Norner News Packaging Edition

Issued by Norner AS May 2017

Packaging Edition

NORNERNEWS

Packaging Innovations Packaging Performance and Control Biobased Materials and Recycling Packaging Development Tools

Highlights Norner Move for Greenovation

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We see a society developing in full speed forward striving for a more sustainable utilisation of our global resources.

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At Norner, we also have to take our share of responsibility - in areas where we actually can influence.

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the last year further developed our technology strategy, Development of Green and sustainable rawmaterials and utilization of them wil be a key element.

We are developing lightweight material solutions, biobased raw materials and build up new knowledge in Marine littering.

We are therefore proud for the recent announcement tat we will move our company to a new Powerhouse (picture).

This will produce more energy than it consume in a cradle-tocradle perspective.

As an innovation company we have to hunt for new ideas and we have to be ahead of the industry. Thus, we have during

It will also be a demonstrator for new sustainable materials in the building and infrastructure industry.

3@Norner Katrin Nord Varhaug Hello, I am working with composites and project manager at Norner for the C6 technology projects. I like new challenges like this and the success.

Liv Thobru Hi, as polymer analyst I am very excited about the new investment in GPC-IR. With this we can achieve more for our clients.

That is very inspiring.

Svein Jamtvedt

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Hi, I deal with additives and suppliers and was responsible for the testing of new antioxidants from Sumitomo.

Chemistry is Cool!

Chemicals in Packaging Food safety is a highly important subject for the food value chain. Most food available have packaging which is a significant and critical part of preservation and safety.

Norner recently finalised a three-year research project, “Chemicals in Packaging� together with Norwegian food and packaging industries where we have analysed chemical composition and migration including NIAS in a wide range of plastics packaging.

We found NIAS components in a high number of packaging products. Read more about this and other aspects of liablity in this magazine.

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Highlights Packaging Prize for Ole Jan Myhre Ole Jan Myhre, Market Manager at Norner has been awarded as “Packaging Professional 2015” by the Norwegian Packaging Association.

He was recognized for his outstanding work and knowledge sharing in Plastic Packaging.

Product Failure Analysis Norner provides failure analysis to the packaging industry on a regular basis.

This includes breakages, delamination or s seen on the picture, gels in co-extruded films The presence of gels is a classic challenge of film extrusion. Such imperfections in form of lumps in the films can be cause by many different factors.

Expanding capabilities We continuously invest in our polymer testing capabilities at Norner.

During the last two years we have made following investments for packaing and pharma: New GPC with IR sensor foraanalising short chain branching together with MWD.

Gels will lead to problms like pinholes, print imperfectionsand delamination. It is of high importance to identify their origin for solving the problems.

You can read more about on page 17, we have experts and a well equipped microscopy and analytical lab to examine and propose solutions to packaging failures.

instrument with state of the art capabilities.

US Pharmacopeia (USP) and EU. Pharm. analysis of plastic packaging materials NIAS screening methods for plastic packaging and EU 10/2011

Beach Clean-Up 2017

Testing and analysis for PET, PS, PP and PE

New dynamic rheology

Norner have unique experience and knowledge for analysing plastics in from sea or beaches weather it ispellets, beads, microplastics or larger items. This May we will be back for another cleanup and we are looking very much forward to it! New report will follow.

Dr. Siw Fredriksen enter research board Dr. Siw Fredriksen enters the board of Norwegian Oslofjord research fund which provides grants for research projects in the counties of Buskerud, Telemark, Vestfold and Østfold with the aim to create regional growth.

We are proud of the appointment that shows that our researchers have high recognition and Norner is a significant technological R & D centre in the region.

www.norner.no

NornSlip

a concept for self cleaning packaging Jørgen Nyhus

jorgen.nyhus@norner.no

An everyday phenomenon met by consumers worldwide is the fact that it’s actually not possible to empty food containers without scraping or flushing.

NORNER took the initiative to develop an environmentally friendly packaging concept with inner plastic surfaces with extremely good slip properties (easy slip) that will enable more or less no residues in the package when emptied.

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Typical examples of products which are difficult to empty can be yoghurts, tomato ketchup, shampoo, mineral oil products or paint to mention a few. The thicker the liquid the more difficult to empty. Often these products are relative expensive too, so loosing access to up to 10 % can be quite annoying for the customer.

When waste handling or recycling is considered, packaging products might end up as special category waste or both consumer and waste handling companies excessively perform cleaning by water – a limited resource in many parts of the world.

Due to the environmental aspects as well as increasing customer focus on these challenges different industries target to find solutions to the problem.

Features of NornSlip include • No added chemical or substances to give the easyslip effect • Use of volume materials suited for the purpose • Typically use existing packaging design but modify surface • Use specific NornSlip processing guidelines

Key results • Non-wetting polyolefin surfaces with contact angle above 140° • Close to superhydrofibic • Easy slip characteristic demonstrated for various food products. Easy to empty • Fulfilling all food regulations • Good environmental impact NornSlip is a technology concept to the benefit of the packaging producers and fillers where easy slip is an advantage. The photo demonstrates the very high contact angle we have achieved for developments in the project for aqueous products.

