Adhesive Biopolmer Film Lamination HB Fuller Workshop

Adhesives and Key Essentials for Laminating Biopolymer Films into Flexible Packaging
Lowell Lindquist Wayne Eklund
2012 H.B. Fuller Company
H.B. Fuller Company

125 years of success as a manufacturer of specialty chemical products Headquartered in St. Paul , Minnesota Recognized for quality adhesives, sealants, coatings, and paints Global with direct presence in 36 countries, 3300 employees, and customers in more than 100 nations 2010 sales of $1.4 billion Public company listed on NYSE (FUL) Component stock of the Standard & Poors Small Cap Index (S&P 600)
Organization
H.B. Fuller Company is organized geographically:
North America Europe Latin America Asia Pacific
Focus Market Areas

Packaging
Case and Carton Container Labeling Flexible Packaging Packaging Reinforcement
General Assemble Building and Construction Personal Hygiene and Nonwovens Paper Converting Consumer Product Adhesives Paper Converting Polymers Woodworking
Outline
Flexible Packaging Review Bio-Films that can be Laminated Flexible Packaging Applications for Bio-Films Lamination Processes
Dry Bond Solvent Free
Bio-Film Surface Treatments Adhesive Chemistry and Interactions with Bio-Films

Solvent Free Solvent Based Water Based
Examples of Bio-Film Laminations
Flexible Packaging Structure

Complete adhesive coverage across entire film Bonding a combination of films, foils, or paper Often reverse printed ink between layers Adhesive thickness ~ 1 lb/ream
Flexible Packaging Film Cross Section

Outer layer Printing ink Adhesive Inner layers / Sealant film, barriers,..
Adhesive
Printing Ink Printing Ink
Flexible Packaging Structure

Substrate Surface
Not perfectly regular Gaps and irregularities in ink
Adhesive
Must overcome surface irregularity Typical coat weight 1.0 pounds / ream Range coat weight 0.8-4.0 pounds / ream Scanning Electron Microscopy (SEM) Thickness 1-5m ~2-6% of a lamination volume is adhesive
Typical Package Construction

Outer Layers
Reverse printed via flexo or gravure Provide barrier properties Carry brand image Typical films

Inner Layers
Primary purpose is to seal package Direct contact with fill goods Typical Films

Cellophane PLA Paper Aliphatic-Aromatic Polyesters Blends of bio-esters Polypropylene (OPP) and Metalized Oriented Polypropylene (MOPP) Aclar Polyester (PET) and Metalized Polyester (METPET) Nylon Foil
Bio - Polyethylene (PE) PLA PHA Starch Based TPUs Aliphatic-Aromatic Polyesters PGA Blends of bio-esters Polypropylene (CPP or OPP) Polyethylene (LDPE, LLDPE, metallocene, EVA, etc.)
9
Flexible Packaging Market Adhesives Perspective

High Performance (Foil) Retort Difficult Foil Mid Performance (Film) Barrier to Barrier Chemical Resistance Heat Resistance General Purpose (Film) Dry Goods Confectionery Snack Lid Stock
Cellophane with Barrier
Biodegradable Polyesters (PLA,PHA,etc.)
Solvent Free
Water-based Market Volume
Solvent-based
Potential Applications-Bio-Films
Frozen Foods Fresh Cut Produce Room Temp Confectionary Snack Hot Fill Condiment Lid Stock Overwraps Pasta Package Some industrial and consumer Not currently used above hot fill temperature
Application of Adhesives
Comparison of Lamination Processes
Dry Bond
Solvent Free
Flexible Packaging Adhesives

Dry Bond Laminating Process Laminate

Slit
Pouch
Fill
In-line corona treatment Coat weight controlled by gravure Coat weights of 0.8 -3.0 pound/ream Line speed limited by drying process Liquid carrier must be removed for health and adhesive quality Nip temperature and pressure as high as possible limited by film properties Typical pot life is 8 hours Smoothing bar is required for WBA Drying related to temperature, air flow, and inlet humidity
Dry Bond Laminator

