WO2018165116A1 - Extrusion coated paper for flexible packaging - Google Patents
Extrusion coated paper for flexible packaging Download PDFInfo
- Publication number
- WO2018165116A1 WO2018165116A1 PCT/US2018/021086 US2018021086W WO2018165116A1 WO 2018165116 A1 WO2018165116 A1 WO 2018165116A1 US 2018021086 W US2018021086 W US 2018021086W WO 2018165116 A1 WO2018165116 A1 WO 2018165116A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- paper
- nylon
- ldpe
- tie
- pouch
- Prior art date
Links
- 238000001125 extrusion Methods 0.000 title description 20
- 238000009459 flexible packaging Methods 0.000 title description 5
- 239000004677 Nylon Substances 0.000 claims abstract description 34
- 229920001778 nylon Polymers 0.000 claims abstract description 34
- 239000000758 substrate Substances 0.000 claims abstract description 29
- 230000004888 barrier function Effects 0.000 claims abstract description 20
- 235000013305 food Nutrition 0.000 claims abstract description 20
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 claims abstract description 12
- UFRKOOWSQGXVKV-UHFFFAOYSA-N ethene;ethenol Chemical compound C=C.OC=C UFRKOOWSQGXVKV-UHFFFAOYSA-N 0.000 claims abstract description 12
- 239000004715 ethylene vinyl alcohol Substances 0.000 claims abstract description 12
- 239000000835 fiber Substances 0.000 claims abstract description 7
- 239000011121 hardwood Substances 0.000 claims abstract description 7
- 238000000576 coating method Methods 0.000 claims description 33
- 239000011248 coating agent Substances 0.000 claims description 28
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 19
- 229920001684 low density polyethylene Polymers 0.000 claims description 19
- 239000004702 low-density polyethylene Substances 0.000 claims description 19
- 239000000203 mixture Substances 0.000 claims description 18
- 239000004927 clay Substances 0.000 claims description 10
- 229920000092 linear low density polyethylene Polymers 0.000 claims description 2
- 239000004707 linear low-density polyethylene Substances 0.000 claims description 2
- 238000004806 packaging method and process Methods 0.000 abstract description 2
- 239000000123 paper Substances 0.000 description 63
- 239000002023 wood Substances 0.000 description 10
- 229920000642 polymer Polymers 0.000 description 8
- 239000000463 material Substances 0.000 description 6
- 239000002655 kraft paper Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000007765 extrusion coating Methods 0.000 description 3
- 239000011888 foil Substances 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 229920002799 BoPET Polymers 0.000 description 2
- 229920002292 Nylon 6 Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920006254 polymer film Polymers 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000003855 Adhesive Lamination Methods 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229920002261 Corn starch Polymers 0.000 description 1
- 101150044878 US18 gene Proteins 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000008120 corn starch Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 230000036314 physical performance Effects 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
Classifications
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/10—Coatings without pigments
- D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
- D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D21H19/30—Polyamides; Polyimides
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
-
- 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
- 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
- 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
-
- 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
- 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
- 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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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
- B32B27/327—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polyolefins obtained by a metallocene or single-site catalyst
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- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B29/00—Layered products comprising a layer of paper or cardboard
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- 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
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard 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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- 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
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D31/00—Bags or like containers made of paper and having structural provision for thickness of contents
- B65D31/02—Bags or like containers made of paper and having structural provision for thickness of contents with laminated walls
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
- B65D65/38—Packaging materials of special type or form
- B65D65/42—Applications of coated or impregnated materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
- B65D75/008—Standing pouches, i.e. "Standbeutel"
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/10—Coatings without pigments
- D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
- D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H19/22—Polyalkenes, e.g. polystyrene
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H19/60—Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/82—Paper comprising more than one coating superposed
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/84—Paper comprising more than one coating on both sides of the substrate
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/10—Packing paper
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- B32B2255/00—Coating on the layer surface
- B32B2255/12—Coating on the layer surface on paper layer
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- B32B2255/20—Inorganic coating
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- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
- B32B2262/067—Wood fibres
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/31—Heat sealable
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- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/41—Opaque
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- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
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- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/546—Flexural strength; Flexion stiffness
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- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
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- B32B2307/00—Properties of the layers or laminate
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- B32B2307/75—Printability
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- B32B2439/00—Containers; Receptacles
- B32B2439/40—Closed containers
- B32B2439/46—Bags
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- B32B2439/70—Food packaging
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- B32B2553/00—Packaging equipment or accessories not otherwise provided for
Definitions
- This invention is directed to an extrusion coated paper for flexible packaging such as bags, stand up pouches, and gusseted bags used for food storage.
