Calcium Carbonate Systems for Packaging Reinforcement

Recyclable composite packaging material that can be efficiently repulped and recycled using both pre-consumer and post-consumer collection methods. The material is made by extrusion coating a mineral-containing layer onto a fiber-containing layer using a mineral-containing resin. The mineral particles are dispersed in a polyolefin bonding agent. The resulting composite structure can be repulped and recycled with high recovery rates and minimal quality issues.

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Laminate sheet and food packaging container with reduced variation in hiding power when filled with a high percentage of inorganic powder. The laminate sheet has a three-layer structure with an inner layer containing the inorganic powder, and outer layers without the powder. The powder particle size distribution is optimized: D20 2.0-3.4 μm, D50 4.8-7.6 μm, D70 7.7-11.6 μm. The inner layer has higher powder content than the outer layers. The powder content is 40-80% by mass of the laminate sheet. The outer layer thickness ratio is 2-20% of the total sheet thickness. This configuration suppresses hiding power variation when producing sheets with high inorganic powder content.

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Laminated sheet and food packaging container with reduced hiding variation when filled with a high content of inorganic powder. The laminate sheet has a specific particle size distribution for the inorganic powder, with D20 of 2.0-3.4 μm, D50 of 4.8-7.6 μm, and D70 of 7.7-11.6 μm. The inner layer contains more inorganic powder than the outer layers. The thickness ratio of the outer layers is 2-20%. This reduces hiding powder variation during mass production. The laminate sheet can be used for food packaging containers.

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A new type of paper for packaging that has improved mechanical properties, printability, and recyclability compared to conventional paper. The paper contains short fibers and mineral filler. The paper has a fiber content of 60-95% and a mineral filler content of 2-15% by weight. The mineral filler improves strength and tear resistance. Coated versions of the paper can be made by applying a barrier composition on the paper using techniques like reverse gravure, blade coating, or printer systems. The coated paper has enhanced barrier properties like oxygen, moisture, and grease resistance. The paper and coated paper are suitable for food and pharmaceutical packaging that requires good sealing and barrier properties. The paper is also biodegradable and compostable.

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A sleeve for use inside a bag to provide a three-dimensional shape and prevent wrinkling. The sleeve contains a polyolefin resin and a filler like calcium carbonate or talc. The filler dispersed in an island shape reduces gas permeability compared to a filler-free sleeve. This prevents wrinkling and bag distortion due to moisture changes. The filler also improves barrier properties against oxygen and moisture to prevent contents degradation.

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Laminate sheet and food packaging container with improved moldability and reduced variation during mass production. The laminate sheet contains an inorganic powder like calcium carbonate with specific particle size distributions. The D10 particle size is 0.9-2.9 μm, D20 is 2.2-4.2 μm, D30 is 5.6 μm or less, D40 is less than 0.3 μm, and D50 is 8 μm or less. This particle size distribution improves moldability compared to high powder content laminates. The inner layer contains the powder and resin, outer layers are resin only. The powder content is 40-80% of the sheet, with more powder in the inner layer.

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Sleeve for packaging bags that improves appearance, stackability, and separate disposability compared to traditional paper or plastic sleeves. The sleeve contains a polyolefin resin and filler like calcium carbonate or talc. The filler increases rigidity and reduces dimensional changes from moisture compared to pure polyolefin sleeves. The sleeve is also thicker than a paper sleeve to provide similar rigidity. The thicker sleeve allows more bags per box for better transport efficiency. The sleeve has creases to aid folding into a tubular shape. A bonding part connects the sleeve to the bag body at a different location than the crease. This prevents the sleeve from peeling off the bag body during separate disposal. The filled polyolefin sleeve provides a consistent shape, reduces wrinkling, and improves stackability compared to paper sleeves. It also avoids the issues of oil absorption and fiber residue from paper

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Laminate sheet for food packaging with improved moldability and processability. The laminate sheet contains a high percentage of inorganic powder, like calcium carbonate, in the inner layer. The powder particle size distribution is critical to avoid variations in moldability during mass production. The particle size range is 0.9-2.9 μm (D10), 2.2-4.2 μm (D20), 3.6-5.6 μm (D30), 5.0-7.0 μm (D40), and 6.4-8.4 μm (D50). The inner layer contains more powder than the outer layers. This composition provides stable moldability and processability of the laminate sheet and resulting food packaging containers, even with high filler content.

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Laminated film and packaging bags made from polyethylene-based resins that can be easily recycled while maintaining properties like stiffness, water vapor barrier, and light blocking. The film structure involves a base film with a high melting point PE and a sealant film with a lower melting point LLDPE. At least one layer of the film contains a colored filler. This allows recycling with mono-material PE bags while still providing desirable properties. The sealant film can have a multi-layer structure with the colored filler in an inner layer. The colored filler can be white, black, or a combination. The filler loading is 10% or less based on film weight.

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Packaging laminate with reduced resin content that improves seal strength and reduces pinholes compared to using just calcium carbonate in the sealant layer. The laminate has a sealant layer with two sublayers, an inner sublayer containing calcium carbonate and a lower calcium carbonate content outer sublayer. This gradient reduces resin use while maintaining seal integrity. The inner sublayer with higher calcium carbonate provides strength, and the outer sublayer with lower calcium carbonate allows better heat sealing.

