BOBST, Brückner and Mitsui Chemicals have joined forces to create a mono-material recyclable retort solution for food packaging, said to have high barrier properties based on opaque metallization.
Anrika Heermant, Senior Specialist at Mitsui Chemicals Europe, says it has previously only been possible to maintain a high barrier in retort solutions using a composite layer structure consisting of polyester, aluminium foil and other materials. The most challenging part of producing a mono-material solution is maintaining the barrier qualities after the retorting process, which happens under very high temperatures. Willi Lindemann, specialist inline coating, New Technologies at Brückner, adds that the other challenge with moving to mono-material polypropylene is the risk of shrinkage, which would have a negative impact on the barrier properties.
Nick Copeland, R&D director of Barrier Solutions at BOBST, states the companies aimed to create an ‘ultra-thin, stretchable, heat-resistant’ barrier primer combined with advanced opaque metallization. Brückner provided the inline coating technology to stretch the primers and create very thin layers, utilised to find the right hardness of the coating material to ensure it was stretchable and could withstand the retort conditions.
Bobst’s Expert K5 vacuum metallizer with AluBond technology was used to improve the barrier, adhesion and maintain the surface energy over time. Mitsui contributed its water-based Takelac polyurethane dispersion and top coating grade to enhance the barrier performance and protect the Alubond layer. The company also applied a newly developed Takelac Primer grade for heat resistance.
The partners have reportedly achieved proof of concept for the solution and have tested the Oxygen Transmission Rate (OTR), the Water Vapour Transmission Rate (WVTR) and adhesion levels before and after the retort process with ‘excellent’ results. More partners may be introduced in future to ensure the solution is robust, repeatable, and production proof.
In related news, Siegwerk, Borouge, and TPN Food Packaging (TPN) collaborated on a fully recyclable, mono-material barrier stand-up pouch said to provide robust protection and superior functionality. The solution aims to meet the needs of converters, brand owners, and consumers seeking sustainable, high-performance packaging for oxygen-sensitive, dry products such as nuts and pet food.
Last month Coveris introduced its new resealable mono-material tray for refrigerated food applications, designed to replace non-recyclable, mixed-material packaging while ensuring extended shelf life and consumer convenience. The solution is ideally suited for processed meats, sausages, dairy products, cheese, and other chilled or refrigerated items.
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