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Food Packaging > Lamination > Flashcards

Lamination Flashcards

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1
Q

Define lamination:

A

combine different plastic film materials (+ non plastic materials) => 1 material

2+ layers (at least 1 is plastic)

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2
Q

Purpose of lamination:

A

COMBINE properties of materials (mechanical properties, barrier, heat-sealing, printability, optical properties, stretch…)

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3
Q

What products usually use laminates for packaging? (3)

A

long shelf-life
$$$$ products (high profit margin)
sensitive products

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4
Q

methods of making laminates: (4)

A

adhesive lamination
extrusion coating
co-extrusion
vacuum metallization

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5
Q

What is the process of adhesive lamination? (4)

A

adhesive (solvent or water based) applied to one web
Cured (dried)
combine with uncoated web (heat + pressure)
continue until all layers complete

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6
Q

Adhesives can be ____ or ____ based

A

aqueous, solvent

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7
Q

Why is curing important in adhesive lamination?

A

dries; excess solvent can cause de-lamination

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8
Q

parts of the adhesive lamination machine: (3)

A

unwind/rewind rolls
adhesive applicator
nip and chill roller

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9
Q

____ coating is comon with PE, PP, PET paper

A

extrusion coating

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10
Q

What are advantages of extrusion coating vs adhesive lamination? (4)

A
  1. avoid handling (thin PE film handling is difficult)
  2. high temp impregnantes plastic into paper
  3. cheaper
  4. less pollution
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11
Q

What acts as the ‘glue’ in extrusion coating?

A

extrudate

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12
Q

What is co-extrusion?

A

2+ extrusion feeders into 1 head -> extrudate is combination

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13
Q

Advantages of co-extrusion: (3)

A

lower cost
less delamination
flexibility

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14
Q

What are some products obtained with co-extrusion?

A

thermoforming films/sheets, retortable films/sheets, flexible films

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15
Q

What is vacuum metallization?

A

metallized plastic film/paper (added metal material)

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16
Q

properties of metallized films: (4)

A

reflectance (metallic/shiny)
tougher
susceptor (microwave energy -> radiant heat)
better barrier

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17
Q

Pre-treatments required before vacuum metallization: (2)

A

mechanical treatment

primer coating

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18
Q

What is the mechanical treatment for vacuum metallization?

A

high voltage/frequency discharge
Corona (continuous arc) @ film surface -> introduce polar groups

-> clean, oxidize, activate surface = better adhesion

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19
Q

What is the ‘primer coating’ in vacuum metallization?

A

thin coat applied that attracts both layers (better adhesion)

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20
Q

What is the process for vacuum metallization? (3)

A

BATCH PROCESS:

  1. metal vaporized in vacuum chamber
  2. sprayed to apply to pre-treated material
  3. coated with varnish to seal/smooth
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21
Q

What films are used for vacuum metallization? (4)

A

PP (80%)
PET (15%)
PA (4%)
PVC, PVDC, PS (1%)

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22
Q

T/F: the most common plastic film in metallization is PS

A

FALSE: Least common (<1%)

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23
Q

What are the functions of various laminate layers? (inside -> outside) (5)

A 
product compatibility
heat sealability
barrier
mech. structure
printability/abrasion resistance
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24
Q

Describe the laminated structure of a juice box (out -> in) (5)

A
  1. PE (outer protection)
  2. Printed paper (printable, strength)
  3. PE (puncture resistance)
  4. Aluminum (moisture/flavor barrier)
  5. PE (sealability, prevent metallic taste)
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25
Q

heat-seal depends on: (3)

A

melt temp
machine pressure
contact time

26
Q

Ideal features for a heat-sealing layer: (3)

A

low melt temp
strong sealing properties
low cost

27
Q

The best sealing materials? What is the downside?

A

Ionomers (Surlyn)

$$$$!

28
Q

generally, the higher the seal ability, the (higher/lower) the cost

A

higher

29
Q

An alternative to ionomers for heat sealing, that is slightly lower in seal ability and cost?

A

acid copolymers

30
Q

common heat seal layers, worst to best heat sealability: (3)

A

LDPE
EVA (ethylene vinyl acetate)
Ionomer (Surlyn)

31
Q

What are the major purposes of intermediate barriers? (3)

A

heat sealing
barrier
toughness/mech structure

32
Q

major purpose of the outermost and inntermost layers?

