Modern packaging materials face increasingly strict requirements for barrier properties, recyclability, and mechanical performance. Current mineral-filled composites achieve oxygen transmission rates of 2-5 cc/m²/day and water vapor transmission rates below 1 g/m²/day, but maintaining these properties while reducing material thickness remains challenging. Field testing shows that mineral particle size distribution significantly impacts both processing stability and final performance.

The fundamental challenge lies in optimizing filler content and distribution to enhance barrier properties without compromising processability or increasing material costs.

This page brings together solutions from recent research—including controlled particle size distribution techniques, layered mineral incorporation approaches, EVA-based masterbatch systems, and strategic placement of mineral-rich layers. These and other approaches focus on achieving consistent performance in high-speed manufacturing while meeting increasingly stringent packaging requirements.

1. Bag Insert Sleeve with Polyolefin Resin and Island-Dispersed Filler for Enhanced Structural Integrity and Barrier Properties

HOSOKAWA YOKO KK, 2024

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.

AU2019231392B2-patent-drawing

2. Polyolefin-Filler Composite Sleeve with Creases and Offset Bonding for Enhanced Packaging Bag Structure

HOSOKAWA YOKO CO LTD, 2024

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

3. Packaging Bag Sleeve with Multi-Layer Construction Including Filler Layer for Rigidity and Sealant Layer for Bonding

HOSOKAWA YOKO KK, 2024

A sleeve for a packaging bag that reduces wrinkling, improves stackability, prevents discoloration, and facilitates separate disposal compared to traditional paper or plastic sleeves. The sleeve has a unique construction with a base material layer, a filler layer, and a sealant layer. The filler layer contains a filler like talc to provide rigidity and prevent dimensional changes due to moisture. This prevents wrinkling and bulging in the bag. The sealant layer bonds the sleeve to the bag to prevent separate disposal issues. The sleeve design improves the bag's stackability, appearance, and functionality compared to traditional paper or plastic sleeves.

EP3763631B1-patent-drawing

4. Polyolefin Packaging Sleeve with Fillers for Enhanced Rigidity and Peelability

HOSOKAWA YOKO CO LTD, 2024

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.

5. Sleeved Packaging Bags with Filler-Enhanced Rigidity and Creased Folding Structure

HOSOKAWA YOKO CO LTD, 2024

Sleeved packaging bags that have improved appearance, stackability, and ease of disposal compared to traditional paper sleeve bags. The sleeves contain fillers like calcium carbonate or talc to provide rigidity without excessive thickness. The fillers also prevent dimensional changes due to moisture. The sleeves have creases to aid folding into a cylindrical shape. The sleeve and bag body are bonded together. The bonding is outside the crease area. This allows easy peeling after use. The bags can have windows in the flat section to show the contents.

6. Composite Packaging Structure with Fiber-Containing Inner Layer and Mineral-Containing Outer Layer

SMART PLANET TECHNOLOGIES INC, 2023

Composite packaging structure for containers with improved seal strength and barrier properties. The packaging has an inner fiber-containing layer and an outer mineral-containing layer. The outer layer has a density of 1.05-1.65 g/cm3, 4.5-50 lbs/3 msf basis weight, and 20-70% mineral particles. This provides hot tack and seal strength improvements compared to pure polymer layers. The mineral particles can be calcium carbonate. The outer layer can be extruded. The inner fiber layer can contain recycled paper or other fibers. The composite structure allows using less polymer, less filler, and less primer compared to traditional packaging. It also enables recycling the composite by screen filtration. The composite has applications in containers, bags, and pouches for food, beverages, and other products.

7. Molding Sheet and Packaging Container with Talc Filler of Defined Particle Diameter and Aspect Ratio in Polyolefin Resin Matrix

FP CORP, 2023

Molding sheet and packaging container with improved strength and impact resistance using a specific size and shape of talc as a filler in the matrix. The talc has an average particle diameter of 2-8 μm and an aspect ratio of 30-50. This talc with small size and high aspect ratio provides significant strength enhancement compared to regular talc fillers when dispersed in the polyolefin resin matrix. The resulting molded sheet and containers made from this composite have improved mechanical properties, particularly impact resistance, compared to conventional biopolymer sheets.

