Multilayer Barrier For Food Packaging
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Food Packaging
Multilayer Food Packaging solutions: The Government of India has recently launched an initiative “Make in India” with the goal on making India as manufacturing hub. With this initiative a huge opportunity is foreseen in the focus sector of food processing Industry. The Ministry of Food Processing Industries (MOFPI) is supporting the “Make in India” initiative with the focus on the reduction in the wastage of perishable agricultural produce and enhancing shelf life of food products thereby ensuring value addition to agricultural produce. Multilayer rigid plastic container for Food Packaging will be very useful as one of the tools by the food processing industry in achieving the goals of “Make in India” with modern improved way of packaging and also reduction in the wastage of perishable agriculture produce along with enhanced shelf life. Conventional rigid plastic containers such as PET, HDPE, PP and LDPE containers are commonly used in the food industries; but these containers do not offer sufficient barrier required against the Oxygen gas which is very detrimental for the products shelf life. Glass containers on the other hand have its own problems such as heavy weight of the container, high transport cost for empty as well as filled containers, difficult handling, design freedom and injury during handling. This makes glass containers less preferable as compared with the plastic containers. In order to increase the product’s shelf life, a barrier layer of EVOH is introduced into the plastic container to decrease the permeability of gases, aromas and moisture. These containers are also known as multilayer EVOH containers or Co-extruded containers or simply Co-ex containers.
Multilayer EVOH plastics containers; because of their high barrier properties gives extended shelf life and in turn can be used for replacement of glass and aluminium packaging. Structure of Multilayer Containers: The six layer structure of co-extruded container is as given below. The regrind layer is either next to outermost Virgin HDPE / PP layer or the innermost HDPE/ PP layer. Inner Virgin HDPE / PP (1) Process grind Layer
Copyright @ 2014 by Bhupendra Singh
Food Packaging (2) Adhesive Layer (3) Barrier Layer (EVOH ) (4) Adhesive Layer (5) Outer Virgin HDPE / PP (6) The raw material used for the majority thickness of container shall be HDPE or other materials such as Polypropylene (PP) as agreed between buyer and seller. The adhesive layer used is EAA based polymer or any other suitable layer as agreed between buyer and seller. The barrier layer used is usually EVOH or PA or any other suitable polymer layer as agreed between buyer and seller. Advantages of using Multilayer / Co-extruded containers having EVOH as barrier layer: O2/ CO2 Barrier No Migration
Low Weight
UV Barrier
Multilayer Container Characteristic s
Design Freedom
Aroma/ Fragrance Barrier
Solvent Barrier
Easy handling
Superior Gas and Moisture Barrier Properties -
EVOH based Multilayer containers provide excellent barrier properties against the permeation of gases. It exhibits superior barrier compared to any other conventional polymers. The gas barrier prevents oxygen from penetration thus preventing the spoilage of the contents and preserves the organoleptic properties of the product..
Barrier to Flavour Permeation -
Multilayer containers also give excellent barrier to flavour of the packaged food.
Barrier to Aroma Permeation -
The EVOH layer provides an excellent barrier against the permeation of aroma. Thus EVOH based Multilayer packaging containers provides high aroma retention for use in food packaging. This helps in retaining the value of the product till it reaches to the ultimate customer.
Resistance to Oil
Copyright @ 2014 by Bhupendra Singh
Food Packaging -
EVOH provides effective barrier to oils and organic compounds by way of reduced oxygen permeation through the packaging wall.
Weather Resistance -
EVOH based multilayer plastic container provides good weather resistance to outdoor exposure. Since the EVOH is sandwiched between other polymer layers hence its barrier remains intact during transportation, handling and storage.
Hot Filling of Container -
The biggest advantage with these EVOH based Multilayer container is that the products can be hot filled at 75 to 80 deg C; this helps in enhanced production on the shop floor for the products.
Co-extruded plastics containers because of their non-porous property gives extended shelf life and in turn can be used for replacement of glass, Tin and aluminium packaging in most of the food products.