Dry Bond Laminating Process Laminate Slit Pouch Fill
Bio-Film Considerations During Dry Bond Lamination

Treatment level of films Adsorbed water on films due to hydroscopic nature may affect adhesion Speed ramp-up-rate is a critical due to tear propagation, many bio-films do not like mechanical shock Conventional coat weights (0.8 to 3.0 lbs/ream) Smoothing bar critical for optimum appearance water-base only Oven temperature limitations due to yield and shrink of some bio-films(may limit line speed due to slower drying at low temp)

Dry Bond Laminating Process Laminate Slit Pouch Fill
Bio-Film Considerations During Dry Bond Lamination

High nip temperature is desirable limited by film stability High nip pressure is desirable limited by film stability Rewind tensions less critical due to high green strength Must be aware of film relaxation (elasticity will cause corrugation and crushed cores) Sensitive to roll damage like nicks and bruises Potential for film solvent sensitivity Modified coat weight testing

Solvent Free Laminating Process Laminate Slit Pouch Fill
In-line corona treatment Two part reactive system (meter-mix accuracy is critical) Pot life 30 to 60 minutes Typical line speed > 1000 fpm Typical coat weight 1.0 lbs/ream Heat used to adjust viscosity Very little green strength Rewind tension is critical due to lack of green strength
Typical Solvent Free Laminator
Secondary film introduced
Adhesive applied to the primary film Primary film nipped to the secondary film Lamination wound onto a core
Primary film introduced Adhesive pumped into the machine
Typical Solvent Free Meter-Mix

Bio-Film Considerations During Solventfree Lamination

Check film dyne level treatment level of films (no solvent to help clean film surface) Adsorbed water on films due to hydroscopic nature may affect adhesion Controlled speed ramp-up-rate is critical due to tear propagation, many bio-films do not like mechanical shock Rewind tensions critical due to low adhesive green strength Less aggressive nip but air must be excluded

Bio-Film Considerations During Solvent Free Lamination

Must be aware of film relaxation (elasticity will cause corrugation, crushed cores, curl, ink smearing, and telescoping) Sensitive to roll damage like nicks and bruises Potential isocyanate reaction with film and ink components (glycol) Conventional coat-weights (0.8-1.5 pounds / ream) Yield and elasticity of some bio-films can create web handling challenges
Comparison of Lamination Processes

Shift toward Solvent Free Adhesives
Dry Bond High Green Tack High Strength Adhesives - High Energy Demand - Emissions - Footprint - Speed Limited by Oven Size
Solvent Free High Speed No Emissions Low Energy Demand Small Footprint - Need for accurate metering - Little Green Tack
Bio-Film Surface Modification

Surface treatments- (Initial treatment critical followed with in-line treatment)
Corona Plasma Chemical / Primers Coatings

PVdC Acrylic PVOH Urethane Metallization Ceramic
Vapor Deposition

Why do we treat the films?

Remove contamination Modify the polarity of film surface Increase the surface roughness on film Add or enhance chemical functionality of film surface
23
Corona Treatment vs. Adhesion