- This invention relates generally to the use of flexible packaging for food that is provided to consumers in a flexible pouch or packaging.
- Many of the pouches for food items involve the use of plastics and mix substrates and materials that may be difficult to recycle. Additionally, many paper substrates that are utilized for stand up pouches and other items are characterized by poor barrier properties that limit either the shelf life or the ability to package items into a paper pouch.
- This invention further relates generally to bags and pouches that are typically used to provide for food products. Pouches and similar containers can be used to store a variety of food items. Many embodiments of food storage pouches have one or more gussets that are defined along either a bottom wall or one or more sidewalls. Some gusseted bags have an ability to provide for a "standup" pouch and may further have a transparent window, as part of the gusset, or positioned in a wall panel to allow consumers to see the container contents.
- a number of food pouches utilize plastic or foil lined laminated structures. Many such structures are difficult to recycle and are provided from non-sustainable resources.
- the paper grade is frequently a Kraft type paper and has a low basis weight and strength characteristics which limits its use for certain good packages.
- the strength of Kraft papers can be increased by the selected use of various barrier coatings.
- the coatings often interfere with the recyclability of the product and the initial low basis weight of the Kraft paper wilt flex easily which can damage the barrier coatings and result in the lose of needed barrier properties for food items.
- a pouch for food items comprising or consisting of a tubular structure having upper and lower ends, the upper and lower ends being sealable, front and back walls joined at opposite bag size by at least two side seams running the length of the bags; the bag substrate being paper and having a ground hardwood fiber content of at least about 50%; a food contact barrier coating applied to a first structure of the paper, the barrier coating applied to the first surface of the paper in the order of 5#Nylon, 3#EVOH, 3#Tie, and 17#LDPE.
- It is a further aspect of at least one embodiment of this invention to provide a paper substrate comprising of consisting of a paper sheet having an exterior surface and an interior food contact surface; and, a barrier extrusion coating applied directly to the interior food contact surface in the order of 5#Nylon, 3#EVOH, 3#Tie, and 17#LDPE.
- Figure 1 is a perspective view of a paper pouch in accordance with one embodiment of the present invention.
- Figure 2 is a perspective view of a paper pouch in accordance with a second embodiment of the present invention.
- Figure 3 is a cross sectional view of an embodiment of a paper substrate laminate of the present invention.
- Figure 4 is a formulation for an anti-curiing clay coating.
- ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.
- ground wood paper has a higher quality and quantity of hardwood fiber and greater paper basis weight that provides for a stiffer and more rigid container. As a result, the paper is subjected to less flexing and any applied barrier coatings have improved integrity that facilitates a longer shelf life of any perishable item contained therein.
- the high ground hardwood fiber content paper also has improved printing capabilities compared to Kraft papers and other similar fiber based substrates.
- the printing capabilities of the ground wood paper is comparable to print quality obtained for printed publications such as magazines and brochures/ catalogs.
- a clay coated one side are a coated-2-side (C2S) paper
- C2S coated-2-side
- C1S paper is used the polymers are extrusion coated on the non-clay coated side of the paper and the clay coated side is used for printing.
- C1S paper is preferred in some applications over C2S due to improved polymer adhesion on the uncoated side.
- some embodiments use uncoated (UC) paper that does not contain clay coating on either side of the paper.
- one side of the paper is extrusion coated with polymers.
- a polymer film or foil layer is attached to the other side of the paper by use of an adhesive or polymer.