A

outer: printability/abrasion resistance
inner: food contact (safe/nonreactive)

33
Q

____ is comonly used as the outer barrier layer. what are its properties?

A

nylon

abrasion resistant/tough, but poor water barrier (*good gas barrier if DRY)

34
Q

a nylon + LDPE laminate is considered a ____ barrier laminate

A

intermediate

35
Q

What can be added to made an intermediate laminate into a high-barrier laminate?

A

Add a barrier layer between

ex: PVDC (excellent water/gas barrier)

36
Q

Example of a low-barrier laminate

A

OPVC outer (breathable) - high water barrier but low gas barrier

LDPE/ionomer (coextruded) - low gas barrier

37
Q

Saran-containing laminates are ____ barrier materials that are (flexible/rigid)

A

high barrier, flexible

38
Q

2 examples of high barrier, semi-rigid laminate materials:

How are they produced?

A

PVC/EVOH/EVA
PVC/EVOH/surlyn
co-extrusion

39
Q

2-layered laminates are usually ____barrier, and are (flexible/rigid)

A

medium barrier, flexible

40
Q

materials commonly used to increase barrier properties: (3)

A

Saran
EVOH
Foil

41
Q

Give the structure/materials of a non-shrink bag:

A

PA/PET outer (strength, O2 barrier)

LDPE/ionomer/EVA inner (moisture barrier, heat seal)

42
Q

Give the structure/materials of a shrink bag:

A

nylon outer (strength)
PVC/PVDC (gas barrier)
EVA/surlyn inner (moisture barrier, heat seal)

43
Q

2 machinery types for forming packages:

A

VFFS (vertical form-fill-seal)

HFFS (horizontal form-fill-seal)

44
Q

Which is faster, VFFS or HFFS?

A

HFFS

45
Q

Describe the process of VFFS:

A 
unwind laminate 
forming &amp; draw down (form package)
product feed (fill package)
longitudinal sealing jaw -> cross seal &amp; cut off
46
Q

T/F: VFFS is larger than HFFS systems

A

false: more compact

47
Q

compare HFFS vs VFFS:

A

HFFS: Faster, multi-tunnel systems, horizontal fill
VFFS: slower, compact, vertical fill

48
Q

Describe the process of HFFS:

A 
unwind laminate
forming plow (forms film)
product deposited (filled)
form seam -> pouch
close/seal
49
Q

What types of seals are used in VFFS? (2) What is used for HFFS? (2)

A

VFFS: fin seal, lap seal
HFFS: 3-side seal pouch, gusseted bottom

50
Q

various forms of packages made by VFFS or HFFS:

A

bags, pouches/stand-up pouches, tear seams, dispenser, re-sealable bags

51
Q

re-sealable zippers for ready-made foods are usually made of _____ in order to ____

A 
PP
withstand retort (heat-stable)
52
Q

resealable closures types:

A

PP zipper

adhesive (ex: cookies)

53
Q

What are specific packaging requirements for coffee/milk powder? What is the solution?

A

degassing (gas release from coffee)
protection from O2, heat, light, moisture (preserve flavor/quality)

solution: metallized PE (stiff, strong, barrier, opaque, seals, vacuum)

54
Q

What packaging is used for coffee concentrate, and why?

A

PE/Al/PE/Al/PE (multilayer)

seals, lightweight, protect from light & O2

55
Q

What packaging is used for pizza, and why?

A

PET/PVDC/PE(or ionomer)

PET: strength,
PVDC: high barrier against gas/moisture/oil
PE/Ionomer: seals

56
Q

What packaging is used for fresh meat? Why?

A

PE/PA/PE or PET/PVDC/PE

PE/PET: water barrier
PA/PVDC: strength/barrier
PE: seals

57
Q

Why does sausage have different packaging material requirements than fresh meat?

A

Different composition (less moisture, more fat)

58
Q

What packaging is used for sausage? Why?

A

PE/OPA

water barrier, strength, oil resistant, seals

59
Q

What packaging is used for fresh pasta? Why

A

PE/PVC

strength, moisture barrier, seal

60
Q

What packaging is used for cheese? Why?

A

PET/PE/PVDC
strength, moisture barrier
seal
barrier (odor), oil resistant

61
Q

What packaging is used for baked goods? Why?

A

PVDC/PET(or PP)/PE

barrier, seal

62
Q

What packaging is used for freeze-dried goods?

A 
48ga PETE
60ga extruded PE
28ga Aluminum
60ga extruded PE
40ga LLDPE
freshlock zipper

Food Packaging (11 decks)

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