INNOVATIONS INDUSTRY ADVANCES WITH RADLAUNCH WINNERS
PepsiCo Explores Electron Beam Curing for Flexible Packaging By Liz Stevens, contributing writer, UV+EB Technology
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adTech International North America celebrated the 2020 Emerging Technology Award winners at the RadTech 2020 Conference, March 8-11, in Orlando, Florida. RadTech’s Emerging Technology Committee selects award winners among end users of the technology, based on new, promising and/or novel use of ultraviolet and/or electron beam curing. RadTech has recognized applications ranging from 3D printing/additive manufacturing to floor coatings to novel electronics to unique uses for automotive and aerospace.
PepsiCo was one of the 2020 Emerging Technology Award winners. The company, which markets food and beverages in 200 countries and territories, is working to develop advanced materials and processes for packaged foods. PepsiCo is exploring electron beam curing as a fast, clean and energy-efficient way to process inks, coatings and adhesives in flexible packaging operations. To learn about PepsiCo’s use of electron beam (EB) curing, we spoke with Todd Fayne, principal engineer and associate director, Global Snacks R&D at PepsiCo. A University of Rhode Island graduate with a BS in Chemical Engineering, Fayne is co-chair of the new Sustainability Committee at RadTech. At PepsiCo, Fayne is exploring using EB overprint varnish and inks in surface print applications for flexible food packaging. With brands such as Lay’s, Ruffles, Cheetos, Tostitos, Fritos and Sun Chips under the PepsiCo umbrella, flexible packaging is a major component in the company’s food production operations. In describing why the company is investigating the use of EB curing for packaging, Fayne said that two factors make EB the top choice: food safety and package durability. For food safety – Fayne’s No. 1 requirement in choosing a curing method – Fayne explained why he favors EB over UV curing. 10 | UV+EB Technology • Quarter 3, 2020
“Under perfect conditions,” said Fayne, “UV technology can produce safe packaging for direct food; however, using an electron to initiate cross-linking is more consistent and easier to control.” And, since EB, a higher energy process than UV, does not need the photoinitiator that UV requires, its use eliminates the potential for the photoinitiator to migrate into food. Additionally, with EB curing, said Fayne, “there also are much higher levels of cross-linking that ensure lower migration of acrylate monomers. These higher levels provide an extra safety factor for direct-food applications.” EB also delivers a durable and scratch-resistant surface, yielding packaging that can hold up throughout production and distribution. “When compared to water-based and even two-part PU systems,” said Fayne, “EB outperforms. Not all applications require EB performance, but many applications that are converting from reverse-print to surface-print have machinery and distribution systems that are very rough on the packaging materials.” To PepsiCo, it is very important that the company’s product packaging can go through the production process without a scratch and reach the store shelf looking just as attractive as it does when it is first taken off press. In addition to food safety and product appeal, Fayne considers EB superior to other curing options because its process controls are more easily managed, thus ensuring a consistent cure over the equipment’s lifespan of thousands of hours. The EB equipment in use at PepsiCo is programmed to deliver a specific dose, to not fall below a certain threshold. The machinery also automatically adjusts its power to compensate for speed changes on the press. If the machine senses a problem with the vacuum level, the oxygen concentration or the quality of the EB filament, the press can be set either to signal an alarm and flag any uvebtechnology.com + radtech.org