GB2539493A - Compostable Laminates - Google Patents

Compostable Laminates Download PDF

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Publication number
GB2539493A
GB2539493A GB1510785.7A GB201510785A GB2539493A GB 2539493 A GB2539493 A GB 2539493A GB 201510785 A GB201510785 A GB 201510785A GB 2539493 A GB2539493 A GB 2539493A
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GB
United Kingdom
Prior art keywords
layer
adhesive
compostable
laminate
discontinuous
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1510785.7A
Other versions
GB201510785D0 (en
Inventor
Shaw Mark
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Parkside Flexibles Europe Ltd
Original Assignee
Parkside Flexibles Europe Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Parkside Flexibles Europe Ltd filed Critical Parkside Flexibles Europe Ltd
Priority to GB1510785.7A priority Critical patent/GB2539493A/en
Publication of GB201510785D0 publication Critical patent/GB201510785D0/en
Priority to PCT/GB2016/051808 priority patent/WO2016203251A1/en
Publication of GB2539493A publication Critical patent/GB2539493A/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B32B23/04—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/716—Degradable
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
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    • B32B2553/00—Packaging equipment or accessories not otherwise provided for

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Abstract

A multi-layer compostable laminate 10 for forming a package comprises a first compostable layer 11, a second compostable layer 12 and a first discontinuous adhesive layer 21 between the first layer and the second layer. The first discontinuous adhesive layer comprises regions of adhesive 22 separated by regions without adhesive 23 to aid compostability of the laminate. The first discontinuous adhesive layer can comprise isolated regions of adhesive fully surrounded by regions without adhesive. The first discontinuous adhesive layer can comprise a pattern of adhesive dots or polygons, wherein individual dots or polygons are each fully surrounded by regions without adhesive. The adhesive in the first discontinuous adhesive layer can have a weight ≤1% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.

Description

LAMINATE FOR FORMING A PACKAGE
Background
There is an increasing requirement to reduce wastage from product packaging.
Laminate packaging materials may be formed into bags, pouches or other types of package and can be used to package products such as foodstuffs, confectionery, household products and tobacco products.
A significant proportion of conventional laminates used to package products comprise layers of plastic material, and can include a metal or a metallised plastic layer as a barrier.
Conventional laminates can require expensive recycling techniques, or may simply be sent directly to landfill sites.
It is desirable that product packaging is compostable by an industrial composting process or by a home composting process as composting can significantly reduce the volume of waste packaging and can be a cheaper form of waste processing compared to other waste processing schemes.
One certification body for compostable packaging is Vingotte, Vingotte operate a certification scheme for industrially compostable packaging under the name "OK Compost" and a certification scheme for home compostable packaging under the name "OK Compost HOME". One of the requirements of these schemes is a limit on non-compostable adhesive as a percentage of total weight of packaging materials of the package. Also, packaging is required to pass a disintegration test within a specified temperature range and disintegration timescale. It has been found difficult to achieve the Vingotte certification, particularly for three-layer (triplex) laminates with two adhesive layers.
There is a requirement for alternative compostable packaging. 25 Summary This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
An aspect of the disclosure provides a multi-layer compostable laminate for forming a package comprising: a first compostable layer; a second compostable layer; a first discontinuous adhesive layer between the first layer and the second layer; wherein the first discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
The discontinuous adhesive layer can provide a bond between the first compostable layer and the second compostable layer which is sufficient to give structural integrity to the laminate while also helping to reduce the total volume of adhesive in the laminate. The spacing of the adhesive regions in the discontinuous adhesive layer can improve the speed of the industrial and home composting processes, as it provides increased exposure of the adhesive to air, bacteria and/or micro-organisms. It also can help to space layers of the laminate and to provide pockets within the laminate material to help assist decomposition.
The adhesive in the first discontinuous adhesive layer may have a weight 51% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
The first discontinuous adhesive layer may comprise isolated regions of adhesive fully surrounded by regions without adhesive.
