RECYCLABLE COATINGS

FOR PAPER FOODSERVICE PACKAGING:

FUNCTIONAL & SUSTAINABLE BARRIERS
Islem Yezza, Technical Director

Worldwide food loss: 1.3 billion tons/year

For decades, packaging was seen as nothing but waste, a nuisance to be avoided Packaging waste pales into insignificance compared with the losses caused by food waste One-third of food in developing countries is destroyed before it ever reaches the consumer
Source: United Nations Food and Agriculture Organization (FAO)
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Food packagingcould now move from being the villain to being the hero
Three main messages came across with great importance for food packaging: 1. Packaging prevents food waste and saves resources 2. Packaging is part of the solution for an overall resource efficient economy

3. Packaging facilitates more sustainable lifestyles

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Source: Innventia

Finding the balance between under-packaging and overpackaging is the aim for all of our businesses 4

Outline
1. Sustainable Packaging: Trends and markets 2. Enhancing barrier properties of paper: Why Wax is on the Wane? 3. Extrusion coating:

Conventional resin: PE, PEHD, PP, PET and Nylon Bioplastics: Challenges, Hurdles & Success factors
4. 5. 6. Water-based coating: A bright Future Paper Foodservice Packaging Innovations Wrap-up

Sustainable Packaging
Sustainability is a Shared Responsibility
World demand for green packagingincluding recycled-content, reusable, and degradable packaging is projected to rise 5.7% per year to $212 billion in 2015 (Freedonia, 2011) Eco-conscious Consumer demand for more Sustainable and Convenient packaging Retailers and manufacturers perceive a marketing advantage. Eco-friendly, Green, Bio-based, Compostable & Biodegradable: big selling points Legislation & regulations pushing for innovative ecofriendly packaging Sustainable packaging: Win-Win-Win for the environment, for manufacturers and suppliers, and for consumers

Paper-based Packaging
The Responsible Package

Provides versatile and responsible packaging solutions for product manufacturers, retailers, and consumers Paper has an excellent image as packaging material (renewable, recyclable and biodegradable) Paper packaging accounts for nearly 3/4 of all packaging materials recovered for recycling (The Responsible Package, 2010)

Paper-based Packaging
Improving barrier properties
Improving paper's barrier properties is seen as a crucial step in increasing its viability as a packaging material

The missing performance and barrier properties of paper can be compensated by:

1. 2. 3.

Wax impregnation: curtain, cascaded Extrusion coating: Petro-based resin and Bioplastics Water-based coating

Wax-coated Packaging
Wax is on the Wane

Petroleum-based wax has traditionally been used as a moisture barrier to preserve the strength of a corrugated container holding iced or wet products Waxed paper-based packaging are raising Recyclability, Sustainability and Renewability Concerns

Growers and retailers are looking for alternatives to wax

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Why Wax is on the Wane

Sustainability & Economic Concerns
Wax-coated packaging are not recyclable: wax coatings do not dissolve in water, so they cannot easily be recycled Wax-coated packaging are heavy Paraffin based wax, a non-renewable resources is becoming more expensive

Many leading retailers and grocers, including Wal-Mart and Costco have been demanding an eco- friendly alternative to wax coated boxes from their suppliers

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Wax Alternative
Growing market
The future is clear wax replacement packaging will become a necessity

Opportunities to sharply reduce their landfill costs, while boosting their recycling levels
In 2010, the corrugated industry shipped 6.4 billion square feet of boxes using recyclable wax alternative coatings. Thats over 30% more than the 4.9 billion square feet shipped in 2009 and 385% more than when first measured in 2002, dramatically increasing the volume of containers that could be recycled. (Source: Corrugated Packaging Alliance)
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Wax replacement
Think Outside & Inside the Box
Inside: Products packaging requirements
FDA compliant, moisture and gas barrier, water repellence, grease and oil barrier, meat release

Outside: Environmental considerations

Storage and handling conditions, Printing, glueability, scealbility, scuff resistance, water resistance, anti-slip, anti-abrasive, heat resistance, high gloss or matte
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Extrusion Coating
PE, PP and HDPE
Extrusion coating allows processing a variety of polymers and board Paper and paperboard (SBS, CCNB, Bending Chipboard, Liner) LDPE - most widely used material for extrusion coating applications: easy to process, provides adequate moisture barrier, has excellent sealing properties, grease resistance and lamination layer and cost competitive PP and HDPE

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Extrusion Coating
Hygroscopic Resin

Hygroscopic resin consume more torque than the standard olefin resin: Low shear (low speed), high torque PET coated paperboard: Thermoformed paper-based trays, Ovenable/Microwavable paper-based trays/folding carton Nylon coated paperboard: Corrugated box (pass through the corrugators) PLA coated paperboard: Compostable Paper-based bags, Takeout box

