Reduced Oxygen Permeability in Fiber Based Packaging

A laminated packaging material for oxygen-sensitive products, comprising a bulk layer of paper or paperboard and a barrier-coated cellulose-based substrate. The barrier coating is applied to the substrate using a dispersion coating technique, and the material is laminated to the bulk layer using a melt extrusion coating process. The laminated material is suitable for packaging containers, such as cartons and tubs, for products like milk, juice, and sauces.

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A laminated packaging material for oxygen-sensitive products, comprising a bulk layer of paper or paperboard and a barrier-coated cellulose-based substrate. The barrier coating is applied to the substrate using a dispersion coating technique, and the material is laminated to the bulk layer using a melt extrusion coating process. The packaging material is suitable for packaging liquid, semi-liquid, or viscous food products, and can be used to manufacture packaging containers such as cartons and tubs.

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Industrially viable method for manufacturing barrier-coated paper or cellulose-based substrates that can replace aluminum foil in packaging for oxygen-sensitive products like food. The method involves coating a thin, smooth cellulose substrate at high line speeds using a specific sequence of steps. This allows thin, defect-free barrier coatings to be applied that provide good gas barrier properties. The sequence involves: 1) forwarding the substrate web at 300 m/min or higher, 2) applying an aqueous barrier coating, 3) roll coating a protective layer, and 4) reverse gravure coating a heat sealable layer. The resulting barrier-coated substrate has low oxygen transmission rates for packaging oxygen-sensitive products.

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Barrier-coated cellulose-based substrate for packaging applications like cartons that provides improved gas barrier properties without using aluminum foil. The substrate has a thin cellulose base layer with density over 900 kg/m3 and grammage 30-80 g/m2. A ductile pre-coating is applied before gas barrier coatings to provide compatibility and adhesion. This allows using less gas barrier material. The pre-coating prevents pinholes in the gas barrier layer and allows thinner coatings. The resulting packaging material has good gas barrier properties, recyclability, and sustainability for long-term food storage.

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Barrier-coated cellulose-based fibrous substrate for oxygen-sensitive food packaging applications like cartons for liquid foods. The substrate has a cellulose base with grammage 30-80 g/m2, density 700-900 kg/m3, and a steam-resistant base coating beneath the gas barrier coating. The base coating contains 25-96% inorganic particles and 4-75% polymer binder. This substrate provides good gas barrier in laminated packaging without aluminum foil.

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A sheet-like composite for food packaging that achieves superior shelf-life through a unique barrier layer structure. The composite comprises a carrier layer, a barrier layer, and an inner polymer layer, with the barrier layer comprising a three-dimensional network of fibres and a second polymer layer. The barrier layer's Young's modulus in the barrier direction is optimized to balance barrier performance with mechanical stability, while the inner polymer layer enhances barrier performance through its thermoplastic properties. The composite is produced through a novel lamination process that integrates the barrier layer, inner polymer layer, and carrier layer, enabling efficient manufacturing of dimensionally stable food containers with enhanced shelf-life.

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Laminated packaging material for pouch containers of liquid, semi-liquid, and viscous food products that provides improved barrier properties and package integrity compared to conventional carton packaging. The material has a cellulose-based bulk layer, a barrier layer between the bulk and inner layer, and an inner polyethylene film. The polyethylene film has specific properties like thickness, composition, and orientation to balance strength and openability. The barrier layer can be a metal foil or coated paper. The inner film improves barrier and sealing while reducing foil use. The layered structure provides good barrier, strength, and sealing properties for pouch packaging of sensitive foods.

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Laminated packaging material for liquid food products that provides improved barrier properties, strength, and openability compared to aluminum foil-based packaging. The material has a cellulose-based bulk layer, a barrier layer, and an innermost polyethylene film. The polyethylene film is a cast, biaxially oriented LLDPE film with specific properties. This unique laminate structure allows using thinner, more sustainable materials while maintaining integrity and barrier properties. The cellulose-based layers provide strength and recyclability, while the polyethylene film improves barrier properties and openability.

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Using a specific type of paper substrate in packaging materials for oxygen-sensitive products like food and water to replace aluminum foil. The paper has properties like high basis weight, high machine direction elongation, and low surface roughness to provide good oxygen barrier without using aluminum. The paper is used as a gas barrier layer in laminated packaging materials for oxygen-sensitive products. The laminate structure includes an inner paper layer, a gas barrier coating, and outer layers for sealing. The paper's improved barrier properties allow packaging oxygen-sensitive products without aluminum foil for reduced carbon footprint.