The first discontinuous adhesive layer may comprise a pattern of adhesive dots or polygons, wherein individual dots or polygons are each fully surrounded by regions without adhesive.
The first discontinuous adhesive layer may comprise a pattern of discontinuous adhesive lines, wherein individual segments of the discontinuous lines are each fully separated by regions without adhesive.
The first discontinuous adhesive layer may comprise a repeating pattern of adhesive regions separated by regions without adhesive.
The multi-layer compostable laminate may further comprise: a third compostable layer; and a second discontinuous adhesive layer between the second layer and the third layer; wherein the second discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
The second discontinuous adhesive layer may be different to the first discontinuous adhesive layer.
The second discontinuous adhesive layer may be different to the first discontinuous adhesive layer in respect of at least one of thickness of the discontinuous adhesive layers; patterns of adhesive regions used in the discontinuous adhesive layers.
The second discontinuous adhesive layer may comprise isolated regions of adhesive fully surrounded by regions without adhesive.
The adhesive in the first discontinuous adhesive layer and the second discontinuous adhesive layer may have a combined weight =1% of total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
The first discontinuous adhesive layer may be a first adhesive and the second discontinuous adhesive layer may be a second adhesive.
The first discontinuous adhesive layer may have a weight =1% of total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate, and the second discontinuous adhesive layer has a weight =1% of total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
The first compostable layer may be a material selected from: paper and cellulose.
The second compostable layer may be a material selected from: cellulose, biopolymer and coextruded biopolymer.
The third compostable layer may be one of: a biopolymer, a co-extruded biopolymer and a compostable sealant web.
The first compostable layer may be paper of maximum weight 50g/m2, the second compostable layer may be cellulose of maximum thickness 25pm and the third compostable layer may be a biopolymer of maximum thickness 50pm.
The first compostable layer may be cellulose of maximum thickness 25pm, the second compostable layer may be cellulose of maximum thickness 25pm and the third compostable layer may be a biopolymer of maximum thickness 55pm.
Another aspect provides a package formed of a laminate.
The adhesive in the first discontinuous adhesive layer of the package may have a weight =1% of a total weight of packaging materials of the package.
The package may comprise a first discontinuous adhesive layer and a second discontinuous adhesive layer wherein the adhesive in the first discontinuous adhesive layer and the second discontinuous adhesive layer has a combined weight =1% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
The multi-layer compostable laminate or the package may meet the requirements for industrial composting under Vingotte OK Compost.
The multi-layer compostable laminate or the package may meet the requirements for home composting under Vingotte OK Compost HOME.
Another aspect provides a method of manufacturing a multi-layer compostable laminate for forming a package comprising: providing a first compostable layer; providing a second compostable layer; forming a first discontinuous adhesive layer between the first compostable layer and the second compostable layer, wherein the first discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
The first discontinuous adhesive layer may be formed such that the adhesive in the first discontinuous adhesive layer is =1% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
The method may further comprise: providing a third compostable layer; forming a second discontinuous adhesive layer between the second layer and the third layer, wherein the second discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
The first discontinuous adhesive layer and the second discontinuous adhesive layers may be formed such that the adhesive in the first discontinuous adhesive layer and the second discontinuous adhesive layer has a combined weight =1% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
The preferred features may be combined as appropriate, as would be apparent to a skilled person, and may be combined with any of the aspects of the invention.
Brief Description of the Drawings
Embodiments of the invention will be described, by way of example, with reference to the following drawings, in which: Figure 1 shows a cross-section through laminate with two layers bonded by a discontinuous adhesive layer; Figures 2A to 2F show plan views of examples of the discontinuous adhesive layer Figure 3 shows a cross-section through laminate with three layers bonded by discontinuous adhesive layers; Figure 4 shows a manufacturing process for a two-layer laminate; Figures 5 to 7 show an example package formed from the laminate of Figures 1 to 3. Common reference numerals are used throughout the figures to indicate similar features.
Detailed Description
Embodiments of the present invention are described below by way of example only. These examples represent the best ways of putting the invention into practice that are currently known to the Applicant although they are not the only ways in which this could be achieved. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.