Advantages of using Multilayer Containers over Glass and Metal packaging: Properties / Features
Multilayer Technology
Glass
Metal
O2 Barrier
Very Good
Excellent
Excellent
H2O Barrier
Excellent
Excellent
Excellent
Migration in Food
None
None
Concern
Design Freedom
Excellent
Concern
Poor
Weight
Very Low
Concern
High
Presentation
Excellent
Good
Poor
Safe Handling
Excellent
Concern
Poor
Shelf Life
Very Good
Excellent
Excellent
Corrosion
Nil
Nil
Concern
Case Study:
Advantage of Multilayer Containers over Glass containers for 1000 gm Ketchup Container: Characteristics Empty Bottle Weight (Per
Multilayer Container 1 Kg SKU 70 gms
Copyright @ 2014 by Bhupendra Singh
Glass Containers 1 Kg SKU 470 gms
Savings compared to Glass container 85 %
Food Packaging Piece) Filled Bottle Weight (Per Piece) Empty Bottle Transport Cost
1070
1470 gm
27 %
Low
High
30 -40 %
Filled Bottle Transport Cost
Low
High
25 – 30 %
Handling Breakages / Product Loss Export Container Stuffing
0
1-3 %
3-6 %
High
Low
20- 30 %
Final Export Packaging Expenses Decoration Options
Low
High
20 %
Shrink Sleeve, Screen Print, Label, Pad Printing
Shrink Sleeve, Label
--
Advantage of Multilayer Containers over Glass containers for 300 gm Pickle Container: Characteristics
Multilayer Container 300 ml
Glass Containers 300 ml
Empty Bottle Weight (Per Piece) Filled Bottle Weight (Per Piece) Empty Bottle Transport Cost
25 gms
250 gms
Savings compared to Glass container 90 %
325
550
40 %
Low
High
30 -40 %
Filled Bottle Transport Cost
Low
High
25 – 30 %
Handling Breakages / Product Loss Export Container Stuffing
0
1-3 %
3-6 %
High
Low
25- 30 %
Final Export Packaging Expenses Decoration Options
Low
High
20 %
Shrink Sleeve, Screen Print, Label, Pad Printing
Shrink Sleeve, Label
--
Copyright @ 2014 by Bhupendra Singh
Food Packaging
Applications and References for Multilayer; High Shelf-life Packaging
Ketch Up in Multilayer Containers Shelf Life : 9 – 12 Months
Flavoured Energy Drink (Powder or Liquid) in Multilayer Containers for Improved Flavour Retention Shelf Life : 9 – 12 Months
Salad Dressing packaging in Multilayer Containers for Improved Shelf Life Shelf Life : 6 – 12 Months
Indian Sweets such as Rasgulla etc. in Multilayer Containers in Multilayer Container These containers can also be retorted. Shelf Life : 6 – 12 Months
Pickle/ Cooking Pastes/ Fruit Jam in Multilayer Containers Shelf Life : 6 – 12 Months
Copyright @ 2014 by Bhupendra Singh
Food Packaging
Ginger Garlic Paste in Multilayer Containers Shelf Life : 6 – 12 Months
Cut Fruits in Multilayer Container for Replacement of Tin Containers Shelf Life : 6 – 12 Months
Tomato Puree and other vegetable Purees in Multilayer Container for Replacement of Tin Containers Shelf Life : 6 – 12 Months
Ghee (Clarified butter) in Multilayer Container for Replacement of Tin Containers Shelf Life : 6 – 12 Months
Coffee and Flavoured Tea packaging in Multilayer Container for retention of flavour Shelf Life : 6 – 12 Months
Suggested Applications of Multilayer Packaging: Ketch up
Dairy Products
Fruit Juices
Ghee
Mustard Paste
Mayonnaise
UHT Milk
Fruit Jams
Infant Foods
Garlic Paste
Topping Sauces
Dips
Mix Fruit Jams
Puree
Pickles
Fruit Pulps
Sweets
Gherkins
Honey
Ginger Paste
Copyright @ 2014 by Bhupendra Singh
Food Packaging
Dry Fruits
Coffee
Cut Fruits
NutriSupplements
Chilli Paste
Snacks
Jellies
Oils
Condiments
Spices
Mango Chutney
Squeezy Chutney
Exotic Chutney
Cooking Sauces
Cooking Pastes
Disclaimer: All the illustrated diagrams and pictures belong to their respective companies and brands.
