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E-grāmata: Multilayer Flexible Packaging

Edited by (Crescent Associates, Inc., Rochester, NY, USA)
  • Formāts: PDF+DRM
  • Sērija : Plastics Design Library
  • Izdošanas datums: 29-Mar-2016
  • Izdevniecība: William Andrew Publishing
  • Valoda: eng
  • ISBN-13: 9780323477185
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  • Formāts: PDF+DRM
  • Sērija : Plastics Design Library
  • Izdošanas datums: 29-Mar-2016
  • Izdevniecība: William Andrew Publishing
  • Valoda: eng
  • ISBN-13: 9780323477185

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Multilayer Flexible Packaging, Second Edition, provides a thorough introduction to the manufacturing and applications of flexible plastic films, covering materials, hardware and processes, and multilayer film designs and applications. The book gives engineers and technicians a better understanding of the capability and limitations of multilayer flexible films and how to use them to make effective packaging.

It includes contributions from world renowned experts and is fully updated to reflect the rapid advances made in the field since 2009, also including an entirely new chapter on the use of bio-based polymers in flexible packaging. The result is a practical, but detailed reference for polymeric flexible packaging professionals, including product developers, process engineers, and technical service representatives.

The materials coverage includes detailed sections on polyethylene, polypropylene, and additives. The dies used to produce multilayer films are explored in the hardware section, and the process engineering of film manufacture is explained, with a particular focus on meeting specifications and targets. In addition, a new chapter has been added on regulations for food packaging – including both FDA and EU regulations.

  • Provides a complete introduction to multilayer flexible packaging, assisting plastics practitioners with the development, design, and manufacture of flexible packaging for food, cosmetics, pharmaceuticals, and more
  • Presents thorough, well-written, and up-to-date reviews of the current technology by experts in the field, making this an essential reference for any engineer or manager
  • Includes discussion and analysis of the latest rules and regulations governing food packaging