- extrusion lamination or adhesive lamination may be used.
- CIS or C2S paper it is possible to use a CIS or C2S paper and laminate a polymer film or foil to those substrates as well.
- Table 1 shows the properties of the preferred, ground wood containing, base sheet for the invention.
- the examples provided have a polymer coat weight of either 28 or 29 lbs/3,000 ft 2 . This was found early in development to be an optimal coat weight from the perspective of product performance and meeting the gauge needs of commercial pouch form and fill equipment. Lower coat weights (to 24 lbs/3,000 ft 2 ) were tested and can be used to meet some applications.
- a hardwood fiber content of between 40%-65% and more preferably between 50%-60% has proven beneficial.
- Test data is set forth in the various Tables which provide physical properties and performance data of the resulting substrate.
- a plowed gusset bottom 20 as seen in Figure 1 can be utilized.
- three panel pouches can also be used in which a dear film can be used as the bottom gusset material to allow a consumer to see the packaged product inside the pouch.
- one useful film combination is a 0.5 mil PET/2.0 mil PE film.
- Another useful film comprises a 0.4 mil PTE/0.1 mil polyuretylene adhesive/0.6 mil nylon/0.1 mil polyuretylene adhesive/3.1 mm polyethylene. Both of the gusset film materials were found to perform well as the bottom gusset in the formation of stand up pouches where the sides are made of a polycoated ground wood paper.
- a press fit closure 12 can be incorporated into the stand up pouch, the materials and techniques for installing closure 12 being well known in the art.
- coated ground wood paper can also be used to produce flat pouches or pillow pouches for certain food products and with similar barrier properties and benefits to the pouch.
- the coated hardwood paper can be used to provide other forms of bags and containers used for food materials.
- gussets can be formed one or more of the side walls of a container 10.
- the coated ground wood paper can also be used to make conventional bags that are typically formed of Kraft paper.
- the bag format allows for a product to be placed in the interior of the bag and the top closure heat sealed.
- the ground wood paper in addition to the integrity of the ground wood paper, the ground wood paper also lends itself to improved printability and a tactile feel or hand finish that is appealing to consumers.
- the exterior surface of the pouch and containers can be clay coated as is known in the art for improved printability.
- the print quality of the resulting pouch is extremely high and is comparable to that obtained from ground wood paper used for printed magazines and catalogs. In addition, consumers are increasingly looking for a biosubstantible package alternative.
- a clear film viewing window 30 can be provided within one or both of the paper substrates to allow viewing of the contents.
- the manufacturing of such a viewing window within a paper pouch substrate is known in the art as set forth in US Patent No. 5,465,842 and which is incorporated herein by reference.
- FIG. 3 Set forth in Figure 3 is one representative substrate as identified in Example 8 below, that is suitable for use as a paper substrate for forming a pouch, bag, or other similar enclosure for a food product.
- a similar paper structure can be provided.
- the extruded structure is identified in terms of composition and coating weight and is applied in the order listed to the uncoated surface of the paper substrate.
- the extruded structure consists of a 29 lb coating of LDPE extrusion coated onto a 60# C1S paper.
- the extruded structure consists of a 29 lb coating of bioLDPE extrusion coated onto a 60# C1S paper.
- bioLDPE i.e. LOPE derived from biobased sources rather than petroleum sources
- LOPE LOPE derived from biobased sources rather than petroleum sources
- This substitution has a minimal effect on the properties of the extrusion coated paper.
- the extruded structure consists of a 28 lb coating of a nylon coex structure extrusion coated onto a 60# CIS paper.
- the coex structure is:
- the extruded structure consists of a 28 lb coating of a nylon blend coex structure extrusion coated onto a 60# C1 S paper.
- the coex structure is;
- the nylon blend consists of 15% amorphous nylon and 85% nylon 6,
- the extruded structure consists of a 28 lb coating of a nylon blend coex structure extrusion coated onto a 60# C1 S paper.
- the coex structure is:
- the nylon blend consists of 15% amorphous nylon and 85% nylon 6.