Copyright @ 2014 by Bhupendra Singh
Multilayer Food Packaging solutions: The Government of India has recently launched an initiative “Make in India” with the goal on making India as manufacturing hub. With this initiative a huge opportunity is foreseen in the focus sector of food processing Industry. The Ministry of Food Processing Industries (MOFPI) is supporting the “Make in India” initiative with the focus on the reduction in the wastage of perishable agricultural produce and enhancing shelf life of food products thereby ensuring value addition to agricultural produce. Multilayer rigid plastic container for Food Packaging will be very useful as one of the tools by the food processing industry in achieving the goals of “Make in India” with modern improved way of packaging and also reduction in the wastage of perishable agriculture produce along with enhanced shelf life. Conventional rigid plastic containers such as PET, HDPE, PP and LDPE containers are commonly used in the food industries; but these containers do not offer sufficient barrier required against the Oxygen gas which is very detrimental for the products shelf life. Glass containers on the other hand have its own problems such as heavy weight of the container, high transport cost for empty as well as filled containers, difficult handling, design freedom and injury during handling. This makes glass containers less preferable as compared with the plastic containers. In order to increase the product’s shelf life, a barrier layer of EVOH is introduced into the plastic container to decrease the permeability of gases, aromas and moisture. These containers are also known as multilayer EVOH containers or Co-extruded containers or simply Co-ex containers.
Multilayer EVOH plastics containers; because of their high barrier properties gives extended shelf life and in turn can be used for replacement of glass and aluminium packaging. Structure of Multilayer Containers: The six layer structure of co-extruded container is as given below. The regrind layer is either next to outermost Virgin HDPE / PP layer or the innermost HDPE/ PP layer. Inner Virgin HDPE / PP (1) Process grind Layer
Copyright @ 2014 by Bhupendra Singh
Food Packaging (2) Adhesive Layer (3) Barrier Layer (EVOH ) (4) Adhesive Layer (5) Outer Virgin HDPE / PP (6) The raw material used for the majority thickness of container shall be HDPE or other materials such as Polypropylene (PP) as agreed between buyer and seller. The adhesive layer used is EAA based polymer or any other suitable layer as agreed between buyer and seller. The barrier layer used is usually EVOH or PA or any other suitable polymer layer as agreed between buyer and seller. Advantages of using Multilayer / Co-extruded containers having EVOH as barrier layer: O2/ CO2 Barrier No Migration
Low Weight
UV Barrier
Multilayer Container Characteristic s
Design Freedom
Aroma/ Fragrance Barrier
Solvent Barrier
Easy handling
Superior Gas and Moisture Barrier Properties -
EVOH based Multilayer containers provide excellent barrier properties against the permeation of gases. It exhibits superior barrier compared to any other conventional polymers. The gas barrier prevents oxygen from penetration thus preventing the spoilage of the contents and preserves the organoleptic properties of the product..
Barrier to Flavour Permeation -
Multilayer containers also give excellent barrier to flavour of the packaged food.
Barrier to Aroma Permeation -
The EVOH layer provides an excellent barrier against the permeation of aroma. Thus EVOH based Multilayer packaging containers provides high aroma retention for use in food packaging. This helps in retaining the value of the product till it reaches to the ultimate customer.
Resistance to Oil
Copyright @ 2014 by Bhupendra Singh
Food Packaging -
EVOH provides effective barrier to oils and organic compounds by way of reduced oxygen permeation through the packaging wall.
Weather Resistance -
EVOH based multilayer plastic container provides good weather resistance to outdoor exposure. Since the EVOH is sandwiched between other polymer layers hence its barrier remains intact during transportation, handling and storage.
Hot Filling of Container -
The biggest advantage with these EVOH based Multilayer container is that the products can be hot filled at 75 to 80 deg C; this helps in enhanced production on the shop floor for the products.
Co-extruded plastics containers because of their non-porous property gives extended shelf life and in turn can be used for replacement of glass, Tin and aluminium packaging in most of the food products.