Papildus informācija

As a comprehensive guide on the topic, this book provides a thorough introduction to the manufacturing and applications of flexible plastic films, covering materials, hardware and processes, and multilayer film designs and applications, giving engineers and technicians a better understanding of the capabilities and limitations of multilayer flexible films and how to use them to make effective packaging
Preface to the First Edition xiii
Preface to the Second Edition xv
Acknowledgments xvii
List of Contributors
xix
Contributors xxi
PART I INTRODUCTION
1(14)
1 Introduction
3(12)
John R. Wagner, Jr.
Scott B. Marks
1.1 Materials: A Historical Perspective
3(2)
1.2 Markets: A Global Economy
5(3)
1.3 Processes, Materials, Needs
8(2)
1.4 Materials and Barrier
10(2)
1.5 Materials and Sealing
12(1)
1.6 Bringing Things Together
12(3)
References
13(2)
PART II RESINS
15(82)
2 Polyethylene
17(18)
Rajen M. Patel
2.1 Introduction
17(1)
2.2 Polyethylene History and Basic Characterization
17(1)
2.3 Melt Index
18(1)
2.4 Density
19(1)
2.5 Gel Permeation Chromatography
20(2)
2.6 Low-Density Polyethylene
22(1)
2.7 Free Radical Polymerization Processes
22(1)
2.8 Autoclave Reactor
22(1)
2.9 Tubular Reactor
23(1)
2.10 Polar Ethylene Copolymers
24(1)
2.11 Low-Pressure Polymerization Processes
25(1)
2.12 Gas-Phase Process
25(1)
2.13 Solution Process
26(1)
2.14 Slurry Processes
27(1)
2.15 Catalyst Chemistry
27(1)
2.15.1 Ziegler--Natta
27(1)
2.16 Chrome Oxide--Based Catalyst
28(1)
2.17 Single-Site (Metallocene) Catalyzed Polyethylene
28(4)
2.18 Tie Chain Molecules
32(1)
2.19 Summary
33(2)
Acknowledgment
33(1)
References
34(1)
3 Polypropylene
35(12)
Allison Calhoun
3.1 Managerial Overview
35(9)
3.1.1 Describing Polymers
35(1)
3.1.2 Polymerization
36(4)
3.1.3 General Polypropylene Resin Classes
40(4)
3.2 Summary
44(3)
References
44(3)
4 Introduction to Bio-Based Polymers
47(6)
Antonio Meraldo
4.1 Commercially Important Novel Biopolymer
47(6)
4.1.1 Poly lactic Acid
47(2)
4.1.2 Polybutylene Succinate
49(1)
4.1.3 Polyhydroxyalkanoate
50(1)
4.1.4 Polyethylene Furanoate
51(1)
References
52(1)
5 Additives to Design and Improve the Performance of Multilayer Flexible Packaging
53(24)
Klaus Keck-Antoine
Els Lievens
Joachim Bayer
John Mara
Duk-Suk Jung
Sung-Leal Jung
5.1 Introduction
53(1)
5.2 Overview
53(1)
5.3 Additive Handling, Addition, and Dosing
53(2)
5.4 Additive Types and Principal Mode of Action
55(16)
5.4.1 Antioxidants and Other Stabilizers
56(7)
5.4.2 UV Stabilizers
63(2)
5.4.3 Optical Brighteners
65(1)
5.4.4 Slip Additives
66(2)
5.4.5 Antiblock Additives
68(2)
5.4.6 Antistats
70(1)
5.4.7 Others
71(1)
5.5 Suppliers and Contacts
71(6)
Appendix 5.1
74(1)
Appendix 5.2
74(2)
References
76(1)
6 Rheology of Molten Polymers
77(20)
John Vlachopoulos
David Strutt
6.1 Introduction
77(1)
6.2 Viscosity and Melt Flow Index
78(3)
6.3 Mathematical Relations
81(3)
6.4 Extensional Viscosity and Melt Strength
84(1)
6.5 Normal Stress Differences and Extrudate Swell
85(1)
6.6 Stress Relaxation and Dynamic Measurements
86(2)
6.7 Constitutive Equations
88(2)
6.8 Sharkskin, Melt Fracture, and Die Lip Buildup
90(1)
6.9 Rheological Problems in Coextrusion
91(1)
6.10 Rheology of Filled Polymers
92(1)
6.11 Rheology of Nanocomposites
93(1)
6.12 Rheometers
94(1)
6.13 Concluding Remarks
95(2)
References
95(2)
PART III TECHNOLOGIES
97(182)
7 Coextrusion Equipment for Multilayer Flat Films and Sheets
99(24)
Eldridge M. Mount
7.1 Designing and Manufacturing Multilayer Flexible Plastic Films with Multilayer Coextrusion Die Technology
99(22)
7.1.1 Overview
99(1)
7.1.2 Introduction
100(1)
7.1.3 General Coextrusion Equipment Overview
101(3)
7.1.4 Theoretical Understanding of Die and Feedblock Design Parameters
104(5)
7.1.5 Feedblock Designs
109(1)
7.1.6 Die Designs
110(4)