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Improved Foam Homogeneity Better insulation with lower weight Katrin Nord-Varhaug

katrin.nord-varhaug@norner.no

Technology for improved foam homogeneity with small void sizes, low cost and lighter weight.

Norner took part in an exciting EU funded project with the target to develop low cost, lightweight, Highly Insulating Polymers (HIP) for refrigerated transport, heating and cooling installations.

and low thermal conductivity, it is important to obtain small void sizes of the final product.

Norner’s main contribution was to develop and up-scale a process which can produce emulsion materials with close control of porosity and pore size distribution.

By proper control of the components in the emulsion, the project has

The project has been funded by the European Commission under the Seventh Framework Programme. 11 partners from 6 European countries contributed.

Foam can be made by several processes and materials. In this project the basic idea has been to produce microcellular foam by using emulsions. The emulsion consists of two immiscible phases which have been mixed by high shear.

In order to obtain good insulation

been able to develop a formulation which is homogeneous and have small voids. By applying a high shear emulsion pump, we could produce homogeneous foams with a void size of around 1 Âľm.

The project attracted high interest

from the insulating industry and had end users needing insulation for small heating and cooling items, such as i.e. water heater up to larger cooling systems, such as i.e. refrigerated vehicles.

Norner has since the closure of this project been part of other projects with the focus to invent processes and identify material solutions with good insulation properties. The end use varies from products being made for hot and cold water, refrigerators, insulations for buildings and large vehicles up to thermal insulation of components used in tough sub-sea conditions.

Norner has also seen that microcellular emulsions and the understanding of this is to be important for not only the polymer industry but also for other products like food and personal care.

A step forward for the insulating industry

Simulating

Packaging barrier and product shelf life Ole Jan Myhre

access to O2, H2O, CO2, N2 and the packaging barrier against gas permeation is very important for shelf life...

Food packaging shall protect and extend the shelf life of food. This will reduce food spoilage.

In particular, we will look at examples of meat products where oxygen permeability is of high importance and cereal products where moisture permeability is the key.

The main idea of food packaging is to contain and protect food like fresh meat and fish, prepared food, vegetables, juices, beverages and more through the distribution and retail chain to the consumer. The time a product can remain fresh for consumption is its “shelf life” and this article discuss how this is influenced and how you can simulate this.

PERMEABILITY Plastics seems impermeable but that is not correct. Conventional packaging polymers such as PET, PE or PP have a rather high permeability for O2 and give limited protection while for moisture they give a good protection.

Some other polymers like PA and EVOH on the other hand have high barrier against O2 and protects food well. These different materials can be combined in order to obtain the right performance - like in below figure.

olejan.myhre@norner.no

SHELF LIFE A good definition of shelf life is: “The period between the manufacture and the retail purchase of food product, during which time the product is of satisfactory quality in terms of nutritional value, flavour, texture, appearance and safety.”

The way a product deteriorate is also many, including: microbiological and/ or enzymatic deterioration (aerobe and anaerobe), oxidation e.g. Lipidic oxidation of fish or Rancidification of fatty foods, moistening, drying and other changes in taste, odour or colour.

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Many of the deterioration processes is dependent of temperature and

SIMULATION Norner have developed a web based calculation tool for oxygen transmission rate (OTR) and water vapour transmission rate (WVTR).

The calculator is available for free on www.norner.no.

“Very interesting! I have already forwarded this to a client who is demanding such application for many years. This was enjoyable” says Mr. Didier Houssier, Kuraray Europe It allows the user to specify: • Various package types • The package dimensions • The type and thickness of different polymers in the wall of the pack • The (storage) temperature and relative humidity • The time for which permeation shall be calculated.

BENFITS The calculator is easy to use and flexible in how you can specify the package and conditions which allows: • Storage/transport condition can be specified and varied • You can use it to generate data for your packaging system as a basis for correlation curves • When you know the product tolerances, shelf life can be estimated • Virtual testing of various package types and layer constructions

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Examples of calculation and simulation Meat has a natural high activity and is affected by the precense of oxygen which may lead to microbiological activity and turn the meat bad.

Case 1 - Meat / OTR

We shall calculate the shelf life of a piece of beef in a vacuum pack. The packaging film is a 7 later PE/PA/ EVOH structure.

We calculate the O2 ingress at different times and storage temperature and plot the results as shown to the right.

We specify the O2 limit to 1ml

CONCLUSIONS

Under the specified conditions: • The shelf life is >60 days at 2°C • At 10°C the shel life is only half Similar calculations can be made for alternative packages.

