Heat seal lacquers how to meet todays and tomorrows demands of the market
European Coatings Conference Packaging Coatings
Ralf Dickmann, 12./13.10.2010
Overview
1. Definition and basics
2. Applications
3. Example Paper/mPET
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
What is a heat seal lacquer
Heat seal:
Two substrates are linked, tied, combined by the mean
of heat and at least some pressure. One or both
substrates have a heat sealable layer (or are heat
sealable by themselves), which is activated by heat.
Other methods to combine substrates:
Cold seal / pressure sensitive tape: no heat is necessary,
mainly pressure
Adhesive lamination: both substrates are combined in-line
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
What is a heat seal lacquer
Heat seal lacquer:
The heat sealable layer is produced by lacquering, the
liquid, diluted phase is transformed to a dry coating by
evaporating the solvents
Other methods to produce heat sealable layer:
Coextrusion of a special heat sealable layer during film
processing
Hot melt / extrusion coating: heat sealable layer is put on by
heating up and subsequent coating on the substrate
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
What is a heat seal lacquer
Liquid coating, which is dried to become tack- and
block- free, solidified, rewound and used later.
Heat activated to become soft and tacky.
Pressed to second substrate to make bond.
Cooled to room temperature to form bond between
layers of substrates.
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Typical heat seal process
Pressure / Heat
Heat seal coating
Lid
Heat seal coating
has to adhere to
lid- substrate
During seal
process the heat
seal coating (in
melted state) has
to give a tie / link
with the cup
Cup
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Adhesion / Cohesion
In order to give the expected performance, the
heat seal lacquer has to adhere to both
substrates and needs cohesive strength:
Adhesion
Cohesion
Adhesion
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Criteria for Heat Seal Lacquers / areas of
development
Drying conditions,
what solvents may
be used
Sealability at
what conditions,
Seal strength
Opening
behaviour
(destructive or
peel)
seal partner
Some
Criteria
hot tack
What type of
filling goods
(product
resistance)
blocking
resistance
optical
appearance
(of lacquer
and seal)
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Criteria for Heat Seal Lacquers / areas of
development Example
Dairy packing should open
smoothly, but still remain
integer during transport!
Lid should not tear, there
should be no rupture
Opening
behaviour
(destructive or
peel)
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Seal Partners
PVC:
PS:
PP:
PE:
A-PET:
Polyvinyl chloride
Polystyrene
Polypropylene
Polyethylene
Amorphous Polyethylene
terephthalate
Typical uses:
PS and PP (softer than PS) and PE in combination with
cardboard for diary packaging;
PVC for pharmaceutical blister;
A-PET for diary packaging (transparent, barrier properties)
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Basics of heat seal lacquer formulations
(non- coloured)
Solvents:
Low boiling: for example: ethyl acetate
Medium boiling: for example: butyl acetate
High boiling: for example: aromatic solvents
Resins:
Thermoplastic resins to give sealability (see next slide)
Resins to give adhesion to substrate
Other resins for special performance
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Basics of heat seal lacquer formulations
Thermoplastic resins to give sealability
Vinylic (PVC and PVDC based)
Acrylate and styrene acrylate based
Acrylate / Polyolefin
Styrene (copolymer) based
Polyester based
PP- Dispersion
EVA/EAA/EMAA
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Basics of heat seal lacquer formulations
Additives:
Waxes / Slip agents (for slip properties, release, antiblock,
seal performance): Polyethylene wax, Carnauba wax, PTFE,
Fatty acid ester
Inorganic pigments / filler (for antiblock, for haptic/optical
properties, for seal performance, for viscosity control): Silica,
talc
Antioxidants / UV- stabilizer / optical brighteners
Antifoam (in water based products)
Adhesion promoter: Epoxy resins for Aluminium substrates
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Basics of heat seal lacquer formulations
Appearance / Stirring:
Typically no stable solution
Heat seal lacquers have to be
stirred well before application
Heat seal lacquer with filler
before (left) and after stirring (right)
Segregation / dephasing
of a heat seal lacquer
without filler
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
New developments:
