of LDPE.
This in turn increases the flex resistance of the high-density polymer. Due to its
high softening point, HDPE unlike the LDPE can be steam sterilised, a property
which is of importance in the food packaging field. Both forms of polyethylene
are fairly inert chemically and are not attacked by solvents at temperatures up
to 60 C. However, they do absorb certain hydrocarbon solvents with swelling
at room temperature. The HDPE is more resistant in this respect. Both types of
polymers are resistant to water and salt solutions and water absorption is
negligible at room temperature. Water vapour permeability is fairly low in the
HDPE, as would be expected due to its lower permeability. Gas permeabilities
are not particularly low, and LDPE, in particular, is not to be recommended as
an oxygen barrier, i.e., it would not be used for the packaging of types of foods
where oxygen ingress is undesirable. Water and oxygen permeabilities have
important implications in the consideration of these polymers as food
packaging materials [1].
Both HDPE and LDPE exhibit the phenomenon of environmental stress cracking.
This can occur when the material is multiaxially stressed when in contact with
certain polar liquids or vapours. These liquids need not be solvents for
polyethylene or even be more than slightly absorbed by it, and if the polymer is
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unstrained, (i.e., no moulding strains) no cracking occurs, no matter how long

the contact time with the liquids. Environmental stress cracking has
implications in the food packaging field as certain foodstuffs, such as vegetable
oils and alcoholic beverages can act as stress cracking agents [3]
Various types of additives can occur in polyethylene used in food packaging.
These include, pigments, carbon black (for ultraviolet light resistance), slip
additives (e.g., silica) to lower coefficient of friction of film and improve the rate
of movement of film through printing and wrapping equipment, antistatic
additives (to reduce dust attraction caused by build up of static changes),
antiblock additives (used in film grades used for the manufacture of bags in
order to overcome difficulties in separating them from a pile) and also to
facilitate rapid opening of the bags on automatic filling equipment, and
antioxidants (to prevent degradation during processing and during service life
of the article). Food contact applications include the household use of
polyethylene bags for storing food, especially in the refrigerator, or freezer,
polyethylene coated cartons for frozen foods, bags for pre-packed fresh
produce and bags for frozen poultry and hams. Blow moulded polyethylene
containers are used for the packaging of table salt and sauces. In the injection
moulding field, however, LDPE and HDPE are used in many types of food
containers, particularly as closures and dispensers. Another very large use is in
pots, tubs, beakers and bowls used as food storage containers. There is also an
increasing use of extruded LDPE pipe for domestic cold water supplies.
2.1.2. Polyethylene Naphthalate

This is a relatively new polymer that has good barrier properties and which has
been used in the packaging of olive oil. It is alos ideal for making amber
coloured bottles suitable for packaging drinks such as beer. It can also be used
for the manaufacture of high-performance fibres that have very high modulus
and better dimensional stability than polyester or polyamide.
2.1.3 Polypropylene

Polypropylene manufactured by the low pressure route gives a polymer which

is largely isotactic (pendant methyl groups all on same side of carbon
backbone). The crystallinity of low pressure polypropylene at 65 to 70% is

somewhat

lower

than

that

of

HDPE

[6].

Polypropylene,

unlike

the

polyethylenes, is not subject to environmental stress cracking, which gives it an

advantage in the food packaging field. It also has a lower density (0.90 g/cm3)
than either LDPE or HDPE. Although the impact strength of polypropylene is
lower than that of HDPE, especially at temperatures below 0 C,this can be
improved by incorporating various synthetic rubbers into polypropylene or by
co-polymerisation with ethylene and propylene [4].
Two important properties of polypropylene are its resiliance and its resistance
to fatigue by flexing. This makes it a suitable material for molding screw cap
closures used extensively in food and beverage packaging. A thin section
diaphragm or fin is mounded into the inner surface of the closure in such a
position that it bears down on the upper surface of the bottle neck. A rigid
material would not have enough give to take up imperfections in the glass
surface and so would not form as good a seal.
On the other hand, a more flexible material, such as LDPE, would give but
would not press back strongly enough to form a seal. The good fatigue
resistance of popypropylene is utilised in the manufacture of snap fit lid food
and beverage containers.
Injection moulded polypropylene is used extensively in the manufacture of food
storage containers either thick walled or thin walled. Polypropylene, due to its
higher softening point when compared to polyethylene, is useful in food
packaging

applications

where

hot

filling

temperatures

are

involved.

Polypropylene film is used extensively in food packaging applications because

of its low water vapour and oxygen permeabilities.
Examples include: biscuits, potato crisps and snack foods. Animal feeding stuffs
are
packed in polypropylene woven sacks, as are grains, sugar and vegetables, this
shows ideal material for packaging drinks and waters from cold to hot state.

2.2 Polymethyl Pentene

This is a polymer of 4-methyl-1-pentene and is better known as TPX (Mistsui
Chemicals). It is a low specific gravity (0.83 g/cm3) polymer of high clarity and
softening point. It is still rather expensive. It has a lower impact strength and a
very much higher permeability to gas and water vapour than either
polyethylene or polypropylene. It is highly resistant to aqueous salt solutions,
acids, alkalies and organic solvents. It is subject to environmental stress
cracking. One of its few applications in which it comes into contact with food is
as a coating on trays used in bakery ovens. In general, its outstanding
properties compared to the other polyolefins are resistance to hot fillings and
outstanding clarity[1,6].

