Delivering
Innovation From
Concept to
Consumer……
working for you.
Colin Smith
Agenda
 Brief Introduction
 From Concept to Consumer – What does it mean?
 Five Innovative Packaging Solutions :- Oxygen Barrier Coating
- UV Barrier Coating
- Oxygen Barrier Adhesive
- Laser Marking Technologies
- Brand Protection
2
Sun Chemical’s global presence and leadership
Strong Parent Company DIC (Japan)
Color & Comfort by Chemistry
$9.7 billion net sales
190 subsidiaries and affiliates
300 regional locations, 10 world-class R&D centers
21,572 employees in 64 countries
13%
18%
Chemical
Solution
Materials
19%
Synthetic Resins
Neo-Graphic
Arts Materials
1%
Other
49%
Printing Ink
and Supplies
3
From Concept To Consumer…..
4
From concept to consumer….delivered!
5
-Oxygen Barrier Coating
-UV Barrier Coating
-Oxygen Barrier Adhesive
-Laser Marking Technologies
-Brand Protection
6
Oxygen Barrier Coating
7
Coating Applications - Barrier
Market / Applications
O2
 Dry Food
Chilled Food
 Liquid Packaging
Market / Applications
Fresh food
Chilled/Frozen Food
Dry Food
Fast Food
Bakery
Barrier technology
 PVdC
 EVOH/PVOH
 Speciality Oxides
 Metallized
 Co-extrusions
Barrier technology
PVdC/Flurocarbons
Silicones
Wax based
Co-extrusions/PE
Package structure
 Bags
 Lidding
 Stand Up Pouches
 Forming Webs
 Wraps
Package structure
Outer cases
Sacks & Bags
Boxes & Trays
Transient Containers
- Oxygen Barrier
- Aroma Barrier
- Mineral Oil Barrier
8
Technical Data- SunBar O2 barrier
SunBar performances: Untreated polyester film OTR 100-110 cc/m2/24 hrs
9
23ºC & 50% RH
Oxygen Transmission Rate
(cc / m² / 24 hrs)
8
Oxygen transmission rate
measured using a
MOCON OX-TRAN® 221
within 24 hours of coating.
7
OTR varies with PET grade.
6
5
4
PET / 50 PE:EVOH:PE Extrusion
3
0.3 dry coating weight
2
1
0
PVdC-PET
Met-PET
AlOx -PET
SiOx-PET
EVOH-PET SunBar-PET
 PVdC major disadvantage – contains chlorine & higher OTR
 AlOx / SiOx major disadvantage – brittle & higher OTR
 EVOH deteriorates over time in humid storage conditions
SunBar coating replaces PVdC, EVOH, AIOx and SiOx for O2 barrier
9
Coating Applications
Light weighting
Commercial 3-Ply Laminate
2-Ply Laminate plus printable
barrier coating
Polymer Film
Polymer Film
Ink
Barrier Coating
Adhesive
Ink
MET Polymer Film
Adhesive
Adhesive
Polymer Film
Polymer Film






Removal of barrier film or foil and one layer of adhesive
Lighter weight packaging (up to 30% reduction)
Improved laminate integrity (post flexing O2 barrier improvement)
Lower material and / or operational costs
Improved recycling
Improved shelf life
10
Coating Applications- SunBar O2 Barrier
Monoweb
Commercial 2-Ply Laminate
PVdC coated
PET
Ink
Adhesive
Polymer Film






1-Ply plus printable barrier
coating
OPV
Ink
Barrier Coating
Polymer Film
No chlorine
No adhesive
Improved O2 barrier
Improved shelf life
Increased sales opportunity for converter-monoweb
Increased yield
11
Technical Data – SunBar O2 barrier
Flexibility of barrier coatings
9
OTR @ 23oC & 50%RH
(cc / m2 / 24 hrs)
8
7
6
5
AlOx-PET
4
SiOx-PET
3
Met-PET
2
PVdC-PET
1
EVOH co-ex/PET
0
SunBar-PET
0
5
10
20
50
Number of Gelbo Flexes
Oxide coated and metallized films have poor flex resistance
12
SunBar value proposition – general summary
Market
Barrier
 Chlorine-free
 Excellent O2 / aroma / odor barrier
 Enables light weighting
 Replaces PVdC and EVOH barriers
 Improves sustainability
 Improves flex crack resistance of oxide / metallized
 Removes metal
films
 Extends shelf life
 Transparent
 Improves ability to recycle
 Alternative to expensive
barrier films
Application
 Coating can be applied at conventional film weights
 Can be applied on existing equipment
 Enables removal of barrier film & adhesive in multi-ply laminates
 Allows duplex laminates to compete with triplex
 Reduces processing waste
 Reduces energy consumption
 Saves on inventory working capital
 Applied only where needed
13
UV Barrier Coating
14
SunBar UV barrier coatings