700
Corona Treatment Study

B 600 o n d 500 S 400 t r e 300 n g t 200 h W-minutes/sq.ft. 100 0 0.5 1 1.5 2
Printed Cello - Clear high slip LDPE
Corona Treatment Adds Polarity to Film
Corona Treatment:
Adds polarity to film increasing adhesion Removes contaminants Increases surface roughness
Lamination Adhesives
Solvent Free Composition- Typical Example
Isocyanate Functional Prepolymer Polyol Curative 40% 60%
No Solvent Reactive chemistry Two-components
Solvent Free Naming and Composition
Common Names Chemical Representation
Isocyanate A-Side NCO Adhesive Prepolymer
OH
Polyol B-side Curative Hydroxyl
OH OH
Laminate
Slit
OH
Pouch
OH OH
Fill
The two components are mixed and applied to the film but have not reacted The ratio of the two components is important for polymer creation Low viscosity to allow application to film Very little green strength to hold films together Water is supplied from the environment and films
Laminate
Slit
Pouch
Fill
OH OH OH
Partial polymerization after 3-12 hours creates enough adhesive strength to allow film slitting Curative and water are reacting to begin formation of ideal polymer structure Heat will accelerate polymer formation time and decrease time-to-slit.
OH
OH
Laminate
Slit
Pouch
Fill
OH
Significant polymerization in 12-48 hours to provide heat resistance for seal making Bond strength is very high Water is used in reaction to increase stiffness of polymer by creating a urea group
Laminate
Slit
Pouch
Fill
Polymerization complete, food can be safely added Full adhesive strength is produced Product resistance is developed This polymer is significantly different from the starting materials
SF Lamination Adhesives
Bio-Film Interactions
Hydroscopic films may provide excessive water which will alter the polymer that is formed
More polyurea (harder, more heat and chemical resistance) Excessive water can cause CO2 generation (gassing)
Plasticizers can be difficult for SF adhesives to displace for optimum adhesive strength Glycols and other reactive film components will likely react into the adhesive which will alter the polymer that is formed Because of the low molecular weight starting materials SF adhesives can smear ink when film tensions are not matched. A film that is over stretched during laminating will relax in the roll with a potential to smear ink. Covalent bonds to film moiety (specifically reaction with OH or COOH groups)
Bio-Film Construction Solvent Free

OPLA / LDPE and OPLA / OPLA for Snack Food
Goal Lamination of renewable films with maximum adhesion Use 1 mil OPLA and 1mil LDPE Unprinted films laminated with 1.0 pounds / ream of SF adhesive Screened three adhesive systems
BOPP/BOPP (Reference Laminations)
SF Adhesive A SF Adhesive B SF Adhesive C
1 Day
2 Day
5 Day
7 Day
All three Solvent Free Adhesives have destruct bond level on BOPP
OPLA / OPLA
1000 900 800 700 600 500 400 300 200 100 0
SF Adhesive A SF Adhesive B
1 day 2 day
SF Adhesive C
5 day 7 day
Not all the Solvent Free Adhesives were successful on these films
OPLA / High Slip LDPE

1000 900 800 700 600 500 400 300 200 100 0
SF Adhesive A SF Adhesive B SF Adhesive C
1 day 2 day
5 day 7 day
Not all Solvent Free Adhesives were successful on these films

OPLA / LDPE and OPLA / OPLA for Snack Food
Conclusions Goal was reached by careful selection of SF adhesive system Not all SF adhesives give high bond strength on OPLA / OPLA or OPLA / LDPE.
Recommendation: Involve the adhesive supplier early in bio-film projects

Example Set #2
OPLA / Cellophane OPLA-PHA blend / Cellophane OPLA / Met PLA OPLA / Met PLA-PHA blend
Bio-Film Constructions Solvent Free

Bond Strength
700 600 500 400 300 200 100 0
Adhesive 1 Adhesive 2 Adhesive 3

Sample Set #2-Conclusions
Lamination OPLA / Cellophane PHA / Cellophane OPLA / Met PLA OPLA / PHA Notes Adhesive selection is critical, can achieve excellent bonding. Adhesive selection is critical, can achieve excellent bonding. These films had metal transfer to adhesive, need to run primer study Adhesive selection is critical, can achieve excellent bonding.