JP2023138387A-patent-drawing

8. Paper Sleeve with Polyolefin and Dispersed Filler for Enhanced Dimensional Stability and Rigidity

HOSOKAWA YOKO KK, 2022

A paper sleeve inside a packaging bag that prevents wrinkling and improves stackability compared to traditional paper sleeves. The sleeve contains a polyolefin resin and filler like calcium carbonate or talc. The filler disperses in the polyolefin in an island-like pattern. This prevents dimensional changes due to moisture that can cause wrinkling in the bag. The filler also improves rigidity and stackability compared to a plain paper sleeve.

RU2770238C2-patent-drawing

9. Packaging Bag Sleeve with Polyolefin Resin and Filler Composition Featuring Crease for Tubular Formation and Adhesive Bonding Area

HOSOKAWA YOKO CO LTD, 2021

A sleeve for a packaging bag that reduces wrinkling and improves stackability compared to traditional paper sleeves. The sleeve contains a polyolefin resin and a filler like calcium carbonate or talc. The filler increases rigidity without adding significant thickness. The sleeve has a crease to help fold it into a tubular shape. This prevents wrinkles when the bag is stacked. The sleeve bonds to the bag inner surface using a separate adhesive area. This allows separate disposal of the sleeve and bag. The filler also reduces moisture absorption compared to paper sleeves.

EP3763631A1-patent-drawing

10. Composite Packaging Material with Fiber-Containing and Mineral-Containing Bonded Layers

SMART PLANET TECH, 2020

Composite packaging material for shipping and transportation applications that is durable, low cost, attractive, and environmentally friendly. The composite material has two layers: a fiber-containing layer for machinability and a mineral-containing layer for strength. The layers are bonded together. The mineral layer is made with earth minerals like talc, diatomaceous earth, mica, or clay mixed with binders like polymers. This provides burst and tear resistance. The fiber layer adds machinability for forming final packaging shapes. The composite structure can be molded into boxes or cards for shipping and transportation uses. The composite balances strength, printability, machinability, and environmentally friendly materials.

11. Composite Sleeve with Polyolefin Film and Filler for Wrinkle-Resistant, Rigid Packaging Bag

HOSOKAWA YOKO KK, 2020

Sleeve and packaging bag with improved appearance and handling properties by using a composite sleeve with a polyolefin film and filler to prevent wrinkling and damage. The sleeve has a rectangular shape that forms a three-dimensional packaging bag when folded. The composite sleeve contains filler like calcium carbonate or talc. This provides rigidity and prevents dimensional changes due to moisture. The sleeve is bonded to the bag interior. The composite sleeve has creases to aid folding and joining points. This allows making thinner, lighter sleeves with better properties than pure polyolefin sleeves. The composite sleeve prevents wrinkles, maintains shape, and provides oil/water resistance. It separates easily from the bag for disposal.

12. Polyolefin Sleeve with Filler-Enhanced Rigidity for Dimensional Stability in Packaging Bags

HOSOKAWA YOKO KK, 2020

Sleeve and packaging bag that prevent wrinkling and deterioration of contents when stored. The sleeve is made of a polyolefin material with a filler like calcium carbonate or talc. The filler increases rigidity compared to the base polyolefin, preventing dimensional changes from moisture. This eliminates wrinkles in the bag when stored. The filler also reduces absorption of moisture from contents. The sleeve is placed inside a bag body to give it a three-dimensional shape. The bag can stand alone and stack neatly.

AU2019231392A1-patent-drawing

13. Biopolymer Coating Structure with Inorganic Stabilizer for Enhanced Extrusion Processing of Paperboard

WESTROCK MWV LLC, 2020

A biopolymer coating structure for paperboard that has improved extrusion processing characteristics, such as reduced neck-in and edge weave. The coating contains an inorganic material like talc, which stabilizes the melt curtain during extrusion and reduces defects. The coating can be made by extruding a blend of biopolymer, adhesion promoter, and talc onto paperboard.

