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Lamination Flashcards

(62 cards)

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1
Q

Define lamination:

A

combine different plastic film materials (+ non plastic materials) => 1 material

2+ layers (at least 1 is plastic)

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2
Q

Purpose of lamination:

A

COMBINE properties of materials (mechanical properties, barrier, heat-sealing, printability, optical properties, stretch…)

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3
Q

What products usually use laminates for packaging? (3)

A

long shelf-life
$$$$ products (high profit margin)
sensitive products

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4
Q

methods of making laminates: (4)

A

adhesive lamination
extrusion coating
co-extrusion
vacuum metallization

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5
Q

What is the process of adhesive lamination? (4)

A

adhesive (solvent or water based) applied to one web
Cured (dried)
combine with uncoated web (heat + pressure)
continue until all layers complete

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6
Q

Adhesives can be ____ or ____ based

A

aqueous, solvent

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7
Q

Why is curing important in adhesive lamination?

A

dries; excess solvent can cause de-lamination

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8
Q

parts of the adhesive lamination machine: (3)

A

unwind/rewind rolls
adhesive applicator
nip and chill roller

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9
Q

____ coating is comon with PE, PP, PET paper

A

extrusion coating

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10
Q

What are advantages of extrusion coating vs adhesive lamination? (4)

A
  1. avoid handling (thin PE film handling is difficult)
  2. high temp impregnantes plastic into paper
  3. cheaper
  4. less pollution
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11
Q

What acts as the ‘glue’ in extrusion coating?

A

extrudate

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12
Q

What is co-extrusion?

A

2+ extrusion feeders into 1 head -> extrudate is combination

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13
Q

Advantages of co-extrusion: (3)

A

lower cost
less delamination
flexibility

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14
Q

What are some products obtained with co-extrusion?

A

thermoforming films/sheets, retortable films/sheets, flexible films

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15
Q

What is vacuum metallization?

A

metallized plastic film/paper (added metal material)

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16
Q

properties of metallized films: (4)

A

reflectance (metallic/shiny)
tougher
susceptor (microwave energy -> radiant heat)
better barrier

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17
Q

Pre-treatments required before vacuum metallization: (2)

A

mechanical treatment

primer coating

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18
Q

What is the mechanical treatment for vacuum metallization?

A

high voltage/frequency discharge
Corona (continuous arc) @ film surface -> introduce polar groups

-> clean, oxidize, activate surface = better adhesion

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19
Q

What is the ‘primer coating’ in vacuum metallization?

A

thin coat applied that attracts both layers (better adhesion)

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20
Q

What is the process for vacuum metallization? (3)

A

BATCH PROCESS:

  1. metal vaporized in vacuum chamber
  2. sprayed to apply to pre-treated material
  3. coated with varnish to seal/smooth
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21
Q

What films are used for vacuum metallization? (4)

A

PP (80%)
PET (15%)
PA (4%)
PVC, PVDC, PS (1%)

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22
Q

T/F: the most common plastic film in metallization is PS

A

FALSE: Least common (<1%)

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23
Q

What are the functions of various laminate layers? (inside -> outside) (5)

A 
product compatibility
heat sealability
barrier
mech. structure
printability/abrasion resistance
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24
Q

Describe the laminated structure of a juice box (out -> in) (5)