7.1.7 Coextrusion Systems for Flat Films and Sheet
114(1)
7.1.8 Layer Instabilities, Causes, and Prevention
115(4)
7.1.9 Practical Examples
119(2)
7.2 Summary
121(2)
References
122(1)
8 Multilayer Blown (Tubular) Film Dies
123(6)
John Perdikoulias
8.1 Introduction
123(1)
8.2 Conventional Coextrusion Dies
123(2)
8.3 Stacked Dies
125(2)
8.4 Interfacial Instability
127(2)
References
128(1)
9 Process Engineering
129(8)
Eric Hatfield
Vincent Vezza
9.1 Managerial Summary
129(1)
9.2 Process Engineering: What Is It and Why Is It Essential?
129(1)
9.3 Some Process Engineer Tools
129(6)
9.3.1 Histogram
130(1)
9.3.2 Scatter Diagram
130(1)
9.3.3 Design of Experiments
131(1)
9.3.4 Statistical Process Control
132(3)
9.4 Examples of How Process Engineers Can Save Time and Money
135(1)
9.5 Conclusion
136(1)
10 Blown Film, Cast Film, and Lamination Processes
137(10)
John R. Wagner, Jr.
10.1 Blown Film
137(2)
10.2 Cast Film
139(3)
10.3 Extrusion Coating and Lamination
142(5)
References
144(3)
11 Machine Direction----Oriented Film Technology
147(6)
Eric Hatfield
11.1 Managerial Summary
147(1)
11.2 Description of MDO Hardware and Technology
147(1)
11.3 How a Machine Direction Orientor Works
148(1)
11.3.1 Preheat
148(1)
11.3.2 Drawing
148(1)
11.3.3 Annealing
148(1)
11.3.4 Cooling
148(1)
11.4 The Process and Its Effect on the Film
148(1)
11.5 Properties of MD-Oriented Films
149(3)
11.5.1 Improved Optics
150(1)
11.5.2 Increased Tensiles
150(1)
11.5.3 Improved Stiffness
151(1)
11.5.4 Improved Barrier Properties
151(1)
11.5.5 Recent MDO Advances
151(1)
11.6 Summary
152(1)
References
152(1)
12 Oriented Film Technology
153(20)
Jurgen Breil
12.1 Introduction
153(1)
12.2 Orienting Technologies
154(5)
12.3 Oriented Film Types---Applications
159(12)
12.3.1 Films Oriented Biaxially
160(10)
12.3.2 Film Oriented in Machine Direction
170(1)
12.3.3 Film Oriented in Transverse Direction
171(1)
12.4 Trends for Oriented Films
171(2)
References
172(1)
13 Polymer Blending for Packaging Applications
173(32)
Barry A. Morris
13.1 Introduction
173(1)
13.2 Why Blend?
173(1)
13.3 Blending Processes
174(5)
13.3.1 Pellet Premixing
175(1)
13.3.2 Melt Blending
176(3)
13.4 Physics of Blending
179(13)
13.4.1 Thermodynamics
180(3)
13.4.2 Morphology Development in Immiscible Blends
183(9)
13.5 Morphology Development in Blown Film
192(3)
13.5.1 Viscosity Ratio
193(1)
13.5.2 Interfacial Tension
193(1)
13.5.3 Minor Phase Concentration in Blend
193(1)
13.5.4 Polymer Elasticity (non-Newtonian behavior)
193(1)
13.5.5 Extruder RPM
194(1)
13.5.6 Extruder Temperature
194(1)
13.5.7 Shear Stress in Extruder, Adaptor, and Die
194(1)
13.5.8 Screw Design
194(1)
13.5.9 Draw Ratio
194(1)
13.5.10 Frost Line Height and Process Time
195(1)
13.6 Dispersion of Rigid Particles and Nanocomposites
195(2)
13.7 Rheology of Polymer Blends
197(1)
13.8 Conclusion
198(7)
References
199(6)
14 Water- and Solvent-Based Coating Technology
205(30)
Edgar B. Cutoff
Edward D. Cohen
14.1 Introduction
205(1)
14.1.1 Coating Uniformity
205(1)
14.2 Coating Structures
205(1)
14.3 Web-Coating Machine Hardware and Functions
206(2)
14.4 Coating Applicators
208(16)
14.4.1 Classification of Applicators
208(2)
14.4.2 Role of Substrate
210(2)
14.4.3 Coatabilty Limits
212(1)
14.4.4 Description of Coating Methods
212(12)
14.5 Effect of Solvent
224(1)
14.6 Hot Melt Coaters
225(1)
14.7 Selecting a Coating Method
225(2)
14.8 Drying and Solidification
227(8)
14.8.1 Constant Rate and Falling Rate Drying
228(1)
14.8.2 Pollution Considerations in Drying
229(5)
References
234(1)
15 Vacuum Metallizing for Flexible Packaging
235(22)
Charles A. Bishop
Eldridge M. Mount
15.1 Introduction
235(1)
15.2 Decorative Coatings
235(2)
15.3 Barrier Coatings
237(2)
15.3.1 Light Barrier
237(1)
15.3.2 Oxygen Barrier
237(1)
15.3.3 Water Vapor Barrier
237(1)
15.3.4 Gas Barrier
237(2)