Total Oxygen Transmission [ml]

The input data for the calculation is: • The following 7-layer structure: 40µm PE / 4µm Tie / 5µm PA6 / 3µm EVOH32 / 5µm PA6 / 4µm Tie / 40µmPE • Film surface area 25x40cm2 • Relative humitidy 65%

3,5

2°C

3

5°C

10°C

20°C

2,5 2 1,5 1 0,5 0 | 0

Cereals are dry and with a very low activity. Their shelf life will naturally be long but a critical issue is moisture incress by which they may turn soft.

| 10

| 20

| | 30 40 Time [days]

| 50

| 60

Case 2 - Cereals / WVTR

We shall calculate the shelf life of cereals in a PE pouch.

We calculate the H2O ingress at different relative humidity in the storage and plot the results as shown to the right.

We specify the H2O limit to 15g

CONCLUSIONS

Under the specified conditions: • The shelf life is 700 days at 20% • At 50% the shel life is only half Similar calculations can be made for alternative structrures or thickness.

Total Water Vapour Transmission [g]

The input data for the calculation is: • The following 3-layer structure: 10µm HDPE / 10µm HDPE / 10µm LDPE • Film surface area 30x50cm2 • Temperature 20°C • Relative humitidy inside 0% 80 70

20%

50%

70%

100%

60 50 40 30 20 10 0 |

0

| 100

| 200

| 300

| 400 Time [days]

| 500

| 600

| 700

Plastics from CO2

plastics utilising the greenhouse gas as raw material

ndependent, Global and Industrial Polymer Institute Siw Fredriksenweight, provided that an siw.fredriksen@norner.no

optimized stabilization package trated by complex viscosity is being used. shear rate in the figure Norner has for several years been active w. in the research of Injection polymerisation mouldingof CO2 is polar while polyolefins to make polymers, with several projects The injection molding should unpolar. A compatibilizer focusing on itdifferent aspects of the apply the same temperature t therefore be added and recommendations as given for been shown that amounts technology. the compounding step above.

-10wt% are optimal, Blends and moulded ending on The the interest blend ratio. in making polymers from injection CO2 is huge due items of PPC and polyolefins ventional compatibilizers to the utilisation of a waste product that is harming the with up to at least 50% polyolefin carrier can climate, as well as the substitution of costlier petro based content of PPC can be made. sed, but the grade and raw be materials. substitute can 35-45% of the The stiffness be modified nology must chosenSuch polymers .

Norner has hydrocarbon based raw material with CO with the content care and this has shown 2 of inherent developed a position as a recognized player in the emerging plasticizer, propylene carbonate ve significantly different patibilization.

“Carbon Capture and Use”(PC). industry.

PPC, polyolefin and Poly(propylene carbonate) patibilizer should be Poly(propylene carbonate), PPC, is produced by the ded by compounding at copolymerisation temperatures below the of CO2 and propylene oxide in the presence a catalyst. PPCofis an environmentally friendly material ompositionoftemperature that needs to be considered for broader applications that . Temperatures up to 20°C er than the thedecomposition current limited commercial use. perature can also be used out loss of molecular

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www.norner.no

Film extrusion Cast film with superior transparency can be made and these films can be laminated onto paperboard with nice appearance.

Melt blends of PPC PPC is a material with significant opportunities, but also with some limitations. One limitation is its use in conventional thermoplastic applications due to a low glass transition temperature, Tg, and a low decomposition temperature.

One way to overcome this limitation, and speed up the time to market for PPC, is using blends and multi-layered solutions with both conventional thermoplastic resins (PE and PP) as well as other bioplastics.

Moulding PPC has superior melt strength compared to conventional polyolefin. This is an advantage with respect to blow moulding performance. As an example, blends and bottles of PPC and polyolefin with up to at least 60% content of PPC can be made. The result is bottles with 25% wt% CO2 as a base material. Injection moulded items of PPC blends with up to at least 50% content of PPC can also be made.

Ravindra Chowreddy

ravindra.chowreddy@norner.no

How can we utilise waste products for new and innovative products?

Norner is an R&D partner in the project, SOILFILM which is funded by the Norwegian Research Council led

by NIBIO (earlier Bioforsk, Norway).

VTT (Finland) and The University of Nebraska (USA) are also participating in the project. In addition, four industrial collaborators in the value chain are supporting the project.

The objective of the SOILFILM project is to develop a sprayable mulch film formulations from food waste streams. Vast amounts of by-products are generated from agriculture based food processing, poultry, marine and slaughter houses.

Some of these by-products are utilised in feed processing and other are underutilized. The SOILFILM project intends to use underutilised food industry by-products in the production of biodegradable mulch film formulations.

The potential co-streams of the food industry have been assessed and competence has been acquired in

the project to develop film-forming formulations.

Food processing is one of the most important industries globally. The byproducts of food processing industry must be handled in an appropriate manner to avoid any environmental violence. Among the variety of food industry by-products, the project intends to utilise peel, pulp, pomace by-products from the agricultural food process and chicken feather from poultry in the development of biodegradable mulch film.

Norner has already made and tested biodegradable soil film made from food by-products.