Figure 1 shows a cross-section through a two-layer laminate 10 having a first layer 11 and a second layer 12. A two-layer laminate is typically called a duplex. An adhesive layer 21 bonds the layers 11, 12 together. Each of the layers 11, 12 is compostable. The term "compostable" means that the material of the layer is biodegradable in a home or industrial composting process. Suitable materials for the layers 11, 12 are: paper, cellulose, biopolymer.
The layers 11, 12 of the laminate can serve different purposes. For example, one of the layers 11, 12 can be a printable layer which is intended to form the outer layer of a package. The printable layer can provide protection against abrasion and can provide a printable surface onto which ink can be deposited to provide product information, graphics, etc. One of the layers 11, 12 can be a sealant layer which is intended to form the inner layer of a package. The sealant layer may form a seal with another surface when it is heated.
During assembly of a package using the laminate, the laminate may be folded and seals can be formed by heating the laminate. One of the layers may have barrier properties against moisture and/or gas. The thickness of the layers 11, 12, can be the same or can be different.
The adhesive layer 21 is discontinuous. The discontinuous adhesive layer 21 comprises regions of adhesive 22 separated by regions 23 without adhesive. The discontinuous adhesive layer 21 has a thickness A. Figures 2A to 2F show some possible examples of the adhesive layer 21 in plan view. In the examples of Figure 2A and 2B the discontinuous adhesive layer 21 comprises a pattern of dots of adhesive 22. Each dot 22 in the pattern is fully surrounded by a region 23 without adhesive. The dots of adhesive 22 have a diameter D1. In the example of Figure 2A, the pattern is a regular grid of dots 22. The spacing (measured between dot centres) of adjacent dots in a row, and between adjacent rows of dots, is a distance 51. In the example of Figure 2B, the pattern is a grid with an offset between adjacent rows of the grid. The spacing, between centres, of adjacent dots in a row is a distance 51. The spacing between adjacent rows (measured between dot centres) is a distance RS1. The (horizontal) offset between dots in adjacent rows is a distance (S1)/2.
The adhesive pattern of the discontinuous adhesive layer 21 can be different to the ones shown in Figures 2A and 2B. For example, the pattern may differ in respect of one or more of the following: -the diameter D1 of the adhesive dots 22 can be increased or decreased; -the spacings S1, RS1 of the adhesive dots 22 can be increased or decreased; -the shape of the adhesive dots 22 can be changed (e.g. triangular, square or other polygon, or an irregular shape).
In one certification scheme, the total weight of adhesive used in a package formed of the laminate can be up to 1% of a total weight of all packaging materials of the package. The total package weight includes any additional components of the package, such as adhesive labels, fixings etc. This limit may apply if the adhesive is of a type which is not compostable. Adhesives may be selected from a list of adhesives specified by a certification body. These adhesives may avoid certain chemicals, such as chemicals which are particularly harmful to the environment.
A certification scheme for compostable laminates may permit up to 5% noncompostable (or non-home compostable) components, with each different non-compostable (or non-home compostable) component up to 1%, e.g. adhesive 1 up to 1%, adhesive 2 up to 1%, inks up to 1%.
In one example, the total weight of adhesive in the adhesive layer 21 of the laminate sheet 10 used to form a package is less than, or equal to, 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate. The adhesive weight can be achieved by a combination of: -adhesive layer thickness A; -adhesive dot diameter D1; -adhesive dot spacing Si; such that the total weight of the adhesive is up to 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate.
In another example, the total weight of adhesive in the adhesive layer 21 of the laminate sheet 10 used to form a package may exceed 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate. One factor which may allow a higher weight of adhesive, above the 1% limit, is the use of a compostable adhesive.