potential uses
 Protects sensitive foodstuffs from degradation
accelerated by UV light
 Improved visibility of UV sensitive products at point of sale
 Allows transparent packaging
 Potential to extend shelf life of UV sensitive foods
100.0
3
% Transmission
90
Absorbance
2.5
2
1.5
80
70
60
50
%T
1
0.5
40
30
20
10
0
0
-10.0
0
0.5
1
1.5
2
2.5
3
Coating Weight gsm
dry
3.5
4
300.0
350
400
450
500
550
nm
600
650
700
750
800.0
Wavelength (nm)
15
SunBar UV barrier coatings
transparent packaging for food applications
Improved shelf life when using transparent
film
 Results after 140 days in typical retail lighting
and 20oC
 Scoring by trained sensory panellists
Sensory Assessment Grades vs Days
9
Light exposed Window
laminate bags
8
Sensory Grade
7
Light exposed UVAC
laminate bags
6
5
Dark control laminate
bags
4
3
Days
2
1
0
0
28
58
84
112
140
16
SunBar UV barrier coatings
transparent packaging for food applications
Reduced photo-bleaching of natural food pigments
 Cooked ham (results after 4 days at D65 and 4ºC)
 - carotene results after 2 weeks at D65 and RTP
17
SunBar UV barrier coatings
 The SunBar UV barrier coating acts as a barrier to UV
light whilst allowing visible light to penetrate into the
package.
 Some foods are affected by visible light as well as UV
light. The SunBar UV barrier coating is not a barrier to
visible light.
 Customers need to understand whether blocking the
UV light will bring the required benefit.
– SunBar UV barrier coating is only available in its pre
commercialisation form and is not fully transparent.
– Volume commitment is needed for scale up to the fully transparent
version.
18
Oxygen Barrier Adhesive
19
What is PASLIM
PASLIM is a new generation of patented solvent based
adhesive, approved for food packaging application, offering
additional oxygen barrier proprieties to the normal feature
provided by conventional solvent based adhesive.
PASLIM product range consist of two systems for following
application:
J40-OX+KX43C
for non metallized substrates
J40-OX+HX42M+AD42 for metallized substrates
20
Range of application
PASLIM adhesives have been developed with aim of:
Light weighting the laminate retaining the oxygen barrier
proprieties
Improve the oxygen barrier proprieties of existing laminates
Retain the barrier proprieties of laminate after retort process
Increasing the shelf life of food staff
21
Key feature of PASLIM adhesive
PASLIM adhesive provide the following features:
Be applied as conventional solvent based adhesive by rotogravure/semi
flexo trolley at higher solid content (50-60%)
Same level of performance in term of Bond and Heat seal strength of
conventional adhesive (laminate related)
Oxygen barrier proprieties
Flexibility when compare with other barrier coating (eg SiOx, AlOx)
avoiding lost of barrier by coating cracking
Oxygen barrier proprieties independent to relative humidity (improve vs
EvOH)
Low retort resistance (121°C x 30 min) without loosing oxygen barrier
proprieties
22
Flexibility feature
Conven
tional
adhesiv
e
PASLIM
OTR：cc/m2・day・atm(23℃)
Coating weight: J40-OX/HX42M/AD42=about 4g/m2(dry)
Conventional adhesive=about 3.5g/m2(dry)
PASLIM protects the barrier layer from flexional stress.
23
Retort feature
24
Comparison data of barrier performance
PASLIM gives barrier performance to conventional laminated films
PET
Conventional Adhesive
Barrier
Adhesive
CPP
Conventional adhesive
Barrier Adhesive(J40-OX/KX43C)
Films organization : Conventional Films
OTR
0%RH
47
OTR
90%RH
53
PET12/PE60
105
PET12/CPP70
Ny15/CPP70
Ny15/PE60
MVTR
OTR
0%RH
14
OTR
90%RH
9
MVTR
5.5
Ny15/PE60
4.7
80
5.2
PET12/PE60
17
11
4.5
116
92
5.9
PET12/CPP70
17
11
5.0
47
58
5.9
Ny15/CPP70
10
8
3.7
OTR：cc/m2・day・atm(23℃) MVTR：g/m2・day(40℃/90%RH)
Coating weight: J40-OX/KX43C=about 5g/m2(dry) Conventional adhesive=about 3.5g/m2(dry)
25
Comparison data of barrier performance
PASLIM enhances the barrier performance of metalized films.