In the SOILFILM project, Norner has already developed a biodegradable film formulation from the byproducts of selected food processing industry. NIBIO has tested some of the formulations in their laboratory to demonstrate the applicability of formulations and the effectiveness of the film against weed germination and growth and the results are very promising. Currently, Norner is optimizing mulch film formulations from selected food industry byproducts.

Processed potato in the form of ready-to-eat products such as frozen products, chips and French fries, generates large amounts potato peel, which is currently used as animal feed or treated as a waste. Similarly, processing of carrots, tomato and fruits generate vast amounts of byproduct residues. Some of these products are utilised in value added products and the rest is treated as a by-product. Similarly, feather is a by-product in the poultry industry.

According to OECD agriculture statistics, in the year 2012, the world’s poultry production was 106 million tons (ready-to-cook). As feathers constitute a significant part of the total weight of a chicken, the amount of feather generated can be estimated at 15-20 million tons.

Co-products of food processing are inexpensive and affordable. If the suitable applications for the co-streams of the food industry are developed, it adds value to inexpensive materials with improved sustainability.

Through several projects, Norner are an active contributor to projects for utilising waste for value creation.

This is also in accordance with our updated strategy.

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SOILFILM A novel aproach to agricultural mulching with by-products of food industry

Norner goes green

New research on sustainable packaging

FuturePack

A Circular Economy Research Program

Siw Fredriksen

siw.fredriksen@norner.no

Circular economy is high on the agenda, but we need to further increase our efforts for development of new solutions.

Norwegian researchers will now take action when the research council granted 2,5 MEUR for a project green packaging for the future - Circular Economy in practice.

Norner Research AS will lead this large research project for development of new technologies for bioplastics and recycling of plastics packaging. The project is financed by the Norwegian Research Council (NRC) and 13 industrial project partners called “FuturePack”

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Plastics are important packaging materials where low weight/volume is combined with excellent protective properties for food in transport, retail and at consumers. Better protection prevents food wastage. But future

packaging must become even more sustainable through increasing share of biobased and recycled materials.

This will contribute to lower CO2 emissions, better resource utilisation and reduced littering. These topics are central to the FuturePack project.

Norner will cooperate with industry partners and other institutes. The participating institutes are Nofima, Paper and Fibre Research Institute (PFI), Østfoldforskning and NTNU IKP. The group of institutes together hold key competence in conversion of biomass to polymers, food packaging, food technology, polymer technology, recycling and plastics processing.

The Norwegian industrial partners are Bama, BEWI, Elopak, Grønt Punkt, Mills, Norgesgruppen, Nortura, Orkla, ROAF and Tine who represent various parts of the value chain of packaging, food production and recycling.

Additionally, we have an exciting international advisory board including Ineos, Unilever and EPRO. Green Dot Norway plc is responsible for financing the recovery and recycling of used packaging on behalf of the industrial sector. “We see a significant

need for increasing the development of new technology that can increase recycling of packaging, especially for that which today is difficult to recycle.

To achieve high goals, research is required, and we are proud that this project received grants from the research council.”, says Eirik Oland in Green Dot Norway plc.

“We have a strong strategic focus on sustainability and circular economy in the plastics value chain through projects in the field of recycling and biobased materials. By long term cooperation with our international clients we have also acquired significant competence in this field. However, more research and competence is needed to solve our global challenges and “FuturePack” is an important project to take new steps in the right direction.”, says Tine Rørvik, CEO of Norner.

“It has been inspiring and rewarding to work with the development of this project and all the positive response we have got from the industry shows that these partners puts sustainability very high on their agenda.”, says Dr. Siw Fredriksen, project manager and Senior Advisor in Green Technology at Norner.

11 The FuturePack project will develop a comprehensive knowledge platform for production of sustainable packaging materials from Norwegian biomass and polymer waste resources, in accordance with the principles of circular economy.

The plastics industry is today highly reliant on feedstock based on oil and gas. Focus on circular economy is a potential way to reduce the demands on finite raw materials and minimizing negative effects while still have possibility to increase prosperity.

This requires systemic and holistic approach. Firstly, an overarching vision is that plastics never becomes waste but re-enters the economy as valuable recycled materials or chemicals.

Secondly, a “green shift” to renewable feedstock will decouple plastic from fossil feedstock.

The major elements of the FuturePack project represent new knowledge and innovations for the partners and in the industry internationally The project will evaluate the fit of Norwegian biomass and plastics waste

resources for polymer production followed by developing a technology for cost-efficient conversion of biomass and plastics waste by pyrolysis into building blocks for polymers. The chemical composition after pyrolysis needs further purification before olefins will be used in polymerisation of bio based PE and/or PP. Another important aspect is the design and solutions for improved material recycling which is another important aspect of circular economy. The new technologies and value chains will be assessed by LCSA assessments.

As a global leader of industrial polymer R&D services, Norner operates an advanced technology centre for development and laboratory testing.

Norner R&D competences Developing new expertise in the whole packaging value chain in the use of recycled PE and PP for packaging.