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Bioplastic
Sustainable and Functional

LDPE: Shortage and Price increase Biopolastcis can be used as barrier coatings

The bioplastic Market in 2010 was 771 million pounds. This is expected to reach nearly 932 million pounds in 2011 and then further increase to 2.5 billion pounds in 2016, at a CAGR of 22% for the 5-year period (BBC Research 2011)
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Bioplastic
Confusion in terminology

Biopolymers are plastics that are biodegradable/ compostable and/or have bio-based content Biomass based biodegradable plastics are not always

Biodegradable plastics are not always biomassbased

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Biodegradable/Compostable/Biobased
Distinctions are subtle but significant
All biodegradable material are not compostable
Biobased not necessarily compostable Biobased: Focus is on the origin of life or where did the carbon come from (ASTM D6866). Uses C14 content measurement Compostable: Focus is on end of life or disposal. Independent of carbon source standards (EN13432 and ASTM D6400)
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Bioplastics
Challenges & Hurdles

1.

Confusion in terminology: Biobased, Compostable, biodegradable, Oxo? Education is needed to clarify in the minds of consumers and clients, the environmental benefits of these new materials End of life hurdles: the puzzle? Consumers are confused when it comes to separating biodegradable, compostable and recyclable plastics. Information about how to best dispose of it, is necessary Carbon footprint: bioplastics not necessarily greener than oil based relatives? Skeptics about LCA studies: data may not be accurate or complete and system boundaries are not easily defined 18

2.

3.

Bioplastics
Challenges & Hurdles

4.

Price: Current prices for bioplastics are significantly higher than the cost of PE People are environmentally conscious when its convenient and affordable Higher oil prices are lowering the gap in prices of bioplastics and conventional plastics Weak barrier properties: MVTR, OTR, heat resistance, microwavable? Barrier and physical properties may limit applications Blends and compounding Value proposition: Promoting Biobased, Biodegradable or Compostable? Is 19 not yet clear in the minds of most consumers and clients

5.

6.

Renewability and sustainability

Effect on food scarcity
Renewability and sustainability of bioplastics are questioned? Bio-resins are made from crops that would otherwise be used for food
At full capacity, PLA will take 0.15% of the total corn for grain production in the USA This cannot be considered to have an effect on food scarcity, especially when compared to bio-fuels: No impact on the food supply The raw material for bio-plastic production is plant starch. With technological developments, soon the starch will be taken from any biomass or crop waste and not the crop parts used in food production: Triticale very promising
(Source: London Biopackaging, Bioplastics Magazine, Cargill Dow)

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Bio-resin extrusion coating

Expectations
1. 2. 3. 4. 5. Compostable and/or bio-based resin Good adhesion Comparable barrier to PE High water and oil resistance (MVTR, oil & grease resistance) Cost-effective

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Bio-resin extrusion coating

Processing Challenges: Screw & Dryer
Bio-resin could not be processed at existing PE screw: Stability is poor, melt temperature are too high, and the available torque is inadequate

1. Bio-resins consume more torque than the standard olefin resin: Low shear (low speed), high torque New screw 2. Bio-resins are very hygroscopic. Hygroscopic materials absorb water, even from the air: In-line drying is essential Dryers

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Bio-resin extrusion coating

Market education
1.
2.

Biopolymer-coating: sustainable and functional barrier

Bio-resin extrusion coating: dedicated screw and dryers

3.

Trends: volatile oil prices; energy security concerns; environmental benefits; favourable regulatory initiatives; and the improving performance and competitiveness The distinctions are subtle but significant: not all bioplastics are created equal and there are a lot of misleading claims out there
Education: has to be a combined effort from resin makers, converters and the companies that will be selling these products to the consumer

4.
5.
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Water-based coatings
Repulpability, an Important Route to Sustainability
With the push towards sustainability, repulpability and recyclability, water-based technologies are gaining acceptance

The packaging combines the best aspects of two materials: environmentally friendly paperboard and good barrier properties of water-based coatings
Sustainable and Functional barrier: can be customformulated to meet the packaging requirements of a wide range of products - Can be recycled, repulped and/or composted Alternative solution to current wax, PE extrusion coating and film lamination
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Water-based Coatings
Basic Formulation
Latex (as binder, other polymer can also be used) Mica (pigment, like rocks to achieve moisture barrier) Clay (second filler, can also be Talc, calcium carbonate) Dispersant (for processing) Defoamer pH control agent Talc

Mica

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Water-based Coatings
SEM Image

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Source: Claude Tremblay, Cascades