PET
Conventional Adhesive
Barrier
Adhesive
VM-CPP
(AL Vacuumed Layer)
Conventional adhesive
Barrier Adhesive(J40-OX/HX42M/AD42)
Films organization : Metal vaporized films
PET12/VMPET12-PE60
OTR
0%RH
2.2
OTR
90%RH
2.1
0.3
PET12/VMPET12-PE60
OTR
0%RH
0.2
PET12/VMOPP15-PE80
8.5
11.1
0.4
PET12/VMOPP15-PE80
1.8
1.7
0.3
PET12/VMCPP25
5.0
5.4
0.4
PET12/VMCPP25
0.4
0.2
0.3
PET12/SiOxPET12-CPP70
0.5
0.2
0.7
PET12/SiOxPET12-CPP70
0.1
0.1
0.7
MVTR
OTR
90%RH
0.1
MVTR
0.1
OTR：cc/m2・day・atm(23℃) MVTR：g/m2・day(40℃/90%RH)
Coating weight: J40-OX/HX42M/AD42=about 4g/m2(dry) Conventional adhesive=about 3.5g/m2(dry)
26
Comparison data of barrier performance
PASLIM replaces organic barrier films to conventional films.
ＰＥＴ
Conventional Adhesive
Barrier
Adhesive
ＥＶＯＨ、ＰＶＤＣ
PE
Conventional adhesive
Barrier Adhesive(J40-OX/KX43C)
Films organization : Organic Barrier Films
Films organization : Conventional Films
OTR
0%RH
OTR
90%RH
MVTR
0.1
9
2.9
PET-K12 *1) /PE60
2
2
Ny-K12 *2) /PE60
8
13
Ny15/EVOH15/PE60
Ny15/ink/PVDC20 *2) /CPP70
*1)：Made in Japan *2)：Made in China
OTR
0%RH
OTR
90%RH
MVTR
Ny15/PE60
14
9
4.7
1.7
PET12/PE60
17
11
4.5
9
3.7
Ny15/PE60
14
9
4.7
15
4.1
Ny15/ink*3)/CPP70
12
10
3.7
*3)：Two component ink
OTR：cc/m2・day・atm(23℃) MVTR：g/m2・day(40℃/90%RH)
Coating weight: J40-OX/KX43C=about 5g/m2(dry) Conventional adhesive=about 3.5g/m2(dry)
27
Project Simulation – Excel Spreadsheet
 To predict the comparative cost/m2, Yield and Barrier performance of
alternative barrier structures
© Chris Robinson October 2014
Creating alternative Barrier laminate structures with SunBar Coatings and Paslim Adhesives
This calculator produces a quick assessment of Project viability
in terms of Yield, Cost/m2, OTR and WVTR
using Paslim Barrier Adhesives to replace traditional lamination films
and adhesives within High Performance barrier laminates
The savings estimated are only as good as the data it uses……..!
They do not represent guaranteed savings.
Using SunChemical products to replace Triplex laminate structures with Duplex alternatives
Using SunChemical products to replace speciality barrier films in Duplex Structures
Using SunChemical products to create Barrier Laminates from standard low-cost films
Using SunBar coatings to replace Duplex laminate structures with Monoweb alternatives
Note: for very thin films and very light coating weights, the prediction of barrier performance
becomes less accurate. Pinholing and surface roughness effects can reduce the effective
barrier to both Water and Oxygen.
If barrier performance is critical to the end use of the final laminate, measure it.