Noner deliver customer advice, projects and support in fields of recycling and biobased materials.

Research on low weight/volume packaging and better food protection

and packaging material development using recycled PE and PP. Bench scale polymerisation and demonstration of production of biobased PE and PP. Norner contribution in FuturePack: • Project leader and R&D partner • Knowledge in bio-based raw materials (wood, algae) and plastic waste as source for ethylene and propylene production.

• Verify ethylene and propylene from biomass and plastic waste as drop-in monomers for PE and PP production in bench scale polymerisation • Packaging material development using recycled PE and PP • Design and develop new packaging fit for recycling in line with circular economy principles.

• Demonstrate packaging simplification through demonstrators and external collaboration.

• Test and characterise the packaging materials • Develop competence and strategies for increased recycled content in packaging.

• Communicate results in various fora.

FuturePack - technology for a circular economy Pyrolysis oil BTX Aromatic Ethylene & Propylene

Pyrolysis Agri/ Marine/ side streams Algae Wood Forrest

Biomass

Molecular recycling of non-recyclable pkg.

Biopolymer

Improve Plastic material recycling

Design & Recycling www.norner.no

Increasing Bioplastics Market Morten Augestad

morten.augestad@norner.no

Norner takes a role in our sustainable future by extending capability and competence in Biopolymers.

The initiative on PEF by Coca Cola,

Bio-degradable

Danone and others is an example

competitive and a good choice for

of this. Another example is the non-

niche areas where bio-degradability

competing

supports the application. One example

industries

cooperating

within biopolymer development such

polymers

are

may be mulch films.

as the cooperation between Heinz (with access to bio waste from its

Whether biodegradable polymers are

ketchup operation) and Ford vehicle

the solution to plastic littering is highly

group.

questioned, but both the efficiency of recycling systems, regional consumer

Biopolymers can be defined in several

Through several bench-mark studies,

habits and infrastructure for waste

ways and it is typical to categorise them

Norner has explored that Biopolymers

management influence this.

into biobased and/or biodegradable.

can offer a lot of potentially sustainable

Some materials can be produced

and also cost efficient products like:

continues

to

perform

Side- and waste-products from

application studies and the expertise

be bio-degradable like polylactic acid

the forestry industry can be a cost

build-up of biopolymers with the

(PLA). Others can be from bio-sourced

efficient raw material and give

purpose

raw materials like BioPE, but are

interesting properties. This can

development and implementation in

not biodegradable. Variations of the

benefit the paper industry and yield

e.g. the FMCG market. Bio-materials

two categories, including blends, are

sustainable polymers.

have been tested on our application

Wood Polymer Composites has

machinery such as blown film and

shown high growth rates both as

injection moulding following a thorough

The importance of bio-degradeble

a durable building material and

investigation and bench mark of article

materials grows and PLA as well as

as performing materials in the

properties disclosing both interesting

automotive industry.

and surprising features.

from bio-based raw materials and

common.

•

Norner

•

starch based plastics are important types of these. With the current high

•

BioPE.

Braskem

has

of

supporting

application

already

focus on circular economy it has been

launched sugar based PE with

Norner is also doing extensive research

a shift towards finding biosources for

success some years ago and Sabic

in another category of sustainable

making traditional plastics like PE, PP,

is

polymers based on CO2.

PA and PET. It is however a challenge

bio-oils. BioPE can be 100% from

that the technologies involved can be

renewable raw materials and can

We look forward to discuss biopolymers

costly.

in principle be used for all areas

with You !

on the market with PE from

where PE are used today.

More recent polymers from bio-sources

•

PHA is a “new” polymer produced

include PEF and PHA, and important

by living organisms. The polymer

technical progress has been made.

has very interesting properties for

Both PEF and PHA have interesting

advanced packaging and within the

properties for several applications and

health care sector.

it can be expected more news related

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to these in the years to come.

www.norner.no

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Focus on marine litter & Norner beach clean-up day Marine litter is a growing environmental challenge we face today. A high degree of this litter is plastics and because it floats, it moves across large distances.

It is a complex issue, which has a negative impact on our world’s oceans, seas and rivers, harming wildlife and fisheries in Norway and around the world.

Norner have unique experience and knowledge for analysing plastics in from sea or beaches weather it ispellets, beads, microplastics or larger items.

According to World Wildlife Found (WWF) and OSPAR 2009 about 6,4 million ton of litter ends up in the ocean each year globally of which 15% ends up on beaches, 15% floats into the ocean and 70% sink. This must be dealt with through litter collection and with initiatives by industry, NGO’s and citizens like “Zero landfill”, “Clean a beach” and various research to understand the problem.

Even if plastics is a material with superior performance at unbeaten light weight well suited for material recycling it is a serious problem if it comes into the oceans.

Marine Litter Study Our shared concern for marine littering has resulted in a Norwegian pilot project sponsored by the industry to explore and analyse samples.

