1. ROLE OF EVOH IN BARRIER
FLEXIBLE PACKAGING
WORLD PACKAGING CONGRESS
09-10 OCTOBER 2015 ,MUMBAI ,INDIA

2. CONTENTS
• BRIEF INTRODUCTION OF KURARAY
• INTRODUCTION OF GAS BARRIER RESIN
EVOH
• EVOH PROCESSING TECHNIQUES
• CONVENTIONAL EVOH APPLICATIONS –
GLASS /METAL / AL FOIL REPLACEMENT
• EMERGING EVOH APPLICATIONS

3. Who is Kuraray?
The world’s largest producer of Vinyl Acetate Monomer derivatives
Kuraray Co. Ltd., founded 1926 in Kurashiki, Japan
World’s largest producer of PVOH (POVAL™) and EVOH (EVAL™)
as well as many other specialty polymers, fibres and films
Leader in gas barrier technology and development
Head office in Tokyo, Japan. Global sites: 43 sites in 17 countries

4. Pasadena, Texas
Antwerp, Belgium
Okayama
Tokyo
24,000T
10,000T
▲ ▲
Regional sales office Production site ▲R&D center
Shanghai
Production capacity of EVOH EVALTM
Singapore
Bangkok
Total Global Capacity = 81,000T
47,000T Deli

5. Higher density
Higher melt point
Higher gas barrier
WHAT IS EVOH
24
27
32
35
38
44
48
a semi-crystalline
thermoplastic
and a random copolymer of
Ethylene and
Vinyl ALcohol
(CH2-CH2)m (CH2-CH)n
OH
More flexible
More orientable
Easier to process
© Applied Market Information Ltd., 2015 – Licensed for the exclusive use of SACHIN GANGAL downloaded on 01/10/2015 at 16:02:41.
Must
not be reproduced, forwarded or distributed wit ho u t p e rm is s io n. T hi s d o c um en t is di g i tal ly
Ethylenemol%
Polyolefin
Tie
EVAL™
Tie
Polyolefin

6. EVOH PHYSICAL PROPERTIES
O2 permeability
cc.20µm/m2.day.at
m
0.1
0.2
0.4
0.5
0.6
1.5
3.2
Mol%
et.
24
27
32
35
38
44
48
g/cc Tm ºC
195
191
183
177
172
165
160
1.22
1.20
1.19
1.18
1.17
1.14
1.12
mol%
ethylene
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7. OXYGEN PERMEABILITY OF POLYMERS
@ 20°C, 65%RH
High
Barrier
Medium
barrier
Low
barrier
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Material cm3.20 μm/m2.day.atm
32 mol% Et. EVOH 0.4
38 mol% Et. EVOH 0.7
PVdC (Polyvinylidine chloride) 2.6
Polyamide (Nylon) 38
PET (Polyester) 54
HDPE (High Density Polyethylene) 2300
PP (Polypropylene) 3000
PC (Polycarbonate) 5000
PS (Polystyrene) 8000
LDPE (Low density Polyethylene) 10000
EVA (Ethylene Vinyl Acetate) 18000

8. Oil - Fats resistance
Oxygen Barrier
Flavour Barrier
Processability
Recycling
Chemical Resistance
Transparency
Antistatic properties
Printable
Odour Barrier
Ageing resistance
EVOH PROPERTIES
Flex-crack Resistance

9. LDPE
Monolayer
EVOH
multilayer
Structure
(µm)
LDPE
100
LDPE/ tie/ EVOH/ tie /LDPE
42.5/ 5 / 5 / 5 / 42.5
OTR
(cc/m2,day,atm)
1650 1.6
EVOH PROVIDES EXCELLENT OXYGEN
BARRIER
Condition: 20C-65%RH(out)/65%RH(in)

10. Monolayer
Polyethylene
CONCEPT OF GAS BARRIER
PACKAGING – MONOLAYER PE BASED
Atmosphere
Content (Food)
Oxygen
Flavor
Aromatics
(1) Loss of flavor/Aromas (2) Oxidation of content
Moisture

11. Atmosphere
Content (Food)
EVOH
Adhesive (Tie)
Inner Layer PE
Outer Layer PE Oxygen
Flavor
Aromatics
Adhesive (Tie)
CONCEPT OF GAS BARRIER PACKAGING –
MULTILAYER EVOH BASED
Moisture
EVOH CONTRIBUTES TO EXTEND SHELF LIFE AND
MAINTAIN EXCELLENT FOOD QUALITY !