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Laminate sheet and food packaging containers with improved moldability and processability during mass production. The laminate sheet contains an inorganic powder like calcium carbonate with specific particle size distributions. The powder content is 40-80% by mass of the laminate, with D10 0.9-2.9 µm, D20 2.2-4.2 µm, D30 3.6-5.6 µm, D40 5.0-7.0 µm, and D50 6.4-8.4 µm. The inner layer has more powder than the outer layers. The outer layer thickness is 2-20% of the total. This prevents variations in moldability when using high powder content laminates.

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Composite paper made from cellulose fibers and mineral particles derived from purified phosphate sludge. The sludge is treated to remove toxic elements before using it as a raw material in the paper. The composite paper has improved thermal and fire resistance compared to pure cellulose paper. The paper is intended for technical and packaging applications. The sludge treatment reduces heavy metal concentrations to meet environmental standards. The composite paper uses the treated sludge as a replacement for other fillers.

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Single-layer opaque plastic bottle with high light protection that achieves nearly complete light occlusion. The bottle is made from a single layer of plastic containing a specific filler composition. The filler is dispersed in the plastic during manufacturing to provide high light blocking without needing multiple layers or coatings. The filler composition includes a white pigment like titanium dioxide (TiO2) along with an additional filler like aluminum (Al) that absorbs light without reflecting it. This combination provides both hiding power and high light absorption to make the bottle nearly opaque.

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Sleeve for packaging bags that provides better stackability, appearance, and separate disposability compared to traditional paper sleeves. The sleeve is made of a polyolefin material with fillers like calcium carbonate or talc. The fillers improve rigidity and dead-holding properties without excessive thickness. The sleeve can be easily peeled off from the bag body after use. The filled sleeve gives a 3D shape to the bag, prevents wrinkling, and has stackability. It also prevents moisture absorption from contents into the sleeve.

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A multilayer film for packaging that mimics paper-coated foil and degrades in the environment. The film has a base made of high-density polyethylene (HDPE) with chalk and titanium dioxide fillers. One side is metallized with aluminum nanoparticles. Adding an OXO-biodegradable additive containing transition metal carboxylates allows rapid breakdown of the HDPE under light and heat, making the film biodegradable. The metallized side provides barrier properties and the fillers give rigidity. The paper-like base reduces environmental pollution versus traditional foil. The biodegradability ensures disposal.

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Composite paper for packaging applications made from cellulose fibers and mineral particles derived from purified phosphate mining waste. The paper aims to repurpose phosphate washing sludge as a sustainable alternative raw material in packaging. The sludge undergoes chemical treatment to remove toxic metals. The treated sludge particles are mixed with cellulose fibers to make composite paper. The composite paper has improved thermal and fire resistance compared to cellulose-only paper. It can be further coated with thermoplastic materials for enhanced water resistance.

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Recyclable composite packaging material that can be effectively repulped and recycled using both pre-consumer and post-consumer collection methods. The composite consists of a mineral-containing layer extrusion coated onto a fiber-containing layer. The mineral particles in the layer break down into dense fragments during repulping, allowing efficient release of fibers and passage through screens. This prevents clogging and fouling issues compared to non-fibrous barrier layers. The mineral layer density, composition, and extrusion conditions are optimized for repulpability.

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A laminated sheet for food packaging with improved moldability, mechanical properties, and appearance. The laminated sheet has an inner layer containing calcium carbonate filler and thermoplastic resin, and two outer layers of thermoplastic resin. The inner layer calcium carbonate filler has calcium carbonate particles with surface treatment containing sulfonic acid or phosphoric acid ester. The calcium carbonate content in the inner layer is 40-80% by mass. The outer layer thickness is 2% or less of the total sheet thickness. This laminate reduces variations in moldability, mechanical properties, and appearance compared to conventional calcium carbonate filler laminates. The surface treatment on the calcium carbonate particles improves dispersibility, reactivity, and reduces void formation during processing.

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A laminated sheet and a food packaging container made from it that has improved appearance and mechanical properties compared to conventional laminated sheets. The laminated sheet has a inner layer with a high ratio of inorganic powder to resin, typically around 70-90% inorganic powder. This improves strength and rigidity. However, laminated sheets with high inorganic filler content often have poor surface finish. To address this, the inner layer also contains a small amount of lauric acid diethanolamide additive. This improves compatibility between the resin, inorganic powder, and additive, resulting in better appearance and mechanical properties of the laminated sheet.

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Laminated sheet and food packaging container with improved appearance and mechanical properties. The laminated sheet has an inner layer containing a specific ratio of polyethylene, polypropylene, inorganic powder, and lauric acid diethanolamide. The outer layer is polyethylene and polypropylene. The inner layer has a unique composition with a ratio of resin to inorganic powder between 10:90 and less than 50:50. This provides good appearance and mechanical properties compared to similar sheets. The lauric acid diethanolamide improves compatibility between the resins and inorganic powder. The outer layer thickness is 2-10% of the total sheet thickness.

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