This study will include plastic type and origin, content of chemicals as well as wittering behaviour and fragmentation into microplastics.

Some key findings are: • Majority of plastic products are foam (EPS and PUR) as well as packaging, parts and ropes of PE and PP. • Bromine flame retardants in foam samples.

• Fast wittering of PE films but much longer for e.g. PET bottles

Beach Clean-Up initiative We wanted to address this global challenge by acting local and started a tradition by taking part in the national “beach clean-up” initiative in Norway.

We chose the Rakkestad beach in our home municipality Bamble. 27 enthusiastic Norner experts, led by our CEO Tine Rørvik took part.

“It is great to combine something so useful and environmental friendly with some social get-together with nice colleagues. We challenge other plastics companies to also act local for the global littering problem.” Says Tine Rørvik, CEO of Norner AS What we in practice did was to: • Pick litter at the 200m beach • Sort the litter in relevant fractions, weigh and document • Report the findings to the Norwegian “Hold Norge Rent” We collected 45kg of litter, which included metal boxes and –scrap, glass bottles, rope and twines, moorings, various hard plastics (boxes, pipes, utensils and fragments), plastic bottles, plastic film, toys and clothes.

This May we will be back for another clean-up and we are looking very much forward to it! New report will follow.

Ole Jan Myhre

olejan.myhre@norner.no

Staying ahead of the healthcare requirements Elina Myhre

elina.myhre@norner.no

Norner has long experience in polymers used in healthcare packaging and medical devices.

The healthcare market has stringent requirements for product safety, quality and consistency. The authorities require extensive documentation regarding regulatory compliance for materials used in pharmaceutical applications.

Being an independent plastics institute Norner provides analytical services, technology developments and consultancy.

Based on our client needs our support can cover wide range of analytical and chemical testing and services.

Polymer long term stability studies.

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Polymer

additive

and

composition

analysis.

Investigation and detection of potential contaminants/foreign matters in products.

Quality control and product consistency of incoming polymer raw materials Analytical Services • Pharm.Eur 3.13, 3.1.4, 3.1.5 and 3.1.6 (Polyolefins. PE and PP) • USP 661 Physical and chemical tests; Containers-plastics • USP 671 Containers performance testing • ISO 10993 -13 Identification and quantification of degradation products from polymers • ISO 10993 -18 Chemical characterization of materials • Analysis of additives and monomers in packaging ( • EC) 1935/2004, (EU) 10/2011, REACH and FDA expertise

• • • • •

Overall migration testing according to EN 1186 Identification and quantification of possible SML components Notification services for US and EU food contact regulations Analysis of Bisphenol A, phthalates, heavy metals Analysis of volatile components

Norner = your technology partner for healthcare packaging and medical devices

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High purity is critical for food and pharma

- how do we manage?

It becomes increasingly important to understand the regulations and requirements for high purity of packaging for food and pharma.

The production of food contact materials and packaging are often complex, e.g. multilayer combinations of different materials with the use of adhesives and inks and can never be free of NIAS.

This is needed for making assessments, chemical analysis and to fulfil the required documentation to authorities.

We • • • • • • • • •

Human health and safety is a high focus area for global food producers and medical companies. Even the smallest concentrations of doubtful substances may be critical and new knowledge on health impact of chemicals are continuously developed.

Norner has leading expertise in plastics and packaging including additives, catalysts and monomers. Our expert group has broad knowledge in international regulations such as for food contact, medicals, toys, utensils, water pipes and REACH.

provide support and projects to customers like: Analysis of additives in plastics and packaging Migration testing and analysis NIAS screening and detailed assessments Long term stability studies Investigation of contaminants Raw material consistency Resin change procedures Advisory services in FCM, FDA, Reach Continuous monitoring of 500 plastic additives

Norner recently finalised a three-year research project, “Chemicals in Packaging” together with Norwegian food and packaging industries. We have analysed chemical composition and migration including NIAS in a wide range of plastics packaging. We found NIAS components in a high number of packaging products. In most cases, we could identify and categorise them as no-risk substances but some needed deeper investigations. It is challenging to analyse what types of NIAS that can be present with a 10ppb limit.

Non-intentionally added substances (NIAS) Food contact materials are regulated in EU No. 10/2011. This gives instructions to allowed monomers and additives. It also defines and put restrictions to NIAS. Any chemical which can be found after migration analysis in amounts larger than 10ppb shall be identified and accounted for. These NIAS components may be reaction intermediates formed during the production processes, decomposition products or reaction products of e.g. common additives.

Svein Jamtvedt

svein.jamtvedt@norner.no

3500

ppm of 2,4-DTBP

3000 2500 2000 1500 1000 500 0 A

B1 B2 C1 C2 D1 D2 E1 E2

F

G1 G2 H1 H2

I

J

K

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EXAMPLE We have investigated the quality of the conventional and fully food approved antioxidant AO168. We analysed the content of one of the most well known substances of NIAS, 2,4-DTBP in this additive from several suppliers as well as several samples from some.

