Multilayer Flexible Packaging

1. Multilayer Flexible Packaging An ecofriendly packaging option

2. Popular Packaging materials used • Polyethylene, Polypropylene and PET are the main polymers used in flexible packaging. • These polymers are approved by international as well as national regulatory bodies for use in food contact as well as medical applications. • Polyethylene is being used in Ampoules used for vaccination in WHO approved projects.

3. National & International Regulations • IS 10141 Positive list of constituents of polyethylene in contact with foodstuffs, Pharmaceuticals and drinking water • IS 10146 Polyethylene for its safe use in contact with foodstuffs, pharmaceuticals and drinking water • IS 10909 Positive list of constituents of polypropylene and its copolymers in contact with foodstuffs, pharmaceuticals and drinking water • IS 10910 Polypropylene and its copolymers for its safe use in contact with foodstuffs, pharmaceuticals and drinking water • IS 12252 PET & PBT for safe use in contact with Food stuffs, Pharma & Drinking Water • IS 10171 Guidelines of suitability of Plastics for food packaging • IS 13601:1993 Ethylene vinyl acetate (EVA) copolymers for its safe use in contact with foodstuffs, pharmaceuticals and drinking water • US FDA CFR 21 Code of Federal Regulations that govern Food and Drug • EU 10/2011 Union Guidelines on Regulation (EU) No 10/2011 on plastic materials and articles intended to come into contact with food • EU European Pharmacopoeia, 4th edition (2002), Supplement 7 (2004) Monograph 3.1.3. Polyolefin • Monograph 3.1.4. Polyethylene without additives for containers for preparations for parenteral use and for ophthalmic preparations

4. Flexible Packaging : Advantages Flexible Packaging material is consisting of films or laminates - a combination of layers of film, Alu Foil & Paper bonded together using adhesives Following performance is expected : –        To deliver items, food, contents to the end user/consumer in the intended quality –        To provide required shelf life –        To deliver safely –        Convenience & ease of use Advantages • ~40% Less packaging materials • Less Storage Space required • ~50% Less solid waste • Improved worker safety • Lower shipping cost • Ease in transportation • ~60% Reduction in GHG and ~70% reduction in energyconsumption

5. Common structures used in Multilayer Packaging

6. Flexible packaging – Materials with thickness range Various types of Packaging materials PE – 20 to 150 micron PET -- 8, 10, 12 micron BOPP -- 12 to 30 micron BOPA – 12 to 15 micron Met PET – 10, 12 micron Met BOPP -- 15 to 30 micron AluFoil – 6.35 to 12 micron CPP – 20 to 70 micron Paper – Maplitho, Glassine, Kraft

7. Case Study – Beverage Packaging • The flexible beverage pouch consumes half the amount of energy compared to the closest alternative. • The flexible beverage pouch generates 75% less emissions than the closest alternative. • Stand-up flexible pouches significantly reduce greenhouse gases released and energy consumed during the transport of unfilled packaging from packaging converter to filling operation. Source: Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for the FPA by Battelle Memorial Institute.

8. Case Study – Raisins Packaging • Stand-up flexible pouches are 37% less by weight compared to bag-in-a-box packaging. • Per 100 g of product, bag-in-a-box packaging produces approximately 3 times more MSW than stand-up pouches. • A flexible pouch consumes about 54% less energy over its life cycle than the next most efficient package. • Energy consumption during transportation is significantly less for flexible packaging than alternatives. Source: Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for the FPA by Battelle Memorial Institute.

9. Case Study – Parcel Mailer • The flexible pouch consumes approximately 1/3 the energy of the alternative to produce, ship, and use. • The flexible pouch generates approximately 1/2 the CO2 emissions of the alternative. • Recycled paperboard mailers produce 7 times more landfill waste by weight per 100 g of product than HDPE flexible pouch mailers (taking into consideration a 27.3% recovery rate of paperboard). • The flexible pouch mailer uses 1/8 the amount of packaging per 100 g of product vs. the paperboard mailer. Source: Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for the FPA by Battelle Memorial Institute.

10. Case Study – Multi-unit packaging Flexible collation shrink wrap packaging reduces product shift in transit, decreasing breakage and/or product waste. • The flexible shrink wrap consumes 35% less energy than the alternative. • Compared to paperboard folding containers (such as in this study), flexible shrink wrap provides an 81% reduction in packaging weight. • Flexible shrink wrap packaging (in this comparison) offers 5 times more product-to-packaging ratio. Source: Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for the FPA by PE Americas

11. Case Study – Coffee packaging • The flexible brick pack generates 75% less emissions than the closest alternative. • The flexible brick pack consumes 1/4 of the energy used by alternate packaging. • The flexible brick pack contains 88% less packaging by weight when compared to metal cans. • The flexible brick pack reduces the weight of waste to landfill by 72% vs. metal cans (taking recycling rates of cans into account).2 • Flexible brick packs use 20% less space in shipping than cans, reducing transportation emissions. Source: Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for the FPA by PE Americas

12. Case Study – Food Service packaging The flexible foodservice pouch eliminates sharp edges and offers dispensing fitments and product visibility. • The flexible foodservice pouch consumes 75% less energy than the metal can. • The flexible foodservice pouch generates 1/10 the CO2 emissions of the metal can. • The flexible pouch is less than 1/10 the packaging weight of the metal can. • Each case of 10 flexible pouches with finished product utilizes 30% less volume than a case of 10 cans. Source: Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for the FPA by PE Americas

13. Lightweight Flexible Packaging improves transportation efficiency

14. Vacuum Metallization Increases Barrier Properties and reduces food waste • Metallization of a plastic substrate makes in a great moisture and air barrier. Applications include food & beverage packaging and medical applications. • One of the most important reasons for using metallized films over the existing clear barrier films is the excellent light barrier which is added to the packaging material by the metal layer which is important for snack packaging. • In the absence of the light barrier, at the level of metallized films, many of our snack foods would be quickly ruined not by the moisture gain or loss (staling) or oxygen gain (oil oxidation giving rancidity) but because the visible and UV light would attack the oils and give an accelerated rancidity reaction.

15. Vacuum Metallizing Process • Vacuum metallizing is a form of physical vapor deposition, a process of combining metal with a plastic substrate through evaporation. • The vacuum metalizing chamber's atmosphere is evacuated to a vacuum level suitable for the evaporation of the aluminum wire. • The evaporation takes place by feeding aluminum onto heated sources or boats, which operate at approximately 1500°C (2700°F). • Upon contact with the substrate being processed, the aluminum vapor condenses and creates a uniform layer of vacuum deposited aluminum and forms a vapor cloud above the boat bed. • As the substrate passes over this active area, a thin layer of aluminum is deposited onto the film, thus creating a barrier layer. • The aluminum coating is measured in angstroms and typically represents less than 0.1 percent of the base film and therefore does not affect the yield or mechanical properties of the base film. • The thickness of vapours deposited is 300 to 400 Angstroms i.e. 0.03 to 0.04 micron • Due to such negligible thickness the aluminum need not be separated from laminate during recycling

16. Vacuum Metallizing Process

17. Flexible Packaging Types

18. Flexible Packaging: Waste Management • All multilayer packaging material is 100% recyclable. • Process and Technology well established across the globe including India. • There are many product gamut which can use recycled plastic material successfully and go in a long life cycle.

19. Products made from recycled plastic

20. Forward Path • Establish efficient collection and segregation system • Develop new range of recycled products • Develop homogeneous structures for easier recycling