- the extruded structure consists of a 28 lb coating of a nylon blend structure extrusion coated onto a 50# UC paper.
- the coex structure is:
- the nylon blend consists of 15% amorphous nylon and 85% nylon
- the extruded structure consists of a 28 lb coating of a nylon coex structure with metallocene LLDPE blend extrusion coated onto a 60# C1S paper.
- the coex structure is:
- the extruded structure consists of a 28 lb coating of a nylon and EVOH coex structure extrusion coated onto a 50# C1S paper.
- the coex structure is:
- Example 8 and 9 The data set forth below with respect to Example 8 and 9 is based on flat sheet samples of the extruded paper product. Performance data on individual pouches formed by the paper substrate is not reported.
- the extruded structure consists of a 28 lb coating of a nylon and EVOH coex structure extrusion coated onto a 50# C1S paper.
- the coex structure is:
- the extruded structure consists of a 29 lb coating of bioLDPE extrusion coated onto a 60# C2S paper with a 1 mil PET film extrusion laminated onto the reverse side.
- the extruded structure consists of a 28 lb coating of a nylon coex structure extrusion coated onto a 60# C2S paper with a 1 mil PET film extrusion laminated onto the reverse side.
- the coex structure is:
- layer multiplication technology can be utilized with any of the nylon coex structures presented.
- Layer multiplication technology allows an increase in the number of layers present in the barrier coatings and which are duplicated in a proportional ratio. Details of the layer multiplication technology useful for the present invention can be seen in reference to the Applicant's co-pending application in PCT/US18/18952, filed February 21 , 2018 and which is incorporated herein by reference.
- the described embodiments utilized a nylon coating weight of substantially about 5 pounds. However, it is believed that a range of between 2 to about 8 pounds of nylon can be utilized so as to achieve the benefits as noted herein.
- the coating weight of EVOH is 3 pounds but can be varied between a range of about 1 to about 5 pounds to meet the objectives of the present invention.
- the coating weights of LDPE or mPE can range between 1-5# when present as an interior layer and between 10-20# when applied as the outermost heat seal layer.
- the coating weights described above are given in reference to pounds per 3,000 square feet of board as is typically expressed within the industry.
- the basis weight of the paper substrate can vary between a range of 40 to 65 and more preferably within a range of between about 50 to about 60 basis weight.
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- Chemical & Material Sciences (AREA)
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- Bag Frames (AREA)
Abstract
A barrier laminate for a paper substrate and a pouch formed from the paper substrate is provided. The paper substrate and pouch are suitable for packaging of food products and utilizes a 40-60% hardwood fiber content paper sheet having nylon barriers and EVOH barriers applied to a food contact surface of the paper.
Description
EXTRUSION COATED PAPER FOR FLEXIBLE PACKAGING
RELATED APPLICATIONS
This application claims the benefit of U.S. Application Serial No. 62/467,411 filed on March 6, 2017 and which is incorporated herein by reference. FIELD OF THE INVENTION
This invention is directed to an extrusion coated paper for flexible packaging such as bags, stand up pouches, and gusseted bags used for food storage.
BACKGROUND OF THE INVENTION
This invention relates generally to the use of flexible packaging for food that is provided to consumers in a flexible pouch or packaging. Many of the pouches for food items involve the use of plastics and mix substrates and materials that may be difficult to recycle. Additionally, many paper substrates that are utilized for stand up pouches and other items are characterized by poor barrier properties that limit either the shelf life or the ability to package items into a paper pouch. This invention further relates generally to bags and pouches that are typically used to provide for food products. Pouches and similar containers can be used to store a variety of food items. Many embodiments of food storage pouches have one or more gussets that are defined along either a bottom wall or one or more sidewalls. Some gusseted bags have an ability to provide for a "standup" pouch and may further have a transparent window, as part of the gusset, or positioned in a wall panel to allow consumers to see the container contents.