Figure 2C shows another example where the discontinuous adhesive layer 21 comprises a pattern of discontinuous lines of adhesive. Each segment 27 of a line in the pattern is fully surrounded by a region 23 without adhesive. The line segments 27 of adhesive each have a length L1 and thickness T1. Lines are spaced by a distance S2. In the pattern of Figure 2D segments 27 of adjacent discontinuous lines are offset from one another, similar to the dots of Figure 2B.
Figure 2E shows another exam ple where the discontinuous adhesive layer 21 comprises a pattern of continuous lines 28 of adhesive. Each line 28 of adhesive is spaced on each side by a region 23 without adhesive. In Figure 2E the lines are parallel. In other examples, the lines may not be parallel.
Figure 2F shows another example where the discontinuous adhesive layer 21 comprises a grid of lines 29 of adhesive. The grid defines regions 23 without adhesive.
Figures 2A to 2F show examples of repeating patterns which are repeated across the laminate material. This provides a consistent strength across the laminate.
The discontinuous adhesive layer 21 provides a bond between layers 11, 12 which is sufficient to give structural integrity to the laminate (i.e. to prevent layers 11, 12 from delaminating) while reducing the total volume of adhesive in the package. The spacing of the adhesive regions 22, 27 in the discontinuous adhesive layer 21 has been found to improve the speed of the industrial and home composting processes, as it provides increased exposure of the adhesive to air, bacteria and/or micro-organisms. It also helps to space layers of the laminate and to provide pockets (23, Figure 1) within the laminate material to help assist decomposition.
The adhesive used in the discontinuous adhesive layer 21 can be, for example, a water-based adhesive. Other possibilities are solvent-based adhesives, solventless adhesives, hot melt adhesives, UV-curable adhesives or any other adhesive type. Advantageously, the adhesive, or adhesives, may be biodegradable in an industrial or home composting process.
Figure 3 shows a cross-section through a three-layer laminate 30 having a first layer 11, a second layer 12 and a third layer 13. A three-layer laminate is typically called a triplex. An adhesive layer 21 bonds the layers 11, 12 together. An adhesive layer 24 bonds the layers 12, 13 together. Each of the layers 11, 12, 13 is compostable. Suitable materials for the layers are: paper, cellulose, biopolymer.
The layers 11, 12, 13 of the laminate can serve different purposes. Typically, a three-layer laminate comprises a printable layer, a barrier layer and a sealant layer. The barrier layer has barrier properties against moisture and/or gas. For example, it may help to prolong the shelf life of a food product by limiting passage of oxygen and/or moisture. The thickness of the layers 11, 12, 13 can be different.
The adhesive layer 24 is discontinuous. The discontinuous adhesive layer 24 comprises regions of adhesive 25 separated by regions 26 without adhesive. The discontinuous adhesive layer 24 has a thickness B. Adhesive layer 24 can be of different thickness to adhesive layer 21. Adhesive layer 24 can have the same form as shown in any of Figures 2A-2F. For example, it can comprise a pattern of dots of adhesive 25. Each dot 25 in the pattern is fully surrounded by a region 26 without adhesive. The dots of adhesive 25 have a diameter D2. The dots are spaced by a distance S2.
The thickness of the discontinuous adhesive layer 24 can be the same, or different, to the thickness of the discontinuous adhesive layer 21.
The pattern of adhesive used in the discontinuous adhesive layer 24 can be the same, or different, to the pattern used in the discontinuous adhesive layer 21. Where the pattern is the same in layers 21, 24, an offset can be provided between the patterns in layers 21, 24, or the patterns in layers 21, 24, can be in register.
The type of adhesive used in the discontinuous adhesive layer 24 can be the same, or different, to the type of adhesive used in the discontinuous adhesive layer 21.
In one certification scheme, the total weight of adhesive used in a package formed of the laminate can be up to 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate.
In one example, a single adhesive type is used in both of the adhesive layers 21 and 24 and the total weight of adhesive in the combination of adhesive layers 21 and 24 is up to 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate. The adhesive weight can be achieved by a combination of: -layer thicknesses A and B; -adhesive dot diameters D1 and D2; -adhesive dot spacings S1 and S2; such that the total weight of the adhesive is s1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate.