The result is shown in the graph and illustrates that the purity of AO168 vary significantly depending on the supplier. This is one factor to take into consideration when selecting your supplier.

www.norner.no

Sibyl

TM

The packaging products database That makes plastics data accessible, functional and easy to use.

Ole Jan Myhre

olejan.myhre@norner.no

Sibyl is our easy to use, database created to give you a well of data that allows you to make real comparison of different grades of PE and PP for packaging applications.

The web based database is available and contain essential polymer data as well as a wide range of application related tests and properties. You can compare products and make your own graphic presentation. You can get access to this significant collection of data through a subscription or you can add your own materials through a test program with Norner.

KEY BENEFITS of SibylTM • Improve your products • Utilise your resources more efficiently • Better basis for decision making • Reduce your costs • Enable your innovations • Quality assurance and resin equivalency • Optimise processing If you want to test its functionality, please visit the demo at: www.sibyl.no and login with: user=demo and pw=norner

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GOOD GRAPHIC FUNCTIONALITY Sibyl contain advanced graphic functionality which facilitates your comparisons.

• Curve overlay for rheology, DSC and FTIR • X-Y plot, histograms and spider graphs of

technical data.

With just a few clicks you can generate your own graphic comparisons.

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Advanced packaging often requires polymer properties to be within specification. This specification is dependent of packaging format. For thin wall packaging dimensions, stacking strength and strength (impact) can be key to the success of the packaging. For blown film process stability, seal properties and mechanical properties can be the key to success. To meet your targets several questions will need answers and Sibyl gives you valuable data comparisons.

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Flexural Modulus, 23°C [MPa]

With a subscription, you can be sure all your development and marketing staff gets easy access to the database and can start to look up product properties and compare immediately.

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Packaging Development A fragmented task If you are a packaging producer or a brand-owner using packaging, there are numbers of challenges every day.

Early phase project involvement of a competence partner more interested in the technicalities involved than design and print can give large improvements in cost and time-to-market. Se separate story in this magazine.

Light weighing, biopolymers, shelf life optimization, output in packaging production or filling line, liability like migration, organoleptic, cost saving, sealing/welding and many more...

Processing Problems Production of packaging and the use at the filling line is both areas that drive a lot of cost for a new packaging.

Dimensional tolerances, sealing, processing-speed are all determined by good use of advanced machinery.

In our laboratories, we do many tests where fast and precise up-front trials and tests simplify and speed up packaging development and launch projects.

We can name so many. Often cross functional competence is needed to move forward.

Figure: In addition to cost, design and size the fundamentals of packaging need to be taken care of.

Pages can be written about this subject but we like to highlight some experiences we have done; Design Failures Packaging consist of endless of designs and often last minute changes will have a huge impact of cost.

Unfortunately, we see repeatedly how small changes gives delays and problems for the packaging project launch.

Package Material Quality It is surprising how simplified materials often are treated as an important parameter for good packaging performance. If the material is selected to be e.g.polypropylene (PP) and the liability is under full control the material discussions are often done. But PP has hundreds of different resins and dozens can be used for the same application. However, change of resin may change dimensions, reduce

Product • Raw material • Process • Hygiene

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Packaging Golden Triangle Packaging and filling line • Barrier • Processability • Sealing properties

Distribution • Time • Temperature • Light

Morten Augestad

morten.augestad@norner.no

mechanical properties of give different sealing characteristics. In multilayer structures for barrier and sealing the picture get even more complex. The systems for “taking control of the material” is proven to be a route for trouble-free operation.

We can support your projects and products with: • Analysis of additives in plastics and packaging • Migration testing and analysis • NIAS screening and detailed assessments • Long term stability studies • Investigation of contaminants • Raw material consistency • Resin change procedures

Polypropylene (PP) are both homopolymers, randoms and impact copolymers and are added a variety of performance supporting additives.

The molecular (Catalyst, Comonomer, Molocular Weigth) and supporting additive characteristics are different in resins used for the same application and may change processing and packaging properties.

Similarly there are several types of other materials like PE, PET an PA too.

Polyethylene (PE) can be pruduced with several different reactor configurations, catalysts and comonomers. The result is a wide range of resin grades and performances.

www.norner.no

Microscopy Labs

A root cause, inspection, troubleshooting and development tool Torkel Bach

torkel.bach@norner.no

Microscopy enables detailed investigations of failures microstructures, particles and more making it is a powerful tool for understanding materials.

Norner has the competence, equipment and resources required to investigate product and material failures, document the reasons for it and provide conclusive reports with suggested solutions.

The production and use of products in our society involve a broad range of requirements. Unfortunately, products or components do break, disintegrate or fail from time to time. Product and material failure represents huge costs in repair, replacement, down time and involvement by personnel.