15.4 Functional Coatings
239(3)
15.5 Security Applications
242(1)
15.6 Metallization Basics
243(6)
15.7 Pattern Metallization
249(1)
15.8 Trends
250(3)
15.9 Summary
253(4)
References
254(3)
16 Web Handling and Winding
257(22)
David R. Roisum
16.1 Web Handling Essentials
257(1)
16.2 Rollers
258(1)
16.3 Tension Control
259(1)
16.4 Nip Control
260(1)
16.5 Temperature Control
261(1)
16.6 Guiding and Path Control
262(1)
16.7 Wrinkles and Spreading
262(2)
16.8 A Word About Slitting and Other Converting Processes
264(1)
16.9 Winding Is Essential
264(1)
16.10 Winding Tightness and the TNT's
265(2)
16.11 Winding Classes and Arrangements
267(4)
16.12 Theory Applied
271(3)
16.13 Other Common Wound Roll Defects
274(5)
References
277(2)
PART IV MULTILAYER FILMS --- DESCRIPTIONS, PERFORMANCE CHARACTERISTICS, USES, CONSIDERATIONS, PROPERTIES
279(84)
17 PE-Based Multilayer Film Structures
281(30)
Thomas I. Butler
Barry A. Morris
17.1 Introduction
281(3)
17.2 Polymer Selection
284(2)
17.3 Mechanical Properties
286(1)
17.4 Barrier Properties
287(3)
17.5 Polymer Sealability
290(2)
17.6 Adhesive Polymers
292(2)
17.7 Applications for Flexible Packaging Film Structures
294(13)
17.7.1 Medical Packaging
295(1)
17.7.2 Food Packaging
296(11)
17.8 Summary
307(4)
References
308(3)
18 Multilayer-Oriented Films
311(8)
Jurgen Breil
18.1 Introduction
311(1)
18.2 Technology for Multilayer-Oriented Films
311(2)
18.3 Structures
313(4)
18.4 Trends for Multilayer-Oriented Films
317(2)
18.4.1 Cost Efficiency
317(1)
18.4.2 Consumer Requirements
317(1)
18.4.3 Sustainability
317(2)
19 Regulatory Aspects of Food Packaging---A Global Matter
319(44)
Sina Ebnesajjad
19.1 Introduction
319(2)
19.1.1 Bisphenol A
320(1)
19.2 Determining the Regulatory Status of Components of a Food-Contact Material in the United States
321(1)
19.2.1 Food-Contact Formulation Compliance Notification
322(1)
19.3 Regulatory Report: FDA's FCS Notification Program
322(4)
19.3.1 Definitions, History, and Scope
322(1)
19.3.2 The Notification Process
323(2)
19.3.3 Increasing the Odds of Success
325(1)
19.3.4 FCS Formulations
325(1)
19.4 Preservation of Foods by Irradiation
326(7)
19.4.1 FDA Regulations for Treatment of Foods with Radiation
327(1)
19.4.2 Title 21 CFR 179---Subpart B: Radiation and Radiation Sources
327(4)
19.4.3 Title 21 CFR 179---Subpart C: Packaging Materials for Irradiated Foods
331(2)
19.5 Regulatory Aspects of Recycled Plastics---US FDA View
333(11)
19.5.1 Introduction
333(1)
19.5.2 Use of Recycled Plastics in Food Packaging: Chemistry Considerations
333(11)
19.6 EU Legislation on Food-Contact Plastics
344(14)
19.6.1 EU Regulation No. 10/2011 on Plastic Materials Intended to Come into Contact with Food
344(1)
19.6.2 Consolidating Paragraphs
344(7)
19.6.3
Chapter I---General Provisions
351(2)
19.6.4
Chapter II: Compositional Requirements
353(2)
19.6.5
Chapter III: Specific Provisions for Certain Materials and Articles
355(1)
19.6.6
Chapter IV: Declaration of Compliance and Documentation
355(1)
19.6.7
Chapter V: Compliance
356(1)
19.6.8
Chapter VI: Final Provisions
357(1)
19.7 EU Legislation for Recycled Plastics
358(5)
19.7.1 Questions and Answers on Recycled Plastics in Food-Contact Materials
358(1)
Acknowledgment
359(1)
References
359(4)
Appendix: Writing Guide for Packaging Films and Other Multilayer Structures 363(12)
Scott B. Marks
Index 375
John Wagner is a Director of Crescent Associates, Inc., which specializes in plastic films and flexible packaging. He holds numerous patents on flexible packaging films and coating technology, has contributed to and co-edited The SPE Guide on Extrusion Technology and Troubleshooting and The Plastics Technicians Toolbox-Extrusion, and is the Editor-in-Chief of the Journal of Plastic Film and Sheeting. He is on the SPE Extrusion Division Board of Directors.