Water-based coatings
Tailored solutions
Water-based coatings can be custom-formulated to meet the packaging requirements of a wide range of products

1. 2.
3.
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Barrier properties : Moisture - Oil and grease barrier Physical & Chemical properties : Scuff resistance, anti-slip, non-abrasive, stacking strength, corrosion inhibitor, heat sealing, conductive & anti-static). Aesthetic & decorative : color coatings

Water-based Barrier
A Balancing Act
There are always exceptions, but
Greater heat sealability = more blocking Higher coating water retention = poorer water barrier effectiveness

Higher water barrier = poorer cold glueability

Higher oil resistance = poorer hot melt adhesion Higher effectiveness = higher cost
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To-Go containers
Grease and Moisture Barrier

Replace not easily Recyclable and Non Renewable EPS containers

Packaging Requirements: Moisture barrier, grease barrier, heat resistance,

microwavable, Gluable. FDA compliant, Compostable/recyclable/Repulpable 29

Corrugated Boxes
Produce, meat, poultry and Fish

Replace not easily recyclable waxed box and Petro-plastic film laminated board

Packaging Requirements: Avoid water wicking inside the linerboard, Endure both
packing house and transport conditions, FDA compliant, withstands Corrugating 30 process heat up to 375F/190C, Recyclable/Repulpable

Folding Boxes
Dry and fatty foods

Replace not easily recyclable Petro-plastic film laminated board/eliminates bags

Packaging Requirements: Prevent Caking and moisture picking, Grease-resistant

linerboard, Holds up to hot-melt glue and cold set adhesives, FDA compliant, 31 Recyclable and Repulpable

Food waste bags

Functional, Repulpable and Compostable

Replace Petro-plastic film laminated paper and plastic bags

Packaging Requirements: Leak proof, Odour proof, Grease barrier, Sealable,

Recyclable, Repulpable and Compostable 32

Thermoformed paper trays

Functional and sustainable

Alternative to the traditional Styrofoam trays, PET microwavable trays and others plastic trays and plates

Packaging Requirements: Leak proof, Grease barrier, FDA compliant,

microwavable, Recyclable, Repulpable and Compostable 33

Mater-Bi Coated Paperboard (Italy)

Compostable folded tray

Italian organic products distributor Ecor, together with Italian bioplastics maker Novamont and agricultural group Filogea, has developed a new 100% home compostable folded tray for readyto-eat washed salads

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Sliced meat (UK)

Flextrus Paperlite
Marks & Spencer has launched sliced meat in paper packaging Paperlite material is paper with high stretchability, which can be formed in existing thermoforming lines without requiring costly investments Coextrusion coating of PE/EVOH/PE The EVOH provides the O2 barrier properties needed for the MAP Material printed black, which is done for aesthetic reasons
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Walki Lids (Sweden)

Durable & Recyclable

Replace aluminum-based lids

The extrusion coated paper-based lid is durable, easy to print on and can be cut into different sizes and shapes

In 2010 growth was at 25% and this year sales are expected to increase by some 15-20%

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Tecta Paperboard (Finland)

Eco-friendly alternative to plastics
Coated Tecta paperboard offers a good resistance against water, water vapour and grease Replace plastic in many applications: Repulpable, recyclable and compostable sandwich packaging

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Boxerchips (Ireland)
Box-in-bag: Innovative Crisp Packaging
Delivers the same volume of product as a standard 40g bag of crisps, but the compact arrangement allows for an overall reduction in size by as much as 50% and dramatically crunches the amount of packaging materials used by 35% The 40 grams product is currently available on 17 European airlines, with 4 million boxes being sold last year

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Wrap-up
Keep the Molecule in Play
Major companies are beginning to take note and a few have stepped forward to lead the sustainable packaging revolution Market drivers: Increased focus on recyclability and Increased demand for sustainability

Innovative paper-based packaging offers environmental, convenience, food safety and preservation and economics benefits for both customers and packaging actors Both the packaging industry and consumers need to work together to develop a unified set of standards that will end confusion and maintain transparency in the rapidly growing sustainability sector.
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Wrap-up
Functionality & Sustainability
Divert from landfill is sustainable, but we must keep in mind the packaging basic functions: Protect Inform Contain Transport Preserve Display Wax-coated papers are usually overkill and packaging specs are frequently unknown

In order to offer custom-formulated wax alternatives, we need to better understand customer specific needs and packaging requirements (see Check List)

At the end of the day: How might we help our customer make more money?
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Thank you
Sustainable Biobased Recyclable Compostable Quality Green Practical Functional Safety Reliable Smart Performance
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Contact Information:
Islem Yezza, Technical Director Email: Islem_yezza@cascades.com Tel: 819 352-0817