US10655277B2-patent-drawing

14. Method for Producing Flexible Packaging Film via Machine Direction Orientation of High Filler Content Blown Film

FRITO-LAY NORTH AMERICA INC, 2019

A method to make a cost-effective, high-performance flexible packaging film by orienting blown film with high filler content. The method involves using a blown film machine to create a film with high density polyethylene (HDPE) resin and at least 50% inorganic filler. The film is then oriented in the machine direction to reduce the thickness by at least 35%. This orientation improves the film's strength significantly. The filler-enhanced blown film is oriented to achieve a final thickness much lower than the initial blown film thickness. The filler displaces resin, reducing material costs, while orientation increases strength. The lower thickness also reduces yield losses. The oriented film has a thickness coefficient of variation of 10% or less.

CA2901170C-patent-drawing

15. Composite Packaging Material with Mineral and Natural Fiber Layers

SMART PLANET TECHNOLOGIES INC, 2018

Composite packaging material for retail and shipping products that provides durability, theft resistance, and environmental friendliness. The composite structure has two layers, a mineral-containing layer and a fiber-containing layer. The mineral layer contains earth-based materials like talc, diatomaceous earth, minerals, mica, silica, glass, clays, zeolites, and shale. The fiber layer contains natural fibers. The layers are bonded together to form a composite structure that can be machined and printed like cardboard, but with improved properties like strength, stiffness, and thermal resistance. The composite provides durable, theft-resistant packaging with an attractive printable surface using earth-based materials.

16. Composite Packaging Material with Fiber Core and Mineral-Enhanced Outer Layers

SMART PLANET TECHNOLOGIES INC, 2018

Composite material for retail and shipping packaging that is durable, attractive, environmentally friendly, and resistant to theft. The composite structure has a fiber-containing layer sandwiched between a mineral-containing layer. The mineral layer provides stiffness, strength, and environmental benefits. The fiber layer improves printability and moisture barrier. The composite balances properties for processing and final product shapes. The mineral content is 35-65% by weight, with specific minerals like talc, mica, and clay.

TR201812932T4-patent-drawing

17. Blown Film Orientation Method with High Inorganic Filler Content for Thickness Reduction

FRITO-LAY NORTH AMERICA INC, 2017

A method for making an oriented flexible packaging film using blown film with high filler content. The process involves starting with a blown film made from HDPE resin and at least 50% inorganic filler. The blown film is then oriented to significantly reduce its thickness by at least 35%. This orientation improves the film's mechanical properties like tensile strength while maintaining smoothness for better printing. The high filler content in the blown film allows reducing the amount of expensive HDPE resin, lowering cost.

US2017190854A1-patent-drawing

18. Biodegradable Paperboard with Talc-Enhanced PLA Biopolymer Coating

WESTROCK MWV LLC, 2017

Biodegradable paperboard coated with a biopolymer like PLA containing a small amount of inorganic talc. The talc improves the processing characteristics of the biopolymer during extrusion coating, reducing issues like adhesion, weave, and neck-in. This allows better quality and consistency of the biodegradable coating on paperboard compared to pure PLA. The coated paperboard can be compostable since the talc content is below the threshold for compostability requirements.

WO2017091392A1-patent-drawing

19. Method for Producing High-Filler Oriented Flexible Packaging Film via Blown Film Extrusion with Thickness Reduction

FRITO-LAY NORTH AMERICA INC, 2017

A method to make a cost-effective, high-strength, and smooth oriented flexible packaging film using blown film extrusion with high filler content. The method involves blowing a HDPE film with at least 50% filler to a thicker initial thickness, then orienting it to a thinner final thickness. This reduces wrinkles, improves yield, and maintains smoothness compared to using high filler levels in blown film itself. The oriented film has at least 35% less thickness than the initial blown film. This allows substituting filler for resin to lower cost, while preserving strength and graphics quality.

20. High-Density Polyethylene Tapes with Inorganic Filler for Shape Retention in Packaging Zippers

IDEMITSU UNITECH CO LTD, 2014

Shape-retaining tapes and zipper tapes for package bags that can hold openings in the open position. The tapes are made from a high-density polyethylene resin with added inorganic filler, like talc. The filler provides rigidity and elasticity to the tapes without requiring stretching during production. The tapes can be easily produced by extrusion molding. The shape-retaining tapes can be attached to bag openings to keep them open. The zipper tapes have engagement parts like teeth and a shape-retaining part made of the filled resin. This allows the zipper to stay open when forced.

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