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Sustainable Converting Bobst innovations to drive more


sustainable flexible packaging The Bobst commitment to sustainability, one of the company’s vision pillars along with automation, digitalisation, and connectivity, is all-encompassing from the management of its production, to the equipment, processes, and services it supplies, and on to the packaging end-product. This is true across the four industries that Bobst serves – labels, flexible packaging, folding carton, and corrugated board as Nick Copeland, research and development director, barrier solutions at Bobst explains.


F


ocusing on the industry trends in the flexible packaging industry, for several years already, Bobst has been a promoter of the development of new generation of ready to recycle packaging substrates as viable alternatives to non-recyclable structures.


The commitment by leading brands to work towards 100% reusable, recyclable or compostable packaging by 2025, has a considerable impact on all the actors along the flexible packaging value chain, and this is especially true for manufacturers of printing and converting equipment. The new substrates differ from conventional ones in terms of machinability and safeguarding of their barrier performance and we must ensure we deliver viable solutions that enable our converting clients to implement brand owners’ pledges.


In terms of flexible packaging structures, there are currently two significant mega trends in the market: there is a big push towards packaging simplification (delayering) and a move from non-recyclable mixed polymer solutions to more recyclable mono-material solutions.


These global trends can be categorized into three


sustainability pillars: OMono-material polyolefin (PE-PP) structures OCompostable, biodegradable & bio-based structures


OPaper / fibre-based structures.


Within the mono-material polyolefin structures Bobst has prioritised the development of PE-based mono materials that on one hand have the right barrier performances and on the other can be recycled. It is actually easier to reach the barrier performances with the PP materials, however as the current mechanical recycling process infrastructures are more advanced for PE, this is where we have concentrated initially, our main efforts under the oneBARRIER offering.


oneBARRIER is a full PE high barrier solution designed for recyclability which is already available. Developed in cooperation with leading industry partners for film production and barrier adhesive formulations, it offers a cost-effective EVOH-free solution designed to maximise the amount of PE in the mono-material packaging structure to satisfy tightening circular economy legislation and increase


the recyclability, whilst also giving a more economical high barrier packaging solution.


The oneBARRIER creation process starts with a Dow special resin designed to maximise thermal resistance and coating and deposition reception to achieve the barrier requirement. The rolls of MDO PE film were produced by converting company Zermatt by blown extrusion.


At the Bobst Competence Centers, a primer layer was applied using a Vision D 850 laminator, while the AlOx deposition using the GEN II process was applied on an Expert K5 vacuum metallizer. The Sun Chemical Paslim solvent-free barrier adhesive was applied on a Nova SX 550 Laminator. The oneBARRIER process eliminates the need for a topcoat to be applied. To sum up, the Bobst oneBARRIER transparent solution provides a barrier performance equivalent to that of metallised polyester (< 1 cm³/(m² d) & < 1 g/ m² d) and the market requirements in terms of laminate bond strength (2 – 3 N/(15mm) is also satisfied.


The definition of mono-material followed by Bobst is based on the CEFLEX guidelines which state that the packaging structure needs to be compatible with the current mechanical recycling process and contain at least 90% by weight of PE or PP.


Other components such as adhesives, coatings and inks can have a maximum of 5% by weight each. In this respect also noteworthy in terms of sustainable operation are Bobst solutions like the oneECG Extended Color Gamut technology available across all printing technologies, including gravure, or automatic register and quality control solutions. Transforming the industry in a sustainable way cannot be done singularly. We must work with our customers, our customers’ customers, and our customers’ suppliers throughout the value chain to achieve the goals and the ambitions. Bobst has the motto, ‘shaping the future of the packaging world’ and it’s true, but we have to do this in collaboration and partnership with the whole value chain.


Xwww.bobst.com


24


October 2021


www.convertermag.com


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