Market pull / Technology push
Market pull:
New requirements for existing packages (for
example new food law regulations)
New packages
Technology push:
New products based on existing technologies /
formulations
New technologies
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Some Applications
Blister Foils for Pharmaceutical Products
Lids for sterilizable Containers
Composite Cans
Lids for Food packages (especially dairy)
* for Aluminium Foils
* for PET- Films and Paper/PET
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Blister Foils for Pharmaceutical Products
Heat seal coating based
on PVC or PVC/Acrylate (sealable to PVC
or PVDC- Blister)
Universal Heat seal coating (sealable to
PP-Blister)
Aluminium foil with
heat seal coating
Blister
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Lids for sterilizable Containers
Heat seal coating on epoxy
resin basis sealable to PP
Heat seal coating PVC-based
Lid: Aluminium foil with heat
seal coating
Tray: Alu-PP laminate
(deep drawn)
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Composite Cans
Paper- / Composite Cans
Internal Protective- / Heat
seal coatings PVC and
Polyester based
Paper / Aluminium foil laminate
with heat seal coating
In this case folded, sealed lacquer
to lacquer
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Lids for Food packages
Heat seal coating based
on PVC or PVC/Acrylate,
sealable to PVC / PS / APET
Universal Heat seal coating
sealable to APET / PP / PVC / PS
Heat seal coating based
on polyester, sealable to APET /
PVC, or itself
Aluminium foil with
heat seal coating
PP Cup
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
10
Lids for Food packages
Heat seal coating on PET (1- or 2- layer),
sealable to APET, PS, PP or Aluminium
Heat seal coating for salad packaging
White PET film with
heat seal coating
PP tray
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Lids for Food packages
Heat seal coating for Chocolate Cream,
chocolates packaging
Printed mPET film
with heat seal
coating
APET tray
Printed PET film with
heat seal coating
APET tray
Heat seal coating
applied on entire
surface or in
pattern
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
11
Paper/PET- Lid material for PS- Cups
Lid material paper/Polyester
or paper/metallised PET as
replacement for aluminium
lids.
Printed Paper / mPET
with Heat seal coating
PS Cup
Delaminated: Printed Paper
and mPET with Heat seal
coating
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Example Paper/mPET
Classification:
2- layer (Primer and Heat seal coating) or
1- layer
Low / medium / high seal
PVC (chlorine) containing or free
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
12
2- layer- system
Classic Construction:
Overprint varnish
Printing ink
Primer
Paper
Adhesive
Metallised
Polyester
Primer
Heat seal coating
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
1- layer- system
Heat seal without Primer = 1 layer
Adhesion on non-treated PET- side of the
Paper/mPET- laminate, seals to PS Cups
Overprint varnish
Printing ink
Primer
Paper
Adhesive
Metallised
Polyester
Primer
Heat seal coating
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
13
Some details
In a typical Paper/mPET single layer heat seal lacquer
minimum two main components are included:
One component to give anchorage to the PET surface,
typically also a polyester resin. (NC or PVC resin for
example do not adhere.)
Second component which seals to PS (typically a resin
based on acrylate and/or styrene copolymer).
Heat seal coating has to
adhere to PET
Heat seal coating
has to seal to PS
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Paper/PET- Lid material for PS- Cups
2- layer
1- layer
PVC free
PVC containing
Low seal
Low seal
Medium seal
Medium seal
High seal
High seal
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
14
Quality characteristics
Seal strength
Hot tack (seal strength immediately after sealing, in warm
condition)
Compliance with health standards
Machinability
Coating weight
Price per kg and most important - price per m coated area
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Some laboratory tests
Cup sealing and evaluation of the
seal performance:
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
15
Some laboratory tests
Control of seal strength including hot-tack
measurement device:
PET with Heat seal
coating
PS Stripe
Force/distance
diagram
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
Closing remarks
- Every day objects
- There is a lot of knowledge behind it
- Ongoing changes
- New developments by market pull and
technology push
2010
Ralf Dickmann
ACTEGA Rhenania GmbH
16
Thank you for
your attention.
17