A number of food pouches utilize plastic or foil lined laminated structures. Many such structures are difficult to recycle and are provided from non-sustainable resources. To the extent some pouches are made of paper products, the paper grade is frequently a Kraft type paper and has a low basis weight and strength characteristics which limits its use for certain good packages. The strength of Kraft papers can be increased by the selected use of various barrier coatings. However, the coatings often interfere with the recyclability of the product and the initial low basis weight of the Kraft paper wilt flex easily which can damage the barrier coatings and result in the lose of needed barrier properties for food items.
Accordingly, there remains room for improvement and variation within the art.
SUMMARY OF THE INVENTION
It is one aspect of at least one of the present embodiments to a pouch for food items comprising or consisting of a tubular structure having upper and lower ends, the upper and lower ends being sealable, front and back walls joined at opposite bag size by at least two side seams running the length of the bags; the bag substrate being paper and having a ground hardwood fiber content of at least about 50%; a food contact barrier coating applied to a first structure of the paper, the barrier coating applied to the first surface of the paper in the order of 5#Nylon, 3#EVOH, 3#Tie, and 17#LDPE.
It is a further aspect of at least one embodiment of this invention to provide a paper substrate comprising of consisting of a paper sheet having an exterior surface and an interior food contact surface; and, a barrier extrusion coating applied directly to the interior food contact surface in the order of 5#Nylon, 3#EVOH, 3#Tie, and 17#LDPE.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS
A fully enabling disclosure of the present invention, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying drawings.
Figure 1 is a perspective view of a paper pouch in accordance with one embodiment of the present invention.
Figure 2 is a perspective view of a paper pouch in accordance with a second embodiment of the present invention.
Figure 3 is a cross sectional view of an embodiment of a paper substrate laminate of the present invention.
Figure 4 is a formulation for an anti-curiing clay coating.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the
invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.
It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.
In describing the various figures herein, the same reference numbers are used throughout to describe the same material, apparatus, or process pathway. To avoid redundancy, detailed descriptions of much of the apparatus once described in relation to a figure is not repeated in the descriptions of subsequent figures, although such apparatus or process is labeled with the same reference numbers.
It has been found that using a polymer coated ground wood paper for stand up and flat pouches offers significant improvements over conventional paper pouches. The ground wood paper has a higher quality and quantity of hardwood fiber and greater paper basis weight that provides for a stiffer and more rigid container. As a result, the paper is subjected to less flexing and any applied barrier coatings have improved integrity that facilitates a longer shelf life of any perishable item contained therein.
The high ground hardwood fiber content paper also has improved printing capabilities compared to Kraft papers and other similar fiber based substrates. The printing capabilities of the ground wood paper is comparable to print quality obtained for printed publications such as magazines and brochures/ catalogs.
In accordance with this invention, it has been found that the use of a clay coated one side (CIS) are a coated-2-side (C2S) paper can be used as a substrate for extrusion coating that offers improvements in the substrate when used for flexible packaging for food items including bags, pouches, gusted bags, and similar articles. As set forth below, it is useful to formulate a clay coating which imparts an anti-curl property to the resulting paper sheet.
When C1S paper is used the polymers are extrusion coated on the non-clay coated side of the paper and the clay coated side is used for printing. C1S paper is preferred in some applications over C2S due to improved polymer adhesion on the uncoated side. In addition, some embodiments use uncoated (UC) paper that does not contain clay coating on either side of the paper. In these embodiments, one side of the paper is extrusion coated with polymers. Then a polymer film or foil layer is attached to the other side of the paper by use of an adhesive or polymer. In case, either standard industry techniques of extrusion lamination or adhesive lamination may be used. It should be noted that it is possible to use a CIS or C2S paper and laminate a polymer film or foil to those substrates as well.
Table 1 shows the properties of the preferred, ground wood containing, base sheet for the invention.
Examples of the various embodiments of the invention are provided below. These examples are intended to illustrate the range of properties that can be covered by the invention. Product attributes, including physical properties and barrier properties, can be adjusted to meet the needs of individual applications by varying the combinations of polymer resins used and the lay downs of individual layers of polymers.