 Developed to quickly assess alternative barrier laminate structures
based on SunBar, Paslim, or a combination of both
28
Example 1 – Retort Sausage Packs (China)
Lam Adh Price
Paslim Price
4.00 Eur/kg
SunBar Price
12.00 Eur/kg
7.00 Eur/kg
TRIPLEX LAMINATE REPLACEMENT
Original Structure
15u PA – polyamide
Lamination Adhesive
25u EVOH CoEx
Lamination Adhesive
50u PE – polyethylene
3.50 gsm
Weight
gsm
93.75
Yield
m2/kg
10.67
Cost
Eur/m2
0.24
OTR 0%RH
cc/m2/day
0.10
OTR 85% RH
cc/m2/day
No data
WVTR
g/m2/day
1.91
3.50 gsm
Alternative Structure 1 - Using Barrier adhesive to replace the Barrier Layer
15u PA – polyamide
Barrier Adhesive
50u PE – polyethylene
5.00 gsm
Weight
gsm
69.3
Yield
Cost
OTR 0%RH
OTR 85% RH
WVTR
m2/kg
Eur/m2
cc/m2/day
cc/m2/day
g/m2/day
14.43
0.21
11.93
No data
2.94
35%
-11%
Yield improved by 35.3% producing 3763 additional m2 per Tonne, Laminate Cost reduced by 0.03 Eur/m2
Alternative Structure 2 - Using Barrier Coating and conventional adhesive to replace the Barrier Layer
15u PA – polyamide
SunBar Barrier coating
Lamination Adhesive
50u PE – polyethylene
0.30 gsm
3.50 gsm
Weight
gsm
68.1
Yield
Cost
OTR 0%RH
OTR 85% RH
WVTR
m2/kg
Eur/m2
cc/m2/day
cc/m2/day
g/m2/day
14.68
0.17
0.98
No data
3.65
38%
-29%
Yield improved by 37.7% producing 4017 additional m2 per Tonne, Laminate Cost reduced by 0.07 Eur/m2
SunBar is not chosen for this application because of the Retort requirement
29
Example 2 – PVdC Film replacement
TRIPLEX LAMINATE REPLACEMENT
Original Structure
12u PET – polyethylene terephthalate
Lamination Adhesive
3.50 gsm
12u PVdC coated PET
Lamination Adhesive
3.50 gsm
50u PE – polyethylene
Weight
gsm
87.98
Yield
m2/kg
11.37
Cost
Eur/m2
0.20
OTR 0%RH
cc/m2/day
1.97
OTR 85% RH
cc/m2/day
No data
WVTR
cm3/m2/day
1.88
Alternative Structure 1 - Using Barrier adhesive to replace the Barrier Layer
12u PET – polyethylene terephthalate
Barrier Adhesive
5.00 gsm
50u PE – polyethylene
Weight
gsm
69.3
Yield
Cost
OTR 0%RH
OTR 85% RH
WVTR
m2/kg
Eur/m2
cc/m2/day
cc/m2/day
g/m2/day
14.43
0.18
13.36
No data
2.87
27%
-8%
Yield improved by 27% producing 3063 additional m2 per Tonne, Laminate Cost reduced by 0.01 Eur/m2
Alternative Structure 2 - Using Barrier Coating and conventional adhesive to replace the Barrier Layer
12u PET – polyethylene terephthalate
SunBar Barrier coating
0.30 gsm
Lamination Adhesive
3.50 gsm
50u PE – polyethylene
Weight
gsm
68.1
Yield
Cost
OTR 0%RH
OTR 85% RH
WVTR
m2/kg
Eur/m2
cc/m2/day
cc/m2/day
g/m2/day
14.68
0.14
0.99
No data
3.55
29%
-28%
Yield improved by 29.2% producing 3318 additional m2 per Tonne, Laminate Cost reduced by 0.06 Eur/m2
OTR improved
Depending on the end use application, both SunBar and Paslim offer cost effective alternatives.
The choice will be based on other factors eg printing and lamination capability.
30
Example 3 – VMPET replacement
12u PET – polyethylene terephthalate
Lamination Adhesive
3.50 gsm
12u Met PET
Lamination Adhesive
3.50 gsm
50u PE – polyethylene
Weight
gsm
87.98
Yield
m2/kg
11.37
Cost
Eur/m2
0.19
OTR 0%RH
cc/m2/day
0.99
OTR 85% RH
cc/m2/day
No data
WVTR
cm3/m2/day
0.78
Alternative Structure 1 - Using Barrier adhesive to replace the Barrier Layer
12u PET – polyethylene terephthalate
Barrier Adhesive
5.00 gsm
50u PE – polyethylene
Weight
gsm
69.3
Yield
Cost
OTR 0%RH
OTR 85% RH
WVTR
m2/kg
Eur/m2
cc/m2/day
cc/m2/day
g/m2/day
14.43
0.18
13.36
No data
2.87
27%
-3%
Yield improved by 27% producing 3063 additional m2 per Tonne, Laminate Cost reduced by 0.01 Eur/m2
Alternative Structure 2 - Using Barrier Coating and conventional adhesive to replace the Barrier Layer
12u PET – polyethylene terephthalate
SunBar Barrier coating
0.30 gsm
Lamination Adhesive
3.50 gsm
50u PE – polyethylene
Weight
gsm
68.1
Yield
Cost
OTR 0%RH
OTR 85% RH
WVTR
m2/kg
Eur/m2
cc/m2/day
cc/m2/day
g/m2/day
14.68
0.14
0.99
No data
3.55
29%
-25%
Yield improved by 29.2% producing 3318 additional m2 per Tonne, Laminate Cost reduced by 0.05 Eur/m2
31
Laser Marking
32
1
SunLase™ - Description of principle (1)
 SunLase™ coating is used to print a white patch on a substrate
 The graphics are created when a low power CO2 laser changes the
colour of the patch to black where marked

PRINTING


Low power
CO2 laser
 MARKING

FORMING, FILLING
33
2
SunLase™ - Description of principle (2)
 Sun Chemical has developed the SunLase™ coatings which are
sensitive to specific low energy lasers, allowing the marking of high
definition variable data on various substrates.