In another example, a single adhesive type is used for the adhesive layer 21 and a second, different, adhesive type is used for the adhesive layer 24. The total weight of adhesive in the adhesive layer 21 is up to 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate. The total weight of adhesive in the adhesive layer 24 is up to 1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate. The weight of adhesive layer 21 can be achieved by a combination of: -layer thickness A; -adhesive dot diameters Dl; -adhesive dot spacing S1; such that the total weight of the adhesive is 51% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate. Similarly, the weight of adhesive layer 24 can be achieved by a combination of: - layer thicknesses B; -adhesive dot diameters D2; - adhesive dot spacing S2; such that the total weight of the adhesive is S1% of the total weight of the laminate, or the total weight of packaging materials of a package formed using the laminate.
The laminates 10, 30 are compostable without the need for initial processing. Packaging can be composted in one of two ways: (i) industrial composting and 00 home composting. There are currently several ways of certifying compostable packaging.
Industrial composting can accelerate the decomposition of material by use of higher temperatures. European Standard EN 13432:2000 and Vingotte "OK compost' concern industrial composting. The standard defines various tests. One test is a test for disintegration. To pass the disintegration test the material sent for testing must disintegrate 90%, with the remaining pieces being able to be sieved through a 2mm mesh. This must be achieved within 12 weeks at a temperature not exceeding 75°C (only allowed for one week), then reduced to an average of 50°C. This test is intended to mimic the effect of processing waste in an industrial composter.
Home composting generally uses lower temperatures than industrial composting.
Vingotte operate a certification scheme for home compostable materials under the name "OK compost HOME". The certification includes a disintegration test at no more than 30"C. The disintegration test has the same requirement that material sent for testing must disintegrate 90%, with the remaining pieces being able to be sieved through a 2mm mesh, but the time limit is expanded to 6 months. This test is intended to mimic the effect of processing waste in a home composting heap.
The spacing of the adhesive regions 22, 25 in the discontinuous adhesive layers 21, 24 has been found to improve the speed of the industrial and home composting processes, as it provides increased exposure of the adhesive to air, bacteria and/or micro-organisms. It also helps to space layers of the laminate and to provide pockets (23, Figure 1; 23, 26 Figure 3) within the laminate material to help assist decomposition.
The adhesive can be applied by a process such as gravure, flexographic, digital printing/coating or by transfer application.
The printable layer (e.g. layer 11) can be printed using compostable inks (if available) or by non-compostable inks.
Figure 4 schematically shows one possible example of a manufacturing process for producing a laminate shown in Figures 1 and 2A-2F. The process uses a quantity 51 (e.g. a roll) of sheet material of the first layer 11 and a quantity 52 of sheet material of the second layer 12. At stage 53 adhesive is applied to the first layer 11. The adhesive is applied from an engraved gravure cylinder which delivers the required pattern of adhesive regions at the required adhesive thickness to the layer 11. At stage 55 the two layers 11, 12 are brought together. Pressure is applied to seal the layers 11, 12 together. The resulting laminate is stored 56. The laminate can be processed to form cut lines or lines of weakness required in the laminate.
It will be understood that the adhesive may be applied to the second layer 12 instead of the first layer 11. A different process can be used to deposit the adhesive onto one of the layers 11, 12. A three-layer laminate can be manufactured using a similar process to that of Figure 4. A quantity (e.g. a roll) of sheet material of the third layer 13 is provided. Adhesive is applied to the third layer 13, or to the second layer 12. The adhesive is applied from an engraved gravure cylinder which delivers the required pattern of adhesive regions at the required adhesive thickness to the layer 12 or 13. At stage 55 the three layers 11, 12, 13 are brought together. Pressure is applied to seal the layers 11, 12, 13 together. Alternatively, layers 11, 12 can first be brought together, and then the third layer 13 can be pressed against the layers 11, 12.
Some example laminate structures will now be described.