The examples provided have a polymer coat weight of either 28 or 29 lbs/3,000 ft2. This was found early in development to be an optimal coat weight from the perspective of product performance and meeting the gauge needs of commercial pouch form and fill equipment. Lower coat weights (to 24 lbs/3,000 ft2) were tested
and can be used to meet some applications. A hardwood fiber content of between 40%-65% and more preferably between 50%-60% has proven beneficial.
In accordance with this invention ft has been found that the properties of the end substrate are improved using a CIS or an C2C paper in which the clay coating has been modified to prevent or minimize curling of the paper. One suitable formulation for applying a backwash coating (anti-curling agent) is seen in reference to the formulation given in Figure 4. Typically, the anti-curl backwash aqueous coating of a kaolin clay and emulsified corn starch is applied to the paper substrate and dried prior to applying an extrusion coating.
Set forth in the various examples below are the extruded composition applied to the indicated paper substrate. Test data is set forth in the various Tables which provide physical properties and performance data of the resulting substrate.
Pouches such as those seen in Figure 1 have been prepared from
combinations of paper and polymer listed in the examples below and have been found to be able to run at forming rates at commercially useful speeds. For a stand up pouch, a plowed gusset bottom 20 as seen in Figure 1 can be utilized. In addition, three panel pouches can also be used in which a dear film can be used as the bottom gusset material to allow a consumer to see the packaged product inside the pouch.
While a variety of suitable films are known in the art, one useful film combination is a 0.5 mil PET/2.0 mil PE film. Another useful film comprises a 0.4 mil PTE/0.1 mil polyuretylene adhesive/0.6 mil nylon/0.1 mil polyuretylene adhesive/3.1 mm polyethylene. Both of the gusset film materials were found to perform well as the bottom gusset in the formation of stand up pouches where the sides are made of a polycoated ground wood paper.
As seen in Figure 1 , a press fit closure 12 can be incorporated into the stand up pouch, the materials and techniques for installing closure 12 being well known in the art.
The coated ground wood paper can also be used to produce flat pouches or pillow pouches for certain food products and with similar barrier properties and benefits to the pouch.
While the representative embodiments evaluated herein are directed to a single gusset pouch with the gusset at the bottom, it is understood that the coated hardwood paper can be used to provide other forms of bags and containers used for food materials. For instance, gussets can be formed one or more of the side walls of a container 10. The coated ground wood paper can also be used to make conventional bags that are typically formed of Kraft paper. For certain items, the bag
format allows for a product to be placed in the interior of the bag and the top closure heat sealed.
in addition to the integrity of the ground wood paper, the ground wood paper also lends itself to improved printability and a tactile feel or hand finish that is appealing to consumers. The exterior surface of the pouch and containers can be clay coated as is known in the art for improved printability. The print quality of the resulting pouch is extremely high and is comparable to that obtained from ground wood paper used for printed magazines and catalogs. In addition, consumers are increasingly looking for a biosubstantible package alternative.
As set forth in Figure 2, is an alternative pouch configuration in an unsealed condition showing opposing layers of two pieces of paper substrate 14 and 16.
Optionally, a clear film viewing window 30 can be provided within one or both of the paper substrates to allow viewing of the contents. The manufacturing of such a viewing window within a paper pouch substrate is known in the art as set forth in US Patent No. 5,465,842 and which is incorporated herein by reference.
Set forth in Figure 3 is one representative substrate as identified in Example 8 below, that is suitable for use as a paper substrate for forming a pouch, bag, or other similar enclosure for a food product. In the examples below, a similar paper structure can be provided. In the examples that follow, the extruded structure is identified in terms of composition and coating weight and is applied in the order listed to the uncoated surface of the paper substrate.
Example 1 :
The extruded structure consists of a 29 lb coating of LDPE extrusion coated onto a 60# C1S paper.
The extruded structure consists of a 29 lb coating of bioLDPE extrusion coated onto a 60# C1S paper. Note that bioLDPE (i.e. LOPE derived from biobased sources rather than petroleum sources) can be used interchangeably with conventional LDPE for any of the variations in the invention. This substitution has a minimal effect on the properties of the extrusion coated paper.