Advantages of using Multilayer Containers over Glass and Metal packaging: Properties / Features
Multilayer Technology
Glass
Metal
O2 Barrier
Very Good
Excellent
Excellent
H2O Barrier
Excellent
Excellent
Excellent
Migration in Food
None
None
Concern
Design Freedom
Excellent
Concern
Poor
Weight
Very Low
Concern
High
Presentation
Excellent
Good
Poor
Safe Handling
Excellent
Concern
Poor
Shelf Life
Very Good
Excellent
Excellent
Corrosion
Nil
Nil
Concern
Case Study:
Advantage of Multilayer Containers over Glass containers for 1000 gm Ketchup Container: Characteristics Empty Bottle Weight (Per
Multilayer Container 1 Kg SKU 70 gms
Copyright @ 2014 by Bhupendra Singh
Glass Containers 1 Kg SKU 470 gms
Savings compared to Glass container 85 %
Food Packaging Piece) Filled Bottle Weight (Per Piece) Empty Bottle Transport Cost
1070
1470 gm
27 %
Low
High
30 -40 %
Filled Bottle Transport Cost
Low
High
25 – 30 %
Handling Breakages / Product Loss Export Container Stuffing
0
1-3 %
3-6 %
High
Low
20- 30 %
Final Export Packaging Expenses Decoration Options
Low
High
20 %
Shrink Sleeve, Screen Print, Label, Pad Printing
Shrink Sleeve, Label
--
Advantage of Multilayer Containers over Glass containers for 300 gm Pickle Container: Characteristics
Multilayer Container 300 ml
Glass Containers 300 ml
Empty Bottle Weight (Per Piece) Filled Bottle Weight (Per Piece) Empty Bottle Transport Cost
25 gms
250 gms
Savings compared to Glass container 90 %
325
550
40 %
Low
High
30 -40 %
Filled Bottle Transport Cost
Low
High
25 – 30 %
Handling Breakages / Product Loss Export Container Stuffing
0
1-3 %
3-6 %
High
Low
25- 30 %
Final Export Packaging Expenses Decoration Options
Low
High
20 %
Shrink Sleeve, Screen Print, Label, Pad Printing
Shrink Sleeve, Label
--
Copyright @ 2014 by Bhupendra Singh
Food Packaging
Applications and References for Multilayer; High Shelf-life Packaging
Ketch Up in Multilayer Containers Shelf Life : 9 – 12 Months
Flavoured Energy Drink (Powder or Liquid) in Multilayer Containers for Improved Flavour Retention Shelf Life : 9 – 12 Months
Salad Dressing packaging in Multilayer Containers for Improved Shelf Life Shelf Life : 6 – 12 Months
Indian Sweets such as Rasgulla etc. in Multilayer Containers in Multilayer Container These containers can also be retorted. Shelf Life : 6 – 12 Months
Pickle/ Cooking Pastes/ Fruit Jam in Multilayer Containers Shelf Life : 6 – 12 Months
Copyright @ 2014 by Bhupendra Singh
Food Packaging
Ginger Garlic Paste in Multilayer Containers Shelf Life : 6 – 12 Months
Cut Fruits in Multilayer Container for Replacement of Tin Containers Shelf Life : 6 – 12 Months
Tomato Puree and other vegetable Purees in Multilayer Container for Replacement of Tin Containers Shelf Life : 6 – 12 Months
Ghee (Clarified butter) in Multilayer Container for Replacement of Tin Containers Shelf Life : 6 – 12 Months
Coffee and Flavoured Tea packaging in Multilayer Container for retention of flavour Shelf Life : 6 – 12 Months
Suggested Applications of Multilayer Packaging: Ketch up
Dairy Products
Fruit Juices
Ghee
Mustard Paste
Mayonnaise
UHT Milk
Fruit Jams
Infant Foods
Garlic Paste
Topping Sauces
Dips
Mix Fruit Jams
Puree
Pickles
Fruit Pulps
Sweets
Gherkins
Honey
Ginger Paste
Copyright @ 2014 by Bhupendra Singh
Food Packaging
Dry Fruits
Coffee
Cut Fruits
NutriSupplements
Chilli Paste
Snacks
Jellies
Oils
Condiments
Spices
Mango Chutney
Squeezy Chutney
Exotic Chutney
Cooking Sauces
Cooking Pastes
Disclaimer: All the illustrated diagrams and pictures belong to their respective companies and brands.
Copyright @ 2014 by Bhupendra Singh
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