Home compostable paper duplex laminates (i) 50g/m2 paper / Adhesive / 39pm coextruded biopolymer; (ii) 50g/m2 paper / Adhesive / 50pm biopolymer; 25g/m2 paper / Adhesive / 39pm coextruded biopolymer; where the order is printable layer/ adhesive / sealant layer.
Home compostable film duplex laminates (i) 19pm cellulose / Adhesive / 50pm biopolymer; 23pm cellulose / Adhesive / 50pm biopolymer; (iii) 23pm metallised cellulose / Adhesive / 50pm biopolymer; where the order is printable layer/ adhesive / sealant layer.
Home compostable paper triplex laminates 50g/m2 paper / Adhesive / 23pm cellulose / Adhesive / 50pm biopolymer where the order is printable layer / adhesive / barrier layer / adhesive / sealant layer.
Industrially compostable film duplex laminates 19pm cellulose / Adhesive / 39pm biopolymer where the order is printable layer/ adhesive / sealant layer.
Industrially compostable film triplex laminates 19pm cellulose / Adhesive / 23pm cellulose / Adhesive / 55pm biopolymer; (ii) 23pm cellulose / Adhesive / 23pm cellulose / Adhesive / 50pm biopolymer; (li) 23pm cellulose / Adhesive / 23pm metallised cellulose / Adhesive / 50pm biopolymer; where the order is printable layer / adhesive / barrier layer / adhesive / sealant layer.
A co-extruded biopolymer or a compostable sealant web can be used in place of a biopolymer.
While the examples given above include specific weights/thicknesses of layers, it will be appreciated that other values could be used.
In the examples described above, a single adhesive type can be used with an adhesive weight s1% of the laminate (or a total weight of all package materials of the package formed using the laminate). This offers best compostability. Alternatively, in the triplex laminates described above, a first adhesive type can be used for one of the adhesive layers and a second, different, adhesive type can be used for the other adhesive layer. The total weight of adhesive in each of the adhesive layers is s1% of the total weight of the laminate (or a total weight of all package materials of the package formed using the laminate).
Figures 5 to 7 show an example of a package 100 in the form of a bag or pouch. The package is provided to illustrate how the laminate shown in Figures 1 to 3 can be used to form a package. It will be appreciated that the laminate could be used to form a different kind of package to the one shown here. Figure 5 shows the package in plan view, viewed from the front. Figure 6 shows a cross-section through the package taken along the line Y-Y' of Figure 5. Figure 7 shows a cross-section through only the front face 107 of the package taken along the line X-X' of Figure 5. The package 100 comprises a laminate 10 which is folded into two and sealed 123, 124, 125 along three edges 103, 104, 105. The package 100 has a front face 107 and a back face 108. The package 100 has an interior volume 109 which can hold a product. The product can be a food product, confectionery, household product, tobacco product (e.g. cigarettes or hand-rolled tobacco) or any other product. The structure of this laminate is as previously described.
A first seal 123 is formed between the front face 107 and the back face 108 along, or adjacent to, edges 103 of the sheet 10. A second seal 124 is formed between the front face 107 and the back face 108 along, or adjacent to, edges 104 of the sheet 10. A third seal 125 is formed between the front face 107 and the back face 108 along, or adjacent to, edges 105 of the sheet 10. Seals can be formed by applying heat to the laminate, thereby forming a seal between respective sealant layers of the laminate. Seals 123, 124, 125 are not intended to be opened by a user. Seals 123, 124, 125 can be welded seals.
The package 100 has an openable portion 115. In this example, the openable portion 115 is in the form of a flap which is openable and subsequently reclosable by reattaching to the package. When the flap 115 is opened, it provides access to the interior 109 of the package via an access aperture 116 defined by a cut line 112. When the flap 115 is reattached to the package, it provides a degree of resealability to the package.