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Nanocelluloses are promising high gas barrier materials for biobased food packaging, but they must be protected from water to preserve high performance. The respective O2 barrier properties of different types of nanocelluloses were compared (nanofibers (CNF), oxidized nanofibers (CNF TEMPO) and nanocrystals (CNC)). The oxygen barrier performance for all types of nanocelluloses was similarly high. To protect the nanocellulose films from water, a multilayer material architecture was used with poly(lactide) (PLA) on the outside. To achieve this, a biobased tie layer was developed, using Corona treatment and chitosan. This allowed thin film coating with nanocellulose layers between 60 and 440 nm thickness. AFM images treated with Fast Fourier Transform showed the formation of locally-oriented CNC layers on the film. Coated PLA(CNC) films performed better (3.2 10-20 m3.m/m2.s.Pa) than PLA(CNF) and PLA(CNF TEMPO) (1.1 10-19 at best), because thicker layers could be obtained. The oxygen barrier properties were constant during successive measurements at 0 % RH, 80 % RH and again at 0 % R... Read More

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Laminated packaging material for oxygen-sensitive products like food and beverages that replaces aluminum foil in cartons. The material uses a high-density cellulose paper substrate with a grammage of 30-75 g/m2 and a density over 1000 kg/m3. The paper is impregnated with a polymer like PVOH, EVOH, starch, or CMC at 0.5-4.0 g/m2. This provides improved oxygen barrier properties for packaging without aluminum. The paper can also be further coated with a thin layer of gas barrier material. The laminated packaging material can replace aluminum-free cartons for long-term storage of liquid foods without compromising oxygen barrier performance.

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Barrier-coated paper or cellulose-based substrates for laminated packaging materials that achieve high barrier properties for oxygen and water vapor while maintaining recyclability and sustainability. The substrates employ a base layer pre-coating followed by a barrier deposition coating, with the barrier deposition coating applied through vapour deposition. The barrier deposition coating is formulated from materials like metals, metal oxides, inorganic oxides, or carbon coatings, and is applied at a controlled thickness to achieve the desired barrier performance. This approach enables the production of laminated packaging materials with improved barrier properties compared to conventional aluminum foil-based materials, while maintaining the substrate's inherent barrier properties and recyclability.

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Many food products are sensitive to oxygen which can promote rancidity, aerobic microorganism growth, browning, vitamin degradation, flavor loss, and other undesirable reactions. Active packaging concepts have been successfully applied to delay these deteriorative phenomena. In particular, oxygen scavengers help limit O 2 ingress into packaging thus extending product shelf-life and thereby reducing food waste. Besides oxygen barrier polymers, other composite materials have been developed to reduce the overall O 2 permeability into the package by adding oxygen scavengers or barrier fillers into the packaging structures. Typical thermoplastic food packaging barrier properties are summarized, including commercially available ones, and reported in the patent literature. Furthermore, various mathematical models have been developed to predict the oxygen transport behavior in active packaging to simulate oxygen transport in polymeric and composite materials. Such models are helpful to provide a better understanding of the mass transport fundamentals involved and shorten product development ... Read More

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Recently, packaging industry has turned to biodegradable packaging, and poly(lactic acid) has become the most remarkable polymer. However, the high oxygen permeability of PLA films significantly limits their use. Therefore, this study, it was aimed to improve the oxygen barrier properties of PLA films without adversely affecting the mechanical and water vapor barrier properties. Biodegradable PLA-Zein bi-layer films were produced by changing PLA and zein thickness. Transparent and UV barrier bi-layer films were obtained. Mechanical properties of PLA films were improved by the production of bi-layer films. Water vapor permeability of bi-layer films increased whereas the permeance decreased with zein coating of PLA. Multi-criteria decision hierarchy was used to select the best bi-layer films based on mechanical, permeance, and opacity results. Oxygen barrier properties of PLA film significantly improved by zein coating, and hydrophobicity of PLA film was not affected by zein coating. The crystallization and melting temperatures of films decreased when compared to PLA films, supporting ... Read More

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Fibrous-based oxygen barrier film for packaging of oxygen-sensitive products in high humidity environments. The film has a microfibrillated cellulose (MFC) layer, an oxygen barrier polymer layer, an optional tie layer, and an outermost polyolefin layer. The oxygen barrier polymer and polyolefin layers are coextruded onto the MFC layer. The film provides low oxygen transmission rates even in high humidity, improving oxygen barrier compared to conventional films. The film can be used in laminates for packaging of oxygen-sensitive products like food in humid environments like tropical climates. The laminate structure includes the film layer sandwiched between a fibrous base and outer polyolefin layer.