2.3 Ethylene-vinyl Acetate Copolymers

These polymers are very similar to LDPE in many of their characteristics. They
are more transparent than polyethylene and have a high flexibility and impact
resistance and good resilience. These polymers have a high permeability to
water vapour and gases and are rather more susceptible to oil/hydrocarbon
attack than is LDPE. When made into film, ethylene-vinyl acetate has a greater
tendency towards blocking than LDPE and consequently it is necessary to
incorporate a rather high percentage of antiblocking additive [1].
Applications are mainly in the fields where flexibility and resilience are useful,
particularly at low temperatures. This makes these copolymers attractive, for
example, for the stretch wrapping of deep frozen poultry in which application
they require a close contour wrap of the bird.

2.4 Ionomers
The only ionomer produced in commercial quantities is produced under the
trade name Surlyn A by DuPont [8]. Ionomers are in effect ionic polymers which
are solid at normal temperatures but which soften as do thermoplastics, upon
heating. Surlyn A is basically a polymer of ethylene containing carboxylate
groups and which is similar in many ways to LDPE. The ionic forces, due to the
carboxylate groups give it a high melt strength so that it has excellent drawing
characteristics.

Surlyn A is useful as an extrusion material and very thin

coatings with a low neck-in can be obtained. Skin packaging is another

application with obvious attractions in the food packaging industry. It is

resistant to strong and weak alkalies and is slowly attacked by acids .
It is resistant to alcohol but swells in contact with oils and hydrocarbons. It is
however, more resistant to oils than LDPE and has in fact been used for the
packaging of olive oil [1,8].

2.5 Vinyl Plastics and Vinyl Copolymers

Polyvinylchloride (PVC) is much less crystalline than the polyolefins. The base
polymer is very hard and for most applications it has to be plasticised to make
it flexible enough for use. There are many plasticisers available for PVC.
Food contact applications, of course, impose their own requirements of intrinsic
safety and low migration rate of the plasticiser. Due to the nearness of its
decomposition and processing temperatures, PVC has to be stabilised against
heat by the addition of 1-2% of heat stabiliser and this, in turn, has food
contact implications.
PVC has a density of about 1.4 g/cm3 which makes it appreciably denser than
any of the unchlorinated polyolefins. It is resistant to alcohol and to many fats
and this encourages its applications in the packaging of wine, beer, and fatty
foods [6].
For food contact uses PVC usually has a low plasticiser content in which form it
has good rigidity and can be moulded into sections and film down to 75 mm
thick. It has the merit of clarity, which is useful in many food uses. PVC film can
be thermoformed into various packages including tubs, trays for foodstuffs,
inserts for chocolate boxes and biscuit tins and other confectioneries. Very thin
film is used for shrink wrapping of prepackaged meat, fruit and vegetables. PVC
bottles are increasingly being used for the packing of foodstuffs and alcoholic
beverages, including wine and beer. It is used extensively in the UK for the
packaging of fruit squashes and to some extent for edible cooking oils. PVC can
be fabricated into jars suitable for the packaging of coffee and chocolate drinks
[1].

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PVC is also copolymerised with other monomers such as vinyl acetate,

vinylidene chloride propylene and acrylonitrile. Copolymerisation with vinyl
acetate tends to soften the polymer to the point that plasticiser addition may
be unnecessary. For low temperature applications, plasticiser addition may still
be desirable and in this form the copolymer is used in the fabrication of
refrigerator trays. Vinyl chloride - vinylidene chloride copolymers are used for
the manufacture of films which have a very low permeability to water vapour
and gases. Such film is used for wrapping cheese and other commodities which
require the absence of oxygen for their preservation. Vinyl chloride - vinylidene
chloride is also applied as a coating to improve the barrier properties of other
food packaging materials such as paper, polypropylene and cellulose film [3].
Propylene - vinyl chloride copolymers are used mainly as bottle blowing
materials. Copolymers of vinyl chloride and acrylonitrile have no food
packaging applications.

3. Conclusion
According to the literature findings, polyethylene and polypropylene and their
derivatives are good selection polymers toward health perspective points of
views. Their mechanical and thermal stability properties are important from
cold to hot fluid career. Additionally these materials are chemical inert than the
other most polymers do, and they have strong additive barrier capability, so
diffusions of unwanted chemical are inhibited. They are also good in design and
manufacturing process, good dimensional stability, and good tolerance are the
most significant characteristics they can offer.

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4 Reference
[1]. T.R Crompton, Additive migration from plastics into foods, A guide to
analytical chemists, Smithers Rapra Technology (2007).
[2].Plastics design Guide,
[3]. Aravnitoyannis I.S. & Bosnea L ,Migration of substances from food packaging
materials to foods (2004).
[4]. www.wikipedia.com
[5]. Jose Maria Lagaron,Maria Jose Ocio,Amparo Lopez-Rubio , Antimicrobial
Polymers.
[6]. Polymer Handbook
[7]. Richard Coles,Mark J. Kirwan , Food and Beverage Packaging Technology
[8]. http://www2.dupont.com/Packaging_Resins/en_US/index.html

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