As shown in Figure 7, the laminate sheet 10 comprises an outer layer 11 and an inner layer 12. The outer layer 11 is bonded to the inner layer 12 by a discontinuous resealable adhesive layer 21, such as a pressure sensitive adhesive (PSA). Cut lines 111, 112 are formed in the layers 11, 12 of the laminate. Cut lines 111, 112 are formed in different layers of the laminate, and are offset from one another such that a region 113 of the inner layer 12 is provided where the outer layer 11 can separate from the inner layer 12 and subsequently reattach to the inner layer 12. This is advantageous, as it provides a resealable closure without the need to fit an additional closure mechanism to the package. While Figure 7 shows a two-layer laminate, it is also possible to provide a resealable openable portion in a laminate having a higher number of layers. For a three layer laminate, such as laminate 30 of Figure 3, cut line 111 can be formed in the outer layer 11 and cut line 112 can be formed in the innermost two layers 12, 13. Alternatively, cut line 111 can be formed in the outermost two layers 11, 12 and cut line 112 can be formed in the innermost layer 13.
The package 100 can include additional elements such as one or more of: an adhesive label; a reclosable/resealable fixing (e.g. zipper). A certification scheme for compostable laminates may permit up to 5% non-compostable (or non-home compostable) components, with each different non-compostable (or non-home compostable) component up to 1%, e.g. adhesive 1 up to 1%, adhesive 2 up to 1%, inks up to 1% etc. The laminate material can be supplied in the form of a web or reel of laminate material. The web is a continuous length of laminate material. The web can be divided into individual pieces to provide the sheet for an individual package.
A method of manufacturing a multi-layer compostable laminate for forming a package comprises providing a first compostable layer and providing a second compostable layer.
The method forms a first discontinuous adhesive layer between the first compostable layer and the second compostable layer. The first discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate. The first discontinuous adhesive layer can be formed such that the adhesive in the first discontinuous adhesive layer is 51% of a total weight of the laminate. Alternatively, the first discontinuous adhesive layer can be formed such that the adhesive in the first discontinuous adhesive layer is 1% of a total weight of all package materials of the package formed using the laminate. The forming can adapt one or more of: the type of adhesive pattern, thickness of the adhesive layer to achieve the required adhesive weight.
It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.
Any reference to 'an' item refers to one or more of those items. The term 'comprising' is used herein to mean including the method blocks or elements identified, but that such blocks or elements do not comprise an exclusive list and a method or apparatus may contain additional blocks or elements.
It will be understood that the above description of a preferred embodiment is given by way of example only and that various modifications may be made by those skilled in the art. Although various embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention.

Claims (27)

  1. Claims 1. A multi-layer compostable laminate for forming a package comprising: a first compostable layer; a second compostable layer; a first discontinuous adhesive layer between the first layer and the second layer; wherein the first discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
  2. 2. A multi-layer compostable laminate according to claim 1 wherein the adhesive in the first discontinuous adhesive layer has a weight =1% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
  3. 3. A multi-layer compostable laminate according to claim 1 or 2 wherein the first discontinuous adhesive layer comprises isolated regions of adhesive fully surrounded by regions without adhesive.
  4. 4. A multi-layer compostable laminate according to any one of the preceding claims wherein the first discontinuous adhesive layer comprises a pattern of adhesive dots or polygons, wherein individual dots or polygons are each fully surrounded by regions without adhesive.
  5. 5. A multi-layer compostable laminate according to any one of the preceding claims wherein the first discontinuous adhesive layer comprises a pattern of discontinuous adhesive lines, wherein individual segments of the discontinuous lines are each fully separated by regions without adhesive.
  6. 6. A multi-layer compostable laminate according to any one of the preceding claims wherein the first discontinuous adhesive layer comprises a repeating pattern of adhesive regions separated by regions without adhesive.
  7. 7. A multi-layer compostable laminate according to any one of the preceding claims further comprising: a third compostable layer; a second discontinuous adhesive layer between the second layer and the third layer; wherein the second discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
  8. 8. A multi-layer compostable laminate according to claim 7 wherein the second discontinuous adhesive layer is different to the first discontinuous adhesive layer.
