Complex films simplify flexible packaging choices: recent innovations in films boost the material's performance and open up new applications in the food and medical markets

Food & Drug Packaging, April, 2004 by William Makely

The Flexible Packaging Association received a record number of entrees for its 2004 Achievement Awards competition. No wonder! Innovative materials and applications are growing exponentially.

For more information

The following companies helped with the research of this article:

Carex Inc., a subsidiary of Mitsubishi Pharma Corp. 908-607-1950 (in U.S.) or 81-6-6935-9255 (in Japan); www.carex.co.jp/e/

Curwood Inc.

920-303-7330; www.curwood.com

Davis-Standard Corp.

860-599-6234; www.davis-standard.com

Kline & Co.

973-435-6262; www.klinegroup.com

Metabolix Inc.

617-492-0505; www.metabolix.com

Pechiney Plastic Packaging Inc. (Alcan)

773-399-3696; www.pechneyplasticpackaging.com

Rollprint Packaging Products Inc.

630-628-1700; www.rollprint.com

William Makely is a Chicago-based freelance writer who specializes in packaging topics.

Nanocomposites: A small idea that's growing

The principle at work in nanocomposite films is this: Tiny particles of a bentonite clay additive distribute themselves in layers within a film, creating a maze through which gas has to find its way to permeate the film. This creates an effective gas barrier that significantly slows the rate at which the gas reaches the product.

An experiment at Clemson University demonstrated that nylon film containing 1% of clay additives by weight reduced the oxygen transfer rate (OTR) by about 30%. This effectiveness lets filmmakers replace the current barrier favorite, ethylene vinyl alcohol (EVOH), with nylon containing nanocomposites--material with a higher melting point and a natural adhesion.

No special processing equipment is required. In production, nylon 6 with nanocomposites processes on equipment designed for neat nylon 6, and the same holds true for the polyolefins.

So far, the process of making a nanocomposite plastic is costly relative to other resins. But cost is always a function of scale: As production volumes increase, higher productivity will make it more cost-effective.

Watch for nanocomposite-enhanced films to take off. Soon.