Solvent Based Composition Typical Example
35%
60% 5%
Prepolymer Curative Solvent
Long pot life Very low viscosity at application station Very high viscosity at nipping station Solvent must be removed in application process
Solvent Based Naming and Composition
Common Names Chemical Representation Polyol OH OH Solvent

B-side Curative Hydroxyl
OH
Isocyanate A-Side NCO Adhesive Solvent Ethyl Acetate
Solvent Based Dry Bond Laminating Application Drying Nipping
OH OH
The three components are in solution Very low viscosity due to solvent Water is supplied from the environment or films Solvent is a carrier to get the adhesive to the film
OH OH
An in-line oven is used to evaporate the solvent The chemical reaction is the same as for a solvent free adhesive but the starting molecules are much larger Reaction is not completed
OH OH
The solvent is evaporated before nipping (dry bond) Very high viscosity due to loss of solvent = high green strength Oven air flow and temperature adjusted to evaporate all the solvent Chemical reaction is not complete
Solvent Based Dry Bond

Laminate Slit Pouch Fill
OH OH
High starting molecular weight allows for slitting in as quick as one hour. Curative and water react to form ideal polymer structure Heat will accelerate polymer formation time and decrease time-to-slit.
OH

OH
Significant polymerization to provide heat resistance for seal making

Less time to get to high polymer formation because of high molecular weight starting material
Bond strength is very high Water is used in reaction to increase stiffness of polymer

Polymerization complete, food can be safely added Full adhesive strength allows for freezing, boiling, microwaving, etc.
Thermal resistance dependant on films and adhesive
Product resistance is developed

Chemical resistance is one of the last properties to develop
SB Lamination Adhesives
Bio-Film Interactions
Ethyl acetate in adhesive may soften bio-film resulting in poor web handling, frosting, shrinking Hydroscopic films may provide excessive water which will alter the polymer that is formed
More polyurea (harder, more heat and chemical resistance) Excessive water can cause CO2 generation (gassing)
Glycols and other reactive film components will likely react into the adhesive which will alter the polymer that is formed Covalent bonds to film moiety (specifically reaction with OH or COOH groups)

Water Based Composition Typical Example
2%
40% 58%
WB Polymer water Crosslinker - optional
Long pot life Can add cross-linker for added performance Very low application viscosity Water has to be removed in application process
Water Based Dry Bond

Primary Film Coalesced Adhesive Primary Film Secondary Film Coalesced Adhesive Primary Film
WB Adhesive is gravure applied to the film. Water is evaporated in the oven, film of adhesive is formed. Second film is dry bonded to adhesive.
Water Based Dry Bond

Secondary Film Coalesced Adhesive Primary Film

The polymer cures, flows, crystallizes over a short time period and has enough bond strength to be slit Drying conditions should be ramped to avoid skinning or bubbling Aggressive nip to increase bond strength and improve appearance Nip conditions specifically set to match Tg of adhesive without exceeding film handling limits Pouching is possible when the polymer is near full cure and has enough heat resistance to make heat seals.
Bio-Film Construction Dry Bond WB

OPLA / OPLA for Lidstock
Goal lightly printed biodegradable lid for biodegradable tray with superior film-to-film adhesion Use matched 1 mil oriented multilayer films for best web handling Reverse printed with light ink coverage Screened six adhesives and two co-reactants Both adhesive and co-reactant impact adhesion values
PLA / PLA Bond Strength Dry Bond - WB

800 700
Green peel 24 hr peel 2 week peel
600
500
400
300
200
100
0 Acrylic / CR1 Acrylic / CR2 Hybrid A / Hybrid A / Hybrid B / Hybrid B / Urethane Urethane Urethane Urethane Urethane Urethane CR1 CR2 CR1 CR2 A / CR1 A / CR2 B / CR1 B / CR2 C / CR1 C / CR2

OPLA / OPLA for Lidstock Conclusions
Goal was reached Acrylic performance is greatly influenced by co-reactant selection Acrylic performance often approached urethane performance based on selection Not all urethanes are better than acrylics, selection of urethane adhesive is important Match the chemistry

Cellophane / Ecoflex+PLA blend for Compostable Pouches
Goal printed biodegradable lid for biodegradable tray with superior adhesion Use matched 1 mil oriented multilayer films for best web handling Reverse printed with light ink coverage Choice of WB dry bond dictated by existing assets

Cellophane / Ecoflex+PLA blend for Compostable Pouches
grams / inch
600 500 400 300 200 100 0
Cellophane / LDPE
Cellophane / Ecoflex+PLA

