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MATERIALS | POLYOLEFINS


including e-commerce packaging, heavy duty sacks, collation shrink and industrial films.


Pouch printing A multi-partner project has demonstrated a concept for recycling digitally printed pouches. Dow and Reifenhäuser – along with HP, Cadel Deinking, and Karlville – have joined forces to recycle PE-based barrier pouches into new PE pouches that are suitable for repeat recycling. Starting with a PE-based barrier food pouch, the


Above: The latest version of Nova’s Bonfire film development platform helps developers to incorporate more PCRs in formulations


engineers shortlist film formulations and reduce the number of physical trials. It can also help converters achieve sustainability goals through downgauging, moving away from multi-material laminates and allowing post-consumer resin (PCR) incorporation. The latest version adds several new modules and enhancements: a laminations structure builder; a sealant dashboard; a molecular architecture dashboard; and the addition of post-consumer resins (PCRs). The laminations structure builder predicts


properties for adhesive laminations made from a print web and a sealant web. In the past, these were most commonly made from mixed materials, such as a metallised PET print web with a PE sealant web. Designers are increasingly looking to use mono-material structures. “Many of our customers rely on Bonfire when


they’re developing new film structures,” said Dan Ward, technical service specialist at Nova. “Adding the laminations module helps them simplify the process of designing films for recyclable packaging.” Two new resin information dashboards provide


data to help select the best resins for a given application. In the sealant dashboard, users can compare seal properties of up to five resins, with results presented in table and visual chart formats. The molecular architecture dashboard provides differential scanning calorimetry (DSC) results, which quantify the thermal properties of a resin. Up to five resins can be compared, and are presented in table and chart formats. Separately, Nova has collaborated with Charter


Next Generation (CNG) to increase the availability of PCR in flexible films. Nova recently delivered “railcar quantities” of PCR to CNG’s manufacturing facilities.


“Incorporating PCR into products and packaging is an essential component to eliminating plastic waste,” said Luis Sierra, president and CEO of Nova. The recycled LLDPE supplied by Nova can be used in a range of non-food film applications


14 FILM & SHEET EXTRUSION | April 2022


team used mechanical recycling and de-inking to create a dishwasher MDO-PE 1 pouch containing 30% recycled content that was itself suitable for recycling. In a next step, the team is working on a digital product passport pilot to record recycling- relevant packaging properties and make the pouch identifiable for recycling within post-consumer waste management. “We applied our full expertise and testing capabilities to make our resins work in this proof of concept,” said Laura Evangelio, senior technical service and development specialist at Dow Packaging & Specialty Plastics. “The first PE-rich pouch was designed for recyclability with up to 5% EVOH in the total structure for barrier functionality.” The resins provided a high stiffness-toughness


balance, low-temperature sealability, adhesion to extruded barrier layers and high bubble stability, she said. For a second PE-based pouch, a solventless adhesive was used to enable the lamination of the MDO-PE film to the PE-film containing recycled resins from the first pouch. The new resins have been co-extruded on an


Evo 9-layer blown film line from Reifenhäuser, to produce PE-based packaging films at fast line speeds. “We have modified and enhanced our produc- tion lines to enable films and packages not just to be economical and functional, but to meet the demand for recyclable packaging based on mono-material structures,” said Ralf Wiechmann, head of film innovation at Reifenhäuser.


Red meat Profol Americas, a manufacturer of cast PP and PE films, has introduced a breathable vacuum packag- ing film. CPVac is a PP-based coextruded film that is designed to maintain the appearance of fresh red meat and produce. The film has the correct oxygen transmission rate to ensure that fresh meat and vegetables retain their colour on the shelf. Other key features include low haze, customised


www.filmandsheet.com


IMAGE: NOVA


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