12. Blown film
Cast film
Sheet & Thermoforming
Coex Tube / Pipe
Co-extrusion process applicable for EVOH
EVOH PROCESSING ON CONVENTIONAL EXTRUDER IS POSSIBLE

13. Screw type ： FULL FLIGHT
L/D ： 24- 26 ( DEPENDING UPON THE GRADE )
NYLON / SCREW WITH MIXING HEAD GENERALLY
NOT RECOMMENDED
120～150°
TYPICAL EXTRUDER FOR EVOH PROCESSING
L/D Feed Compression Metering
28 8D 10D 10D
26 8D 9D 9D
24 8D 8D 8D

14. TYPICAL TEMPERATURE PROFILE FOR EVOH
J171

15. GENERAL PROPERTIES OF EVOH
 EVOH IS EASILY PROCESSED ON CONVENTIONAL
EXTRUDERS
 BUT EVOH IS LESS THERMALLY STABLE THAN
POLYOLEFINS
 EVOH DOES NOT HAVE COMPATIBILITY WITH
POLYOLEFINS HENCE NEED FOR TIE RESINS
 HYGROSCOPIC IN NATURE
 STRONG REACTIVITY WITH PA HENCE CAREFUL HANDLING
REQUIRED WHEN PROCESSING PA/EVOH BASED
STRUCTURE

16. EVOH FOR VARIOUS APPLICATIONS

17. Lid for barrier cup & tray
EVOH FOR FLEXIBLE APPLICATIONS
Ham & sausage Bag In Box
UHT-milk
Meat (MAP)

18. EVOH TRENDS IN WORLD
REPLACEMENT OF TRADITIONAL PACKAGING
PACKAGING REASON FOR REPLACEMENT
GLASS LIGHT WEIGHT , EASY TO
HANDLE
CAN TRANSPARENT , DESIGN
FLEXIBILITY
AL FOIL METAL DETECTABLE , FLEX
CRACK
PVdC ENVIROMENTAL FRIENDLY

19. GROWING NEED FOR BARRIER PACKAGING
USING EVOH
• IMPROVEMENT IN LIVING STANDARDS OF CONSUMER
•GROWTH OF CONVENIENCE STORES / MEGAMARKETS
•PUSH FOR HIGHER BARRIER PACKAGING
•FOOD FACTORY EXPORT TO DEVELOPED WORLD
•LOCAL PUSH TO REPLACE IMPORTED BARRIER
PACKAGING FOR THE EXPORTED FOOD

20. NEW STYLE OF PACKAGING USING EVOH
• UHT MILK IN FLEXIBLE POUCH
•FLEXIBLE POUCH FOR SAUCES
•BAG IN BOX ( BIB)
•LAMINATED OR COEXTRUDED TUBES
•METALIZED EVOH BARRIER FOR SNACK FOOD
•AGRICULTURAL FILMS
•EVOH FOR FOOD SAFETY

21. BENEFITS OF UHT POUCH WITH EVOH
6 grams IS THE WEIGHT OF A 1 LITER
POUCH USING EVOH BARRIER
LESS PRODUCT WASTE AS DESIGN
FLEXIBILITY POSSIBILE WITH EVOH
BASED MULTILAYER POUCH
BARRIER POUCH IS ALL PLASTIC BASED
HENCE TOTALLY RECYCLABLE
NO NEED FOR COLD CHAIN TO
MAINTAIN 100 % STERILITY IN THE
PRODUCT

22. BENEFITS OF UHT POUCH WITH EVOH
A FEW MICRONS OF EVOH ARE
SUFFICIENT TO PROVIDE THE DESIRED
AND FUNCTIONAL BARRIER OF UHT
MILK POUCH
SPOILAGE OF THE PRODUCT IS AVOIDED
AND ALSO PROTECTION TO VALUABLE
VITAMIN CONTENT
EVOH ACTS AS FLAVOUR BARRIER AS
WELLAS WELLAS KEEPING THE
OUTSIDE ODOUR AWAY
BESIDES MILK OTHER PRODUCTS
PACKED ARE FLAVOURED MILK , LASSI ,
YOGHURT AND FRUIT JUICES