Cellophane / Ecoflex+PLA blend for Compostable Pouches Conclusions
Goal was reached The compostable sealant had web handling like a conventional sealant The compostable sealant had superior adhesion properties to LDPE with this adhesive.
Adhesive Comparison
Solvent Based Coat Weight (#/Ream) Initial Bonds Viscosity Pot Life Retained Solvent Emissions Energy used Lamination speed Time to Slit Fire Hazard Cost (adhesive + energy) 1.5-3.5 300 grams Low 8 hours Possible Yes High Oven limit 2 hours Yes 3.5X Solvent Free 1.0-1.8 20 grams High 30 minutes No No Low 1500 12 hours No X Water Based 1.0-2.0 300 grams Low 8 hours Amine possible No High Oven limit 1 hour No 2.7X
Last Example
PLA / MetPLA snack food application
Last Example
Correct adhesive gives high bond strength Correct adhesive gives sound reduction Working together accelerates success
ITR Workshop Support

HB Fuller would like to thank the following supporters for their contributions to this workshop!
Taghleef Industries Innovia Metabolix BioBag Heritage Plastics/Plastimin Imaflex Sierra Converting
Thank You
This presentation is for informational purposes only and does not constitute an offer by H.B. Fuller to sell or a warranty of any kind.

Adhesive Biopolmer Film Lamination HB Fuller Workshop

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Adhesive Biopolmer Film Lamination HB Fuller Workshop

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Adhesives and Key Essentials for Laminating Biopolymer Films into Flexible Packaging

Lowell Lindquist Wayne Eklund

2012 H.B. Fuller Company

H.B. Fuller Company

North America Europe Latin America Asia Pacific

2012 H.B. Fuller Company

Focus Market Areas

2012 H.B. Fuller Company

Bio-Film Surface Treatments Adhesive Chemistry and Interactions with Bio-Films

Examples of Bio-Film Laminations

2012 H.B. Fuller Company

Flexible Packaging Structure

2012 H.B. Fuller Company

Flexible Packaging Film Cross Section

2012 H.B. Fuller Company

Flexible Packaging Structure

2012 H.B. Fuller Company

Typical Package Construction

Flexible Packaging Market Adhesives Perspective

Cellophane with Barrier

Biodegradable Polyesters (PLA,PHA,etc.)

Water-based Market Volume

2012 H.B. Fuller Company

2012 H.B. Fuller Company

2012 H.B. Fuller Company

Flexible Packaging Adhesives

Dry Bond Laminator

2012 H.B. Fuller Company

Flexible Packaging Adhesives

Bio-Film Considerations During Dry Bond Lamination

2012 H.B. Fuller Company

Flexible Packaging Adhesives

Bio-Film Considerations During Dry Bond Lamination

2012 H.B. Fuller Company

Flexible Packaging Adhesives

2012 H.B. Fuller Company

Typical Solvent Free Laminator

Secondary film introduced

Primary film introduced Adhesive pumped into the machine

2012 H.B. Fuller Company

Typical Solvent Free Meter-Mix

2012 H.B. Fuller Company

Flexible Packaging Adhesives

Bio-Film Considerations During Solventfree Lamination

2012 H.B. Fuller Company

Flexible Packaging Adhesives

Bio-Film Considerations During Solvent Free Lamination

2012 H.B. Fuller Company

Comparison of Lamination Processes

Bio-Film Surface Modification

PVdC Acrylic PVOH Urethane Metallization Ceramic

Why do we treat the films?

Corona Treatment vs. Adhesion

Corona Treatment Study

Printed Cello - Clear high slip LDPE

2012 H.B. Fuller Company

Corona Treatment Adds Polarity to Film

2012 H.B. Fuller Company

No Solvent Reactive chemistry Two-components

2012 H.B. Fuller Company

Common Names Chemical Representation

Isocyanate A-Side NCO Adhesive Prepolymer

Polyol B-side Curative Hydroxyl