  9. 9. A multi-layer compostable laminate according to claim 8 wherein the second discontinuous adhesive layer is different to the first discontinuous adhesive layer in respect of at least one of: thickness of the discontinuous adhesive layers; patterns of adhesive regions used in the discontinuous adhesive layers.
  10. 10. A multi-layer compostable laminate according to any one of claims 7 to 9 wherein the second discontinuous adhesive layer comprises isolated regions of adhesive fully surrounded by regions without adhesive.
  11. 11. A multi-layer compostable laminate according to any one of claims 7 to 10 wherein the adhesive in the first discontinuous adhesive layer and the second discontinuous adhesive layer has a combined weight =1% of total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
  12. 12. A multi-layer compostable laminate according to any one of claims 7 to 10 wherein the first discontinuous adhesive layer is a first adhesive and the second discontinuous adhesive layer is a second adhesive.
  13. 13. A multi-layer compostable laminate according to claim 12 wherein the first discontinuous adhesive layer has a weight =1% of total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate, and the second discontinuous adhesive layer has a weight =1% of total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
  14. 14. A multi-layer compostable laminate according to any one of the preceding claims wherein the first compostable layer is a material selected from: paper and cellulose.
  15. 15. A multi-layer compostable laminate according to any one of the preceding claims wherein the second compostable layer is a material selected from: cellulose, biopolymer and coextruded biopolymer.
  16. 16. A multi-layer compostable laminate according to any one of claims 7 to 15 wherein the third compostable layer is one of: a biopolymer, a co-extruded biopolymer and a compostable sealant web.
  17. 17. A multi-layer compostable laminate according to any one of the preceding claims wherein the first compostable layer is paper of maximum weight 50g/m2, the second compostable layer is cellulose of maximum thickness 25pm and the third compostable layer is a biopolymer of maximum thickness 50pm.
  18. 18. A multi-layer compostable laminate according to any one of the preceding claims wherein the first compostable layer is cellulose of maximum thickness 25pm, the second compostable layer is cellulose of maximum thickness 25pm and the third compostable layer is a biopolymer of maximum thickness 55pm.
  19. 19. A package formed of a laminate according to any one of the preceding claims.
  20. 20. A package according to claim 19 wherein the adhesive in the first discontinuous adhesive layer has a weight S1% of a total weight of packaging materials of the package. 15
  21. 21. A package according to claim 19 comprising a first discontinuous adhesive layer and a second discontinuous adhesive layer wherein the adhesive in the first discontinuous adhesive layer and the second discontinuous adhesive layer has a combined weight 51% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
  22. 22. A multi-layer compostable laminate according to any one of claims 1 to 18 or a package according to any one of claims 19 to 21 which meets the requirements for industrial composting under Vingotte OK Compost.
  23. 23. A multi-layer compostable laminate according to any one of claims 1 to 18 or a package according to any one of claims 19 to 21 which meets the requirements for home composting under Vingotte OK Compost HOME.
  24. 24. A method of manufacturing a multi-layer compostable laminate for forming a package comprising: providing a first compostable layer; providing a second compostable layer; forming a first discontinuous adhesive layer between the first compostable layer and the second compostable layer, wherein the first discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
  25. 25. A method according to claim 24, wherein the first discontinuous adhesive layer is formed such that the adhesive in the first discontinuous adhesive layer is 1% of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
  26. 26. A method according to claim 24 or 25 further comprising: providing a third compostable layer; forming a second discontinuous adhesive layer between the second layer and the third layer, wherein the second discontinuous adhesive layer comprises regions of adhesive separated by regions without adhesive to aid compostability of the laminate.
  27. 27. A method according to any one of claims 24 to 26, wherein the first discontinuous adhesive layer and the second discontinuous adhesive layers are formed such that the adhesive in the first discontinuous adhesive layer and the second discontinuous adhesive layer has a combined weight 51°/0 of a total weight of the laminate, or a total weight of packaging materials of the package formed using the laminate.
GB1510785.7A 2015-06-19 2015-06-19 Compostable Laminates Withdrawn GB2539493A (en)

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