23. EVOH UHT POUCH VERSUS AL FOIL /PAPER CARTON

24. EVOH UHT POUCH VERSUS AL FOIL /PAPER CARTON

25. Outside
Inside
Outside
Inside
PE + Slip agent
PE + White Masterbatch
LLDPE tie
EVAL™ H171B
LLDPE tie
LLDPE tie + Black Masterbatch
LLDPE + mLLDPE
PE + White Masterbatch + Slip agent
LLDPE tie
EVAL™ H171B
LLDPE tie + Black Masterbatch
LLDPE + mLLDPE
TYPICAL EVAL BARRIER POUCH BASED
ON 5 AND 7 LAYER STRUCTURE

26. UHT milk pouch in oversea
India / Sri Lanka/Indonesia
India
Sri Lanka
Indonesia

27. UHT milk pouch in oversea
Latin America

28. METAL CAN REPLACEMENT
 Lighter weight (reduce energy during transportation)
 Transparent
 Metal detector available
 Convenient (Easy/safe to open)
EVOH POUCHES FOR SAUCES PACKAGING

29. Storage condition: 40degC
Benefit of EVOH - Ketchup/sauces -
 Lower weight than tin can and glass
 Convenience (easy open)
 Safety (transparency, metal detectable)
 Less preservative due to high O2 barrier
 Better brand image
PP/EVOH/PP

30. EVOH FOR BIB APPLICATIONS
Carbon dioxide emission per 100 gallons wine
 Reduced ecological footprint: boxed wines contribute fewer
carbon emissions to the atmosphere than traditional glass
bottles during making and shipping process.
Glass
BIB
PE/tie/EVOH/tie/PE

31. EVOH FOR LAMINATED TUBES
Aluminum foil Plastic with EVOH

32. Prevent oxydation of valuable ingredients
Excellent aroma barrier
Excellent oil and grease barrier
Longer formula preservation
Laminate tube (toothpaste, cosmetic)
Typical structure, manufacturing method
(1) Co-extrusion, PE/tie/EVOH/tie/PE 5-layer
(2) Blown film and lamination
PE film/ PE/tie/EVOH/tie/PE (co-ex blown) / PE film
(3) Extrusion coating
PE film/LD/ tie/EVOH/tie (Co-ex coating) / PE film
EVOH FOR LAMINATED OR COEXTRUDED TUBE
Co-extrusion
Film lamination

33. METALIZED EVOH BARRIER FOR SNACK FOOD PACKAGING
Lamination
Current structure Proposed structure
Film (micron) OTR*1 WVTR*2
PET (12) 85 55
VM-PET (12) 0.5-1.0 0.5-1.0
BOPP (18) 2300 8
VM-BOPP (18) 20 1
VM-EVOH-BOPP (18) ~0.2 ~0.4
VM-CPP (30) 20 1
VM-EVOH-CPP (30) ~0.1 ~ 0.3
*1: 20degC-65%RH, *2: 40degC-90%RH
1. Structure
- Metalized “EVOH/tie/homo-PP/ter-PP (Co-ex) ”
- BOPP and CPP types are available
2. Benefits of met-EVOH-PP
(1) Higher barrier than met-PET and met-BOPP
(2) High bonding strength b/w AL and EVOH
(EVOH high surface energy, ~50dyne/cm)
(3) Cost down from 3ply to 2 ply
(Heat seal ability by ter-PP layer)
* Heat seal strength: TBC for each application
VMPET(12)
LLDPE or CPP(30)
PET(12) or OPP(20)
EVOH
PET(12) or OPP(20)
Tie
h-PP Co-Ex
Metalized
ter-PP

34. EVOH FOR AGRICULTURALAPPLICATIONS
r
 EVOH FOR HERMETIC BAGS
EVOH FOR TIF ( FUMIGATION
FILM )
EVOH FOR BULK SILO BAGS

38. HERMETIC BAG

42. EVOH FOR HERMETIC BAG
• Post harvest problem: Moisture, molds, insects
• Living organism’s respiration makes high CO2 and low O2
atmosphere
• Prevent the growth of bacteria/insect by MAP (low O2
and high CO2 concentration)
Typical structure; PE/tie/EVOH/tie/PE co-ex blown

44. WHAT IS FUMIGATION
&
WHY IS EVOH REQUIRED

45. Fumigation is needed for “Kill disease or weeds”
Disease increase by continuous cropping/grow same crop and same area continuously.
For efficient farming
bacterium Nematoda
Fumigants
Fumigant Risk Status
Methyl bromide ozone layer destruction Decided full phase-out untill Y15 by Montriol Protocol.
Chloropichrin strong tear gas/smell Increasing as alternative. Developed by Nazi as wepone.
Dichloropropene carcinogen Increasing as alternative.

