Extrusion Coating, Lamination. and Coextrusion. The complete process manual. B.H. Gregory. P las tics NFORMATION^
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1 Extrusion Coating, Lamination and Coextrusion The complete process manual B.H. Gregory First edition 2012 P las tics NFORMATION^ A division of Applied Market Information Ltd. AMI House, Stokes Croft, Bristol BS1 3QP, United Kingdom
2 Contents Introduction 1 Chapter 1 The extrusion coating process Chill roll cooling section Chill roll surfaces Pressure roll Web tension control Winders and splicing Stretching flows and neck-in Draw resonance 31 Chapter 2 Extrusion coated products Paper/aluminium/polyethylene structures Triplex coating lines for aseptic packaging Photographic paper coating Laminates for toothpaste tubes Barrier coatings and laminations Extrusion coating PP on aluminium foil 42 Chapter 3 Extruder and screw design Basic extruder functions Origins of extruder output pulsations Optimizing screw design Barrier screws Sizing extruders Polyester (PET) extrusion Ethylene-vinyl alcohol extrusion 68 Chapter 4 Die design Automatic dies Flat die computer simulations Design modification oft slot die T slot die and other polymers 82 Hi
3 Extrusion Coating, Lamination and Coextrusion: The complete process manual 4.5 Coat hanger die Comparative die performance 88 Chapter 5 Adhesion in extrusion coating Effect of polyethylene additives on adhesion Chill roll cooling and coating weight Effect of melt temperature on adhesion Time in air gap Temperature drop in the air gap Elongational stress and melt relaxation Screw speed and residence time 108 Chapter 6 Adhesion promotion methods Corona treatment High density atmospheric plasma Ozone treatment Flame treatment Chemical priming Aqueous primers Solvent based primers 128 Chapter 7 The adhesive lamination process Adhesives Solvent-free adhesives Product resistance The anti-sealing effect in laminates 143 Chapter 8 Polyethylene lamination films Tubular film production Corona treatment of lamination film Heat seal behaviour Hot tack Additive migration to surfaces Surface contamination Peelable seal film and coatings Scalping 168 iv
4 Contents Chapter 9 Coextrusion processes Flat die coextrusion options Typical coextrusion problems Layer rearrangement Coextrusion profiling Interfacial instabilities Computer simulations Some methods to minimize interfacial shear stress Flow dividers Heat transfer inside a coextrusion die Coextrusion with dual manifold dies Coextrusion coating with ethylene copolymers Some coextruded structures Tubular film coextrusion 199 Chapter 10 Coextrusion tie-resins 203 Chapter 11 Substrates and films Adhesion of cellulose/paper materials to PE Paper and paperboard Aluminium foil Flexible packaging films Regenerated cellulose film (RCF) Oriented polypropylene film (BOPP) Oriented polyester film (OPET) Polyamide film (nylon) HDPE coextrusions Metallized films Oxide (ceramic) coated films 224 Chapter 12 Multilayered film applications Calculating film stiffness Form, fill and seal packaging (FFS) Aseptic packaging Bag-in-box (BIB) laminates 237 v
5 Extrusion Coating, Lamination and Coextrusion: The complete process manual 12.5 Dry food (cereal) packaging Snack foods Films for coffee packaging Frozen food films (retail) Liquid pouches Modified atmosphere packaging (MAP) 249 Chapter 13 Polyethylene materials and processes Low density polyethylene High pressure ethylene copolymers Ethylene-vinyl acetate copolymer (EVA) Ethylene-alkyl ester copolymers (EAE) Ethylene-acid copolymers Ionomers Linear low density polyethylene (LLDPE) Melt viscosity of LD/LLDPE High density polyethylene (HDPE) Polyolefin blends for extrusion coating Metallocene-catalyzed PE 286 Chapter 14 Barrier and other polymers Ethylene-vinyl alcohol polymers (EVOH) Polypropylene in extrusion coating Polyester (PET) 299 Recommended further reading 302 Index 304 VI
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