Example 3:
The extruded structure consists of a 28 lb coating of a nylon coex structure extrusion coated onto a 60# CIS paper. The coex structure is:
10# bioLDPE/1.5# tie/5# nylon/1.5# tie/10# bioLDPE
The extruded structure consists of a 28 lb coating of a nylon blend coex structure extrusion coated onto a 60# C1 S paper. The coex structure is;
10# bioLDPE/1.5# tie/5# nylon blend/1.5# tie/10# bioLDPE
The nylon blend consists of 15% amorphous nylon and 85% nylon 6,
Example 5:
The extruded structure consists of a 28 lb coating of a nylon blend coex structure extrusion coated onto a 60# C1 S paper. The coex structure is:
2# LDPE/1.5# tie/5# nylon blend/1.5# tie/17# LDPE
The nylon blend consists of 15% amorphous nylon and 85% nylon 6.
The extruded structure consists of a 28 lb coating of a nylon blend structure extrusion coated onto a 50# UC paper. The coex structure is:
2# LDPE/1.5# tie/5# nylon blend/1.5# tie/17# LDPE
The nylon blend consists of 15% amorphous nylon and 85% nylon
Example 7:
The extruded structure consists of a 28 lb coating of a nylon coex structure with metallocene LLDPE blend extrusion coated onto a 60# C1S paper. The coex structure is:
2# 20%mPE-80%LDPE/1.5# tie/5# Nylon/1 ,5# tie/17# 20%mPE-80%LDPE
The extruded structure consists of a 28 lb coating of a nylon and EVOH coex structure extrusion coated onto a 50# C1S paper. The coex structure is:
5# Nylon/3# EVOH/3# tie/17# LDPE
The data set forth below with respect to Example 8 and 9 is based on flat sheet samples of the extruded paper product. Performance data on individual pouches formed by the paper substrate is not reported.
Example 9:
The extruded structure consists of a 28 lb coating of a nylon and EVOH coex structure extrusion coated onto a 50# C1S paper. The coex structure is:
5# Nylon/5# EVOH/3# tie/15# LDPE
Example 10:
The extruded structure consists of a 29 lb coating of bioLDPE extrusion coated onto a 60# C2S paper with a 1 mil PET film extrusion laminated onto the reverse side.
Example 11 :
The extruded structure consists of a 28 lb coating of a nylon coex structure extrusion coated onto a 60# C2S paper with a 1 mil PET film extrusion laminated onto the reverse side. The coex structure is:
10# LDPE/1.5# tie/5# Nylon/1.5# tie/10# LDPE
In addition to the examples listed above, layer multiplication technology (LMT), can be utilized with any of the nylon coex structures presented. Layer multiplication technology allows an increase in the number of layers present in the barrier coatings and which are duplicated in a proportional ratio. Details of the layer multiplication technology useful for the present invention can be seen in reference to the Applicant's co-pending application in PCT/US18/18952, filed February 21 , 2018 and which is incorporated herein by reference.
In the various examples set forth above, the described embodiments utilized a nylon coating weight of substantially about 5 pounds. However, it is believed that a range of between 2 to about 8 pounds of nylon can be utilized so as to achieve the benefits as noted herein. Similarly, the coating weight of EVOH is 3 pounds but can be varied between a range of about 1 to about 5 pounds to meet the objectives of the present invention. The coating weights of LDPE or mPE can range between 1-5# when present as an interior layer and between 10-20# when applied as the outermost heat seal layer. The coating weights described above are given in reference to pounds per 3,000 square feet of board as is typically expressed within the industry. Similarly, the basis weight of the paper substrate can vary between a range of 40 to 65 and more preferably within a range of between about 50 to about 60 basis weight.
Although preferred embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, both in whole, or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein.
Claims
1. A pouch comprising:
a tubular structure having upper and lower ends, the upper and lower ends being sealable, front and back walls joined at opposite bag size by at least two side seams running the length of the bags;
the bag substrate being paper and having a ground hardwood fiber content of at least about 50%;
a barrier coating applied to a first structure of the paper, the barrier coating applied to the first surface of the paper in the order of 5#Nylon, 3#EVOH, 3#Tie, and 17#LDPE.