Our specialised microscopy lab provides failure analysis to a wide range of industries ranging from polymers, packaging, plastic processing, offshore and automotive. We have a dedicated team with long experience in the field of microscopy and analytical techniques. This secures that we can provide appropriate conclusions from our analysis. Surgical precision is required for sample preparation and a functional understanding of the product is necessary for the evaluations. We also carry out similar investigations to document the quality of products.

We strive to achieve a close cooperation with our customers in order to facilitate a good flow of information. Any information regarding the product, its production and use is vital for the investigations and conclusions we provide. In this way we have a high focus on meeting our customer needs.

Our microscopy team of experts deliver conclusive reports where the documentation through high quality

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Determination of failure in coextruded blow moulded bottle Problem: Failures in bottom weld Solution/cause: Sharp notch inside and delamination/void at the barrier layer. Need adjustment of mould and conditions

pictures have priority combined with other analytical information.

Our team is experienced in analysis of multilayer films and laminates including polymer recipe identification.

We have the insight to make microscopy investigation provide documentation of the following materials and products • Metals and inorganic materials.

• Catalysts, polymer powders, morphology and homogeneity.

• Plastics parts and packaging • Injection, blow and rotational moulding, extruded pipe, cable insulation, films, laminates, compounds and alloys.

Failure categories in Plastics • Mechanical strain and pressure burst • Stress introduced by processing or mould/product design • Chemical stress cracking • Inclusions, inhomogeneity, gels and contaminations,

Determination of multilayer flexible packaging.

Problem: Performance inconsistency challenges Solution: Recipe variations in the inner PP cast film

www.norner.no

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Extrusion blow moulding of PET PET is a packaging material with strong growth in packaging due to its good properties for bottles, film and thermoformed trays/cups.

PET is also well proven as an easy to recycle material.

PET bottles are commonly produced with the two step ISBM process where prefroms are injection moulded that are reheated and stretch blow moulded. The blow moulding is often made by the producer of beverage or any other liquid content. The ISBM process lack the ability to form handles on the product and some PET resin producers have been developing new PET resins for the extrusion blow moulding process – well known for HDPE bottles.

New Material Development This challenge is being addressed by polymer producers and a few years ago Invista introduced their Polyclear® EBM PET 5505 which is designed with higher intrinsic viscosity and melt strength for use in EBM operations and thereby is suited for containers requiring a handle. Products can be recycled in the standard PET stream.

More recently Indorama has introduced an improved copolyester resin named PET 5507 which also is approved Elina Myhre

elina.myhre@norner.no

+47 3557 8059

Norner have competence in PET polymer analysis, performance and equivalency testing and our labs offer testing according to international standards for PET. Other key services are failure analysis, food contact assessments and analysis as well as pharmacopeia testing procedures.

for PET recycling by the Association of Plastic Recyclers.

Eastman has also introduced copolyester with the trade name Aspira.

Extrusion Blow Moulding We wanted to find out how PET 5505 could be processed and carried out extensive testing. Our trials included some adaptions of our EBM line to be able to process PET. The blow moulding machine is a Fischer W. Müller BFB 1-6 EBM line with a 24D grooved feed screw designed for PE and PP extrusion.

Successful Extrusion Our trials were challenging but successful. We produced good quality bottles and experienced some key factors that needed machiniery modifications to succeed, listed below.

Main challenges during the trials vs. PE/PP: • Drying of PET to achieve <50ppm H2O • Extruder feed zone must be heated • Sensitive to adjustments of die gap and profile • High extrusion temperature up to 285-295°C • Parison cutting system must be modified • High polished mould for transparency and gloss.

Return address: Norner AS, Asdalstrand 291, NO-3962 Stathelle, Norway

Non nucleated PP

Talcum nucleated PP

At the back Thermoplastic materials have either a semi-crystalline or amorphous solid state structure. The crystallinity of PP can be significantly changed by the addition of nucleators.

Na-Benzoat nucleated PP

Beta-nucleated PP

DMDBS Nucleated PP

Norner have long experience in R&D, recipe development and characterisation pf PP nucleation which is used to modify the solidification, stiffness and/or optical performance of polypropylene (PP).

The effect of various nucleators can be assessed by optical microscopy under polarised light as demonstrated with the images.

Chemical derivatives of benzoic acid like sodium benzoate and minerals as talc is effective nucleating agents. These additives offer decreased cycle times, increased output and profits. Some organic molecules also act as nucleators but will additionally give improved clarity of the material. These, so called clarifiers, are often chemical derivatives of dibenzylidene sorbitol (e.g. DMDBS).

PP Nucleation gives several benefits: Improved physical performance and stiffness Faster crystallisation gives higher production rates High clarity and aesthetical performance Better productivity, price and profit

Did you miss earlier editions?

You can access these earlier editions of Norner News through the following QR code or at http://issuu.com/norner

NORNERNEWS Norner AS Asdalstrand 291 NO-3962 Stathelle Norway

Tel: Fax: Web: Mail:

Photo by Tom Riis, Torkel Bach, Istockphoto and Norner

+47 35578000 +47 35578124 www.norner.no post@norner.no