Multilayer Flexible Packaging

Part I: Introduction

1. Introduction

• Abstract
• 1.1 Materials: A Historical Perspective
• 1.2 Markets: A Global Economy
• 1.3 Processes, Materials, Needs
• 1.4 Materials and Barrier
• 1.5 Materials and Sealing
• 1.6 Bringing Things Together
• References

Part II: Resins

2. Polyethylene

• Abstract
• 2.1 Introduction
• 2.2 Polyethylene History and Basic Characterization
• 2.3 Melt Index
• 2.4 Density
• 2.5 Gel Permeation Chromatography
• 2.6 Low-Density Polyethylene
• 2.7 Free Radical Polymerization Processes
• 2.8 Autoclave Reactor
• 2.9 Tubular Reactor
• 2.10 Polar Ethylene Copolymers
• 2.11 Low-Pressure Polymerization Processes
• 2.12 Gas-Phase Process
• 2.13 Solution Process
• 2.14 Slurry Processes
• 2.15 Catalyst Chemistry
• 2.16 Chrome Oxide–Based Catalyst
• 2.17 Single-Site (Metallocene) catalyzed Polyethylene
• 2.18 Tie Chain Molecules
• 2.19 Summary
• Acknowledgment
• References

3. Polypropylene

• Abstract
• 3.1 Managerial Overview
• 3.2 Summary
• References

4. Introduction to Bio-Based Polymers

• Abstract
• 4.1 Commercially Important Novel Biopolymer
• References

5. Additives to Design and Improve the Performance of Multilayer Flexible Packaging

• Abstract
• 5.1 Introduction
• 5.2 Overview
• 5.3 Additive Handling, Addition, and Dosing
• 5.4 Additive Types and Principal Mode of Action
• 5.5 Suppliers and Contacts
• Appendix 5.1
• Appendix 5.2
• References

6. Rheology of Molten Polymers

• Abstract
• 6.1 Introduction
• 6.2 Viscosity and Melt Flow Index
• 6.3 Mathematical Relations
• 6.4 Extensional Viscosity and Melt Strength
• 6.5 Normal Stress Differences and Extrudate Swell
• 6.6 Stress Relaxation and Dynamic Measurements
• 6.7 Constitutive Equations
• 6.8 Sharkskin, Melt Fracture, and Die Lip Buildup
• 6.9 Rheological Problems in Coextrusion
• 6.10 Rheology of Filled Polymers
• 6.11 Rheology of Nanocomposites
• 6.12 Rheometers
• 6.13 Concluding Remarks
• References

Part III: Technologies

7. Coextrusion Equipment for Multilayer Flat Films and Sheets

• Abstract
• 7.1 Designing and Manufacturing Multilayer Flexible Plastic Films with Multilayer Coextrusion Die Technology
• 7.2 Summary
• References

8. Multilayer Blown (Tubular) Film Dies

• Abstract
• 8.1 Introduction
• 8.2 Conventional Coextrusion Dies
• 8.3 Stacked Dies
• 8.4 Interfacial Instability
• References

9. Process Engineering

• Abstract
• 9.1 Managerial Summary
• 9.2 Process Engineering: What Is It and Why Is It Essential?
• 9.3 Some Process Engineer Tools
• 9.4 Examples of How Process Engineers Can Save Time and Money
• 9.5 Conclusion

10. Blown Film, Cast Film, and Lamination Processes

• Abstract
• 10.1 Blown Film
• 10.2 Cast Film
• 10.3 Extrusion Coating and Lamination
• References

11. Machine Direction–Oriented Film Technology

• Abstract
• 11.1 Managerial Summary
• 11.2 Description of MDO Hardware and Technology
• 11.3 How a Machine Direction Orientor Works
• 11.4 The Process and Its Effect on the Film
• 11.5 Properties of MD-Oriented Films
• 11.6 Summary
• References

12. Oriented Film Technology

• Abstract
• 12.1 Introduction
• 12.2 Orienting Technologies
• 12.3 Oriented Film Types—Applications
• 12.4 Trends for Oriented Films
• References

13. Polymer Blending for Packaging Applications

• Abstract
• 13.1 Introduction
• 13.2 Why Blend?
• 13.3 Blending Processes
• 13.4 Physics of Blending
• 13.5 Morphology Development in Blown Film
• 13.6 Dispersion of Rigid Particles and Nanocomposites
• 13.7 Rheology of Polymer Blends
• 13.8 Conclusion
• References

14. Water- and Solvent-Based Coating Technology

• Abstract
• 14.1 Introduction
• 14.2 Coating Structures
• 14.3 Web-Coating Machine Hardware and Functions
• 14.4 Coating Applicators
• 14.5 Effect of Solvent
• 14.6 Hot Melt Coaters
• 14.7 Selecting a Coating Method
• 14.8 Drying and Solidification
• References

15. Vacuum Metallizing for Flexible Packaging

• Abstract
• 15.1 Introduction
• 15.2 Decorative Coatings
• 15.3 Barrier Coatings
• 15.4 Functional Coatings
• 15.5 Security Applications
• 15.6 Metallization Basics
• 15.7 Pattern Metallization
• 15.8 Trends
• 15.9 Summary
• References

16. Web Handling and Winding

• Abstract
• 16.1 Web Handling Essentials
• 16.2 Rollers
• 16.3 Tension Control
• 16.4 Nip Control
• 16.5 Temperature Control
• 16.6 Guiding and Path Control
• 16.7 Wrinkles and Spreading
• 16.8 A Word About Slitting and Other Converting Processes
• 16.9 Winding Is Essential
• 16.10 Winding Tightness and the TNT’s
• 16.11 Winding Classes and Arrangements
• 16.12 Theory Applied
• 16.13 Other Common Wound Roll Defects
• References

Part IV: Multilayer Films – Descriptions, Performance Characteristics, Uses, Considerations, Properties

17. PE-Based Multilayer Film Structures

• Abstract
• 17.1 Introduction
• 17.2 Polymer Selection
• 17.3 Mechanical Properties
• 17.4 Barrier Properties
• 17.5 Polymer Sealability
• 17.6 Adhesive Polymers
• 17.7 Applications for Flexible Packaging Film Structures
• 17.8 Summary
• References

18. Multilayer-Oriented Films

• Abstract
• 18.1 Introduction
• 18.2 Technology for Multilayer-Oriented Films
• 18.3 Structures
• 18.4 Trends for Multilayer-Oriented Films

19. Regulatory Aspects of Food Packaging—A Global Matter

• Abstract
• 19.1 Introduction
• 19.2 Determining the Regulatory Status of Components of a Food-Contact Material in the United States
• 19.3 Regulatory Report: FDA’s FCS Notification Program
• 19.4 Preservation of Foods by Irradiation
• 19.5 Regulatory Aspects of Recycled Plastics—US FDA View
• 19.6 EU Legislation on Food-Contact Plastics
• 19.7 EU Legislation for Recycled Plastics
• Acknowledgment
• References