46. Alternative chemicals still
pose health hazards to
field workers and
bystanders
Chloropicrin,
1,3-dichloropicrin
Dimethyl disulfide Methyl
iodide
METHYL BROMIDE being
phased out worldwide due
to ozone depletion
potential
Fumigant is injected or dripped
into the soil prior to transplantHigh barrier
mulch film
retains
moisture and
fumigant
vapors
Nematodes, bacteria, fungi
SOIL
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ISSUES WITH FUMIGANTS USED

47. Fumigant
Methyl bromide
Chloropicrin
1,3-Dichloropropene
Methyl iodide
STD
(Standard film)
Fumigated soil
PE
PE
PE
TIF
(Totally Impermeable Film)
PE
EVALTM
PE
Film
EVOH FOR FUMIGATION FILM
• Increase the fumigation efficiency
• Higher yield and/or lower fumigant cost

48. Typical Commercial Structure of a
TIF Film
1.5 – 2.0 µm
25 – 35 µm
Proper material selection and processing technique will
influence the mechanical properties of the film
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PE
PE
Adhesive
EVOH
Adhesive
PE
PE

49. “Economical merit”
552
639
921
991
1020 1006
975
526
595
781
829
945
914
991
300
400
500
600
700
800
900
1000
1100
Control = 0
lb/ac
Pic-Clor60 =
50 lb/ac
Pic-Clor60 =
100 lb/ac
Pic-Clor60 =
200 lb/ac
Pic-Clor60 =
300 lb/ac
Pic-Clor60 =
400 lb/ac
MBPic = 350
lb/ac
gramsmarketablefruit/plant
Strawberry Yield
TIF
75% reduction
TIF
（EVAL)
STD
(LDPE)

50. EVOH FOR SILO BAGS

51. EVOH SILO BAGS
DECREASE OF O 2 CONCENTRATION AND INCREASE
IN CO 2 LEVELS
 DETORIATION REDUCED BY CREATING HERMETIC
ENVIRNOMENT
ODOR BARRIER AND PEST CONTROL
GRAIN LOSS REDUCTION & EXTENDED SHELF LIFE
RESULTING IN INCREASE IN COMMERCIAL VALUE OF
FOOD GRAIN

52. Summary
• Multilayer film with EVAL™ can add value to
agriculture
– It protects the environment by reducing fumigant
emissions without sacrificing the yield or quality of
fruits of vegetables
– It preserves the quality of grains and animal feed by
limiting the gas exchange in/out and reducing the
metabolic activity of the packaged food
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53. EVOH FOR FOOD SAFETY
PREVENTS MIGRATION OF
“MINERAL OIL HYDROCARBONS “
FROM RECYCLED CARTONS

54. Prevent migration of mineral oil (MOSH, MOAH)
from recycled cardboard into food
Proving EVOH barrier to MOSH/MOAH
(1) Barrier inner liner with EVOH
(2) EVOH lamination onto cartonboard
Inner liner with EVOH
(coated paper or all-plastic bag)

55. Sources of Mineral Oil Hydrocarbons
Contamination of rice by different sources
8

56. EVOH MAINTAINS FRESHNESS OF FOOD AND EXTENDS
SHELF LIFE WHICH CONTRIBUTES TO REDUCTION IN
FOOD WASTAGE .
CONVENTIONAL PACKAGING REPLACEMENT BY
BARRIER PLASTIC PACKAGING INCORPORATING
EVOH IS A GROWING MARKET TREND .
EVOH IS EASILY PROCESSED ON CONVENTIONAL
EXTRUSION PROCESS.
KURARAY IS A LEADING COMPANY OF BARRIER
TECHNOLOGY .
SUMMARY

57. THANK YOU