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A fiber-based laminate with oxygen barrier properties comprising a porous fiber layer made from nanocellulose and cellulosic fibers, and a polymer layer attached to at least one side of the fiber layer. The laminate exhibits improved oxygen barrier performance compared to the individual components, enabling high-speed production while maintaining effective barrier properties.

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Spray coating for vacuum formed fiber food containers that incorporates barrier chemistries and surface coatings to achieve desired moisture, oil, vapor, and oxygen barriers. The coating system enables fiber-based packaging to replace single-use plastic containers in food and beverage applications, particularly for microwavable and oven-safe containers, while maintaining structural integrity and food safety. The coating incorporates a combination of moisture barrier, oil barrier, and vapor barrier chemistries, along with a water vapor barrier, to address common issues in food packaging. The coating system is achieved through selective application of barrier layers to specific surfaces of the finished vacuum-formed container.

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There are available reports on the barrier properties of composites; however, with highly focused research in this field, there is a need to reevaluate the findings and current trends. Hybrid composites are a mixture of inorganic and organic components at the nanometer or molecular level, whereas, biocomposites are formed by reinforcing natural fibers into a matrix to improve their properties, including barrier characteristics. Such composites can be used for many applications, including packaging, to maintain the quality of products. Thus, the barrier properties of films are important characteristics. This chapter discusses the parameters that influence the barrier properties of composites such as the pore size, chemical structure, free volume, and crystallinity of the polymer. The aims of this chapter are to provide comprehensive knowledge about factors affecting the permeability and preparation methodology, the types of composites, and the types of barrier characteristics including oxygen, carbon dioxide, water vapor, and aroma, and to present the potential applications of such hy... Read More

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Oxygen barrier coatings have the potential to greatly extend the lifetime of certain food products by incorporating them into existing food packaging. Present technologies face definite challenges of maintaining high performance, while attaining simple and inexpensive preparation methods. The oxygen barrier effect obtained with these coatings is also susceptible to a plasticization effect when exposed to high humidity, since water vapor molecules are readily soluble in typically hydrophilic resins. In this work, we demonstrate a 1 2 micron thick oxygen barrier coating, prepared on a 12 micron poly(ethylene terephthalate) substrate, that has oxygen transmission rates as low as 1.44 cc m-2 day-1 under standard conditions and can maintain similar oxygen barrier performance at high humidity. This degree of oxygen barrier meets the standard of 1 10 cc m-2 day-1 established for food packaging applications. The coating is prepared through use of sol-gel chemistry between poly(vinyl alcohol) and vinyltrimethoxsilane molecules, which form a strong network resin through hydrolysis and cond... Read More

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Multilayer container for food packaging that combines excellent oxygen barrier properties with improved heat pasteurization performance. The container features a unique gas barrier layer comprising an oxygen permeability resin, an oxygen absorptive adhesion layer, and an oxygen penetration layer. The gas barrier layer is integrated into the container's structure through a specialized manufacturing process that creates a continuous oxygen barrier layer throughout the thickness of the container. This approach eliminates the need for separate oxygen barrier layers, achieving superior oxygen barrier properties while maintaining the container's structural integrity. The container also incorporates an oxygen absorptive adhesion layer containing a deoxidizer component and thermoplastic resin, ensuring effective oxygen absorption during the packaging process.

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The interface of fibrous composites is a key factor to the whole properties of the composites. In this study, the effects of air dielectric barrier discharge (DBD) plasma discharge power density on surface properties of poly( p phenylene benzobisoxazole) (PBO) fiber and the interfacial adhesion of PBO fiber reinforced poly(phthalazinone ether sulfone ketone) (PPESK) composite were investigated by several characterization methods, including XPS, SEM, signal fiber tensile strength, interlaminar shear strength, and water absorption. After the air DBD plasma treatment at a power density of 41.4 W/cm 3 , XPS analysis showed that some polar functional groups were introduced on the PBO fiber surface, especially the emergence of a new oxygencontaining group (OC = O group). SEM observations revealed that the air DBD plasma treatment had a great influence on surface morphologies of the PBO fiber, while the signal fiber tensile strength results showed only a small decline of 5.9% for the plasmatreated fiber. Meanwhile, interlaminar shear strength value of PBO/PPESK composite was increased ... Read More

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