2. The pouch according to claim 2 wherein the paper has a second surface which is clay coated.
3. A barrier laminate for a paper substrate comprising:
a paper sheet having an exterior surface and an interior food contact surface; a barrier coating applied directly to the interior surface in the order of 2-8#Nylon, 1 -5#EVOH, a Tie layer, and 10-12#LDPE.
4. A barrier laminate for a paper substrate comprising:
a paper sheet having an exterior surface and an interior food contact surface; a barrier coating applied directly to the interior surface in the order of Nylon, EVOH, tie, & LOPE.
5. The paper substrate according to claim 4 wherein the nylon is present at a range of between 2-8#, the EVOH is present at a range of between 1-5#, the tie Iayer is present between 1 -5# and the LOPE is present between 10-20#.
6. The paper substrate according to claim 5 wherein the LDPE is a blend of a blend of metallocene LLDPE and LDPE.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US201762467411P | 2017-03-06 | 2017-03-06 | |
US62/467,411 | 2017-03-06 |
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WO2018165116A1 true WO2018165116A1 (en) | 2018-09-13 |
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PCT/US2018/021086 WO2018165116A1 (en) | 2017-03-06 | 2018-03-06 | Extrusion coated paper for flexible packaging |
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WO (1) | WO2018165116A1 (en) |
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WO2024048392A1 (en) * | 2022-08-29 | 2024-03-07 | Toppanホールディングス株式会社 | Packaging and packaging product |
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CN111094141B (en) * | 2017-06-13 | 2023-05-02 | 凸版印刷株式会社 | Packaging container and method for manufacturing the same |
US11827397B2 (en) * | 2021-06-17 | 2023-11-28 | Evergreen Packaging Llc | Multilayer paperboard pouch and method of making the same using conventional bag-making equipment (CBME) |
WO2024024855A1 (en) * | 2022-07-29 | 2024-02-01 | 住友精化株式会社 | Coated paper and method for producing same |
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US20040209021A1 (en) * | 2003-04-18 | 2004-10-21 | Shih Keith S. | Multi-layer laminate structure |
US20070116929A1 (en) * | 2003-12-26 | 2007-05-24 | Dai Nippon Printing Co., Ltd. | Embossed release paper for synthetic leather production and support therefor, and synthetic leather using the release paper and process for producing the synthetic leather |
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US4323586A (en) * | 1980-10-20 | 1982-04-06 | Ludlow Corporation | Thermally-processable flexible package and process for using same |
US5410857A (en) * | 1994-04-20 | 1995-05-02 | Vitex Packaging, Inc. | Process for making windowed form, fill and seal bags |
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2018
- 2018-03-06 US US15/913,093 patent/US20180251944A1/en not_active Abandoned
- 2018-03-06 WO PCT/US2018/021086 patent/WO2018165116A1/en active Application Filing
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US6149993A (en) * | 1991-06-26 | 2000-11-21 | Westvaco Corporation | Oxygen and flavor barrier laminate including amorphous nylon |
US20030180489A1 (en) * | 2002-03-25 | 2003-09-25 | Reighard Tricia Susan | Non-foil barrier laminates |
US7229678B2 (en) * | 2002-05-02 | 2007-06-12 | Evergreen Packaging Inc. | Barrier laminate structure for packaging beverages |
US20040209021A1 (en) * | 2003-04-18 | 2004-10-21 | Shih Keith S. | Multi-layer laminate structure |
US20070116929A1 (en) * | 2003-12-26 | 2007-05-24 | Dai Nippon Printing Co., Ltd. | Embossed release paper for synthetic leather production and support therefor, and synthetic leather using the release paper and process for producing the synthetic leather |
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WO2024048392A1 (en) * | 2022-08-29 | 2024-03-07 | Toppanホールディングス株式会社 | Packaging and packaging product |
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