A
  1. PE (outer protection)
  2. Printed paper (printable, strength)
  3. PE (puncture resistance)
  4. Aluminum (moisture/flavor barrier)
  5. PE (sealability, prevent metallic taste)
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25
heat-seal depends on: (3)
melt temp machine pressure contact time
26
Ideal features for a heat-sealing layer: (3)
low melt temp strong sealing properties low cost
27
The best sealing materials? What is the downside?
Ionomers (Surlyn) | $$$$!
28
generally, the higher the seal ability, the (higher/lower) the cost
higher
29
An alternative to ionomers for heat sealing, that is slightly lower in seal ability and cost?
acid copolymers
30
common heat seal layers, worst to best heat sealability: (3)
LDPE EVA (ethylene vinyl acetate) Ionomer (Surlyn)
31
What are the major purposes of intermediate barriers? (3)
heat sealing barrier toughness/mech structure
32
major purpose of the outermost and inntermost layers?
outer: printability/abrasion resistance inner: food contact (safe/nonreactive)
33
____ is comonly used as the outer barrier layer. what are its properties?
nylon abrasion resistant/tough, but poor water barrier (*good gas barrier if DRY)
34
a nylon + LDPE laminate is considered a ____ barrier laminate
intermediate
35
What can be added to made an intermediate laminate into a high-barrier laminate?
Add a barrier layer between | ex: PVDC (excellent water/gas barrier)
36
Example of a low-barrier laminate
OPVC outer (breathable) - high water barrier but low gas barrier LDPE/ionomer (coextruded) - low gas barrier
37
Saran-containing laminates are ____ barrier materials that are (flexible/rigid)
high barrier, flexible
38
2 examples of high barrier, semi-rigid laminate materials: | How are they produced?
PVC/EVOH/EVA PVC/EVOH/surlyn co-extrusion
39
2-layered laminates are usually ____barrier, and are (flexible/rigid)
medium barrier, flexible
40
materials commonly used to increase barrier properties: (3)
Saran EVOH Foil
41
Give the structure/materials of a non-shrink bag:
PA/PET outer (strength, O2 barrier) | LDPE/ionomer/EVA inner (moisture barrier, heat seal)
42
Give the structure/materials of a shrink bag:
nylon outer (strength) PVC/PVDC (gas barrier) EVA/surlyn inner (moisture barrier, heat seal)
43
2 machinery types for forming packages:
VFFS (vertical form-fill-seal) | HFFS (horizontal form-fill-seal)
44
Which is faster, VFFS or HFFS?
HFFS
45
Describe the process of VFFS:
``` unwind laminate forming & draw down (form package) product feed (fill package) longitudinal sealing jaw -> cross seal & cut off ```
46
T/F: VFFS is larger than HFFS systems
false: more compact
47
compare HFFS vs VFFS:
HFFS: Faster, multi-tunnel systems, horizontal fill VFFS: slower, compact, vertical fill
48
Describe the process of HFFS:
``` unwind laminate forming plow (forms film) product deposited (filled) form seam -> pouch close/seal ```
49
What types of seals are used in VFFS? (2) What is used for HFFS? (2)
VFFS: fin seal, lap seal HFFS: 3-side seal pouch, gusseted bottom
50
various forms of packages made by VFFS or HFFS:
bags, pouches/stand-up pouches, tear seams, dispenser, re-sealable bags
51
re-sealable zippers for ready-made foods are usually made of _____ in order to ____
``` PP withstand retort (heat-stable) ```
52
resealable closures types:
PP zipper | adhesive (ex: cookies)
53
What are specific packaging requirements for coffee/milk powder? What is the solution?
degassing (gas release from coffee) protection from O2, heat, light, moisture (preserve flavor/quality) solution: metallized PE (stiff, strong, barrier, opaque, seals, vacuum)
54
What packaging is used for coffee concentrate, and why?
PE/Al/PE/Al/PE (multilayer) seals, lightweight, protect from light & O2
55
What packaging is used for pizza, and why?
PET/PVDC/PE(or ionomer) PET: strength, PVDC: high barrier against gas/moisture/oil PE/Ionomer: seals
56
What packaging is used for fresh meat? Why?
PE/PA/PE or PET/PVDC/PE PE/PET: water barrier PA/PVDC: strength/barrier PE: seals
57
Why does sausage have different packaging material requirements than fresh meat?
Different composition (less moisture, more fat)
58
What packaging is used for sausage? Why?
PE/OPA | water barrier, strength, oil resistant, seals
59
What packaging is used for fresh pasta? Why
PE/PVC | strength, moisture barrier, seal
60
What packaging is used for cheese? Why?
PET/PE/PVDC strength, moisture barrier seal barrier (odor), oil resistant
61
What packaging is used for baked goods? Why?
PVDC/PET(or PP)/PE | barrier, seal
62
What packaging is used for freeze-dried goods?
``` 48ga PETE 60ga extruded PE 28ga Aluminum 60ga extruded PE 40ga LLDPE freshlock zipper ```

Food Packaging (11 decks)

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