POLIPROTECT
M&G’s new barrier solution
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Poliprotect & BicoPET:
Poliprotect differs from M&G’s previous solution, Actituf, primarily because of
the technology used, the BicoPET.
BicoPET ™ is an innovative technology patented by M&G which allows to mix
in a single chip the active barrier (preventing the oxygen entry) and the passive
barrier, BASF’s new nylon Ultramid X17 (preventing the loss of CO2).
In such a way M&G offers to converters the possibility to have both active and
passive barrier without the need to dose. This avoids possible errors and limits
the necessity for quality control.
RECIPE 2
RECIPE 1
BicoPET
Standard
PET
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M&G’s new range of barrier resin:
•
Poliprotect PB (passive barrier)
this is the solution for products that require passive barrier only:
 CSD
 Ready to drink
•
Poliprotect APB (active and passive barrier)
this solution guaranties a high active barrier associated with the necessary
passive barrier for the following applications:
 Juices, smoothies, juice based products
 Beer, Wine
 Milk and dairy products
 Food applications (ketchup, salad dressing, etc...)
•
Poliprotect JB (juice barrier)
this solution suits particularly products that need medium active barrier:
 Juices, smoothies, fruit based beverages
 Food applications (ketchup, salad dressing, etc...)
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The BicoPET™ structure:
Polyprotect PB
PET
Nylon
•
•
•
Polyprotect APB & JB
PET/new scavenger
Nylon
For the PB grade, the core of the pellet contains the passive barrier.
For the APB grade, the core contains the passive barrier while the shell is
made of modified PET mixed with the active barrier.
For the JB, the structure is identical to the APB but with a nylon content
significantly lower.
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What are the advantages of BicoPET™?
•
No additional investment required by the converter because it is
dried, injection molded, and reheat blow molded like standard
PET
•
No separate handling system for nylon
•
No dosing errors
•
Excellent dispersion
•
Barrier active only when bottles are blown which allows to keep
preforms at stock without time limit
•
Recyclable
•
Fully approved by FDA and EC
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With Poliprotect, a perfectly transparent bottle:
Material tested
Haze*, %
Standard PET
2.4
Standard PET + 7% nylon
(MDX6)
15.5
Poliprotect
2.8
*Haze is measured by Gardner haze meter.
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Ultramid® X17, the key to our transparency:
•
What makes Poliprotect unique in comparison to the other existing solutions is the
new nylon Ultramid® X17 included in each pellet.
•
The development of Ultramid® X17 is the result of a considerable R&D investment
from the part of BASF for the exclusive use of M&G.
•
This innovative nylon has a perfect compatibility with our modified PET and allows to
have high transparency in the final bottle appearance.
•
The comparison with the MDX6 (in the same % of dosage) shows that the final haze
on clear bottles is dramatically reduced.
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With Poliprotect, the same bottle resistance as
standard PET:
Poliprotect vs Standard PET
mechanical characterisation 500 ml bottle
35
30
25
STD
Polyprotect
20
15
10
5
0
Burst
•
•
•
Top load
Creep
Burst (bar): it determines the bottle strength by pressurizing it until it bursts.
Creep (%): it examines the progressive expansion of a bottle once it is filled and
carbonated and then put under pressure.
Top load (kg): it measures a container's maximum resistance to a vertical pressure.
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With Poliprotect APB, a permanent barrier on O2
O2 ingress - Fibox monitoring
Beer bottle 28 g 500 ml
storage temperature 22°C
1,8
STD
1,6
STD + 7% Nylon
STD + 4 % AMOSORB
1,4
Polyprotect APB
Delta O2 (ppm)
1,2
1,0
0,8
0,6
0,4
0,2
0,0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200 210 220
230 240 250 260 270 280 290 300
Tim e (day)
•
•
The red line indicates the rate of 1 ppm of 02 ingress which is the typical market
requirement.
It appears clearly that Poliprotect APB’s performance exceeds by far this target and
therefore is the ideal barrier solution for sensitive beverages.
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Poliprotect continous barrier on
O2
500 ml - 2.8 vol@22°C
28 mm PCO neck
1
0,9
0,8
O2 ingress [ppm]
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0
0
50
100
150
200
250
300
350
400
450
500
550
-0,1
Time [Days]
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High protection against Vit. C loss
This test was commissioned by an Italian top-quality juice
maker on a 250 ml bottle 100% Poliprotect APB + barrier
cap filled with a smoothies (100% juices of mixed fruits)
The Vit. C loss is very limited due to the fact that the oxygen
ingress is prohibited by the barrier scavenger, also odour
and color test show no evident change during time.
SMOOTHIES 100% FRUIT (strawberry + other fruits)
120
Vit C loss
100
80
60
40
20
0
0
1 weeks 2 weeks 4 weeks 45 days
2
3
months months
4
5
months months
6
months
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Long lasting barrier for juices
This graph represents a real test done with a premium orange juice (100% pure juice)
that has given a very positive results after approx 9 months shelflife.
The customer was using mulitlayer bottles and comparing the Poliprotect results on
Vit. C loss saw no difference with its solution and switched to Poliprotect.
This will grant the customer higher flexibility and economical convenience at the same
barrier performance.
ppm Vit C
Vit C loss of orange juice
500
450
400
350
300
250
200
150
100
50
0
4 wk 37°C
8 wk 37°C
Start
4 wk 20°C
brown
12 wk 20°C
18 wk 20°C
26 wk 20°c
36 wk 20°C
40 wk 20°C
transparent
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With Poliprotect, a reliable and flexible barrier on CO2
• CO25 loss simulation- 1L Bottle - 52 g
carbonatation level (vol)
4.5
4
3.5
3
2.5
2
1.5
1
0
30
60
90
120
shelf life (days)
150
180
• Poliprotect was developed to meet current market requirements
on CO2.
• Nevertheless, in case of higher performance needs on passive 13
barrier, our solution can easily be adapted by adding a greater %
of nylon.
Poliprotect performances versus
competitors solutions
Attività 170PA/08
1000 ml - 38g PCO - 2,8vol
0,200
0,180
Poliprotect APB- 280°C
Oxygen Ingress [ppm]
0,160
Poliprotect APB - 300°C
0,140
0,120
Polyshield
0,100
0,080
0,060
0,040
0,020
0,000
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
Time [days]
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Masterbatches
•
M&G has homologated a family of colorants from Holland Colours,
which have perfect compatibility with our Polyprotect resin.
•
The same co-operation is ongoing with Colormatrix, Clariant, Repi,
Toyo, Sukano, Polyone.
•
Upon request, M&G can homologate a specific masterbatch in
short time.
•
Already a list of colorants tested and approved to be used with
Poliprotect is available.
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PoliProtect is recyclable as part of the regular PET
stream :
•
Extensive testing has shown that PoliProtect has the
same physical properties as PET when recycled at
25%
•
PoliProtect is fully recyclable in the colored bottle
stream
•
Due to the presence of nylon a color shift can occur
during recycling of bottles into the clear stream
•
At projected market penetrations of around 2%,
testing has shown color shift well within the
recycling industry’s tolerance levels
•
Sorting equipment exists which can move nylon
containing flakes to the colored stream
•
Recycled resin can be toned
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EEC approval – FDA - Migrations
•
•
Poliprotect fulfills the requirements of the European Community
and national food packaging regulations.
None of the substances listed in Directive 76/769/EEC are present
in this resin
Poliprotect has received the FDA in 2008.
•
In Fraunhofer Institute Poliprotect PET bottles for juices were
screened for migration of relevant compounds with satisfactory
results. (available report with results)
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Manufacturing areas and R&D
Poliprotect resins are produced today in:
•
Europe, Italy, Patrica (south of Rome) – M&G Polimeri Italia
Installed capacity: 30.000 MT/year
•
USA, West Virginia (Apple Grove) – M&G Polymers LLC
Installed capacity: 60.000 MT/year
•
M&G is working on improvement and innovation in barrier PET
through the work of the two R&D centers:
- R&D in USA, Sharon Center for resin
- R&D in Italy, Rivalta for packaging application of the barrier
resins
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M&G a reliable partner
Thanks to our past experience as preform producer (M&G sold its
Packaging BU in 2008 to Plastipak), we work with our customers
as consultants also for specific projects.
In this context our Technical Assistance, and our R&D people
combine their know-how to offer a support for launching new
product packaging or for the restyle of existing one.
-
In this area we provide together with the support of Proplast
Institute the following services:
Production of preforms/bottles samples
Study for new design of preforms/bottles
Tests on permeation (02 and Co2)
Test on Vit. C for juices or other beverages
Mechanical tests: creep, burst, top load
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M&G Registered Patents
•
Mg30:
Polyester resin blends with high-level gas barrier properties
(Barrier Composition)