 SunLase™ coatings contain specific pigments, that change from white
to black when hit by a low energy laser. There is no ablation.
 SunLase™ range offers packers and end-users the platform to
introduce greater efficiencies and productivity as well as higher quality
on their identification marking applications
 SunLase™ range covers most of printing and coating technologies:
flexo, gravure, dry offset, water-based, solvent-based, oil-based, UV
Surface imaging
Reverse imaging
 Patch is printed with a SunLase™
coating
 When the coating is marked with a
laser – a high definition black
graphic appears
34
3
SunLase™ - Description of principle (3)
Option 1
Main substrate
Transparent
substrate
Adhesive
Overprint
lacquer
Option 2
Main substrate
SunLase™
coating
Option 3
(plastic film, glass…)
REVERSE
PRINTING
SunLase™
coating
Laser
Laser
Image
Laser
SURFACE
PRINTING
 Printing options: surface, surface lacquered, or reverse
Other substrate
35
1
SunLase™ - Target markets and applications (1)
Markets: all packaging printers/converters or packing companies:
–
–
–
–
–
–
–
Corrugated containers
Flexible packaging
Folding carton
PE Films
Reverse-printed sleeves
Multiwall sack
Liquid carton packaging
Variable Data Applications:
–
–
–
–
–
–
–
Need of sequential numbers per pack / batch…
Unique identifiers per pack, batch, consumer…
Personalisation
Network based coding
Primary coding on flexible packaging
Date / Price / Batch codes
Language / ingredients / GDA &
nutritional information
36
2
SunLase™ - Target markets and applications (2)
End-uses:
– High volume food producers with short shelf life products, for example:
 milk: sleeves and labels
 yogurts: PET/PP lids and labels
 beverage: beer bottle labels
 cereal primary packs
– Personal care labels and sleeves
– Pharmaceutical labels, foils, blisters
– Existing production over 5 million outer cartons per year
– Current users of Hi-Resolution ink jet –
print and hand applied labels
– Businesses that suffer fines
for poor barcode quality
– etc
37
SunLase™ - How it compares with labelling, inkjet, ablation
Productivity
5
Quality
control
4
Productivity
5
Quality
control
Downtime
3
2
Evolution
ability
4
Downtime
3
2
1
Cost
of mark
0
Image
quality
Waste
Investment
1
Evolution
ability
0
Image
quality
Waste
Investment
Productivity
5
Quality
control
4
Cost
of mark
Ablation
Downtime
3
2
Evolution
ability
1
0
Cost
of mark
Labelling
Image
quality
Waste
Investment
These comparisons
are based on Sun
Chemical’s internal
rating, and would be
slightly different case
by case.
5 is the best score
38
Brand Protection
39
Brand Protection Solutions
For mid- to high-level, overt and covert
security solutions




Taggant reader systems
Hidden image technology
Holograms
Specialty inks and effects
40
Brand Protection & Anti Counterfeiting Portfolio
Covert Hidden
Indicia®
Covert UV fluorescing
inks
Covert IR
responsive
Orion Inks
Green 1022-073
Covert IR
responsive
Apollo Inks
Covert Verigard™
authentication – yes/no
Overt SunShift™ colour
shifting inks
Overt
Smart Hologram®
Covert non line of
site authentication
Forensic
authentication
Overt/Covert
SunGram™ machine
readable
holograms/foils
41
Thank You!
working for you.
Please visit us at www.SunChemical.com or for more
information contact us at packaging@sunchemical.com
42