•
Mg41:
Transparent polyester resins and articles there from
(Appearance)


•
PET/ PA mix with domains between 200 - 400 nm
PA domains in Bottle or Preform in the range of:
30 – 110 nm
Mg48:
Article comprising light absorbing composition to mask the
visual haze and related method
(Appearance)

Use Colour to mask Haze: any Domains between 400 – 700 nm
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The Mossi & Ghisolfi Group
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The structure of the Mossi & Ghisolfi Group
M&G Group Business Units
Polymers BU
PET standard grades
PET barrier grades
Chemtex
Film
R&D
Acetate BU
Diocetate Plastic
Eng. & Tech
Film
PET foamable grades
Recycling
Triacetate Plastic
Project
Management
Procurement
Diacetate Textile
PTA
Construction
Polyester Fiber
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M&G is the global leader in PET production
The M&G group is today the biggest
PET producer thanks to its total
capacity of 2 Millions tons of PET per
year
kt/year
Suape, Brasil
Altamira, Mexico
Apple Grove, WV USA
Patrica, Italy
TOTAL APPROX
600
650
450
300
2000
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Polymers B.U. - Market Shares
M&G Group: a 10% market share in 2009 that makes M&G
Group the world leader of the PET market
Others
49%
M&G 10%
Eastman 8%
Invista 7%
Far Eastern
5%
La Seda 5%
Indorama
4%
NanYa 4%
Wellman 4%
San Fang Xiang
4%
Based on 2009 capacities
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A worldwide presence:
Wilmington
Apple Grove Engineering
Resin
Central Office
Tortona
Milan
Group Head
Office
Group Head Office
Europe Reg. Office
Sharon
Center
Verbania
Resin
Cellulose Acetate
R&D Centre
Rivalta
Houston
R&D Centre
North America
Regional Office
Patrica
Resin
Altamira
Resin
Beijing
Engineering
Poços de Caldas
Resin
Fiber
R&D Centre
Shangai
Engineering
Mumbai
Mumbai
Engineering
Engineering
Sao Paulo
South America
Regional Office
Bangalore
Engineering
Cabo
Fiber
Indaiatuba
Paulínia
Recycle
PTA
Suape
Resin
Pignataro M.
Film
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Thank you
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