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Packaging Adhesives
The packaging adhesives market is estimated to witness a healthy growth, during the
forecast period, 2018-2023. Out of the total adhesives used globally, more than 70%
goes into the packaging industry. The kinds of adhesives are used in various packaging
applications, such as rigid packaging, flexible packaging, corrugated packaging, folding
carton, labeling, etc. Asia-Pacific is expected to witness strong demand for packaging
coatings, fuelled by increasing investments in the region, rise of various end-use
industries, such as food & beverage, pharmaceutical, manufacturing, e-commerce, etc.
A glance at food packaging clearly says not likely. The range of application is
enormous from aroma impermeable soup packets to frozen gourmet sushi, from sealed
cheese slices to air and watertight dairy products. Just take a walk through your local
supermarket – you’ll find yourself in a paradise held together by adhesive. The result:
the modern systems of distribution, self-service, ready-meals and frozen foods are
unimaginable without adhesives to produce impermeable packaging materials such as
laminating foil or to hermetically seal packaging (e.g., packets of coffee). The smallest
amounts of laminating adhesive (approx. 1 to 3 g/m²) are added to laminating foils at
rates of up to 1640 ft/min.
Adhesives that are resistant to high and low temperatures allow packaging to be
made for frozen and microwavable foods. Of course it goes without saying that
adhesives used to make packaging for food conform to all of the strict regulations
governing food production.
Invisible, tasteless and odourless – adhesives hold the very fabric of our supermarkets
together and even play their part in our culinary paradise at home.
The only materials that are able to easily undergo this type of transition, either through a
chemical reaction or a melting / crystallization process at reasonable temperatures, are
polymers. Therefore, all adhesives are polymer-based; their design aims to control both
the rate of bond formation and the bond strength (resistance to stress, strain, and brittle
fracture).
Adhesive Materials
Adhesives and sealants have been used for centuries, with the earliest adhesives and
sealants being made of natural materials, such as tree sap, beeswax and tar. Later,
processed natural products were used such as animal protein, resin, natural latex.
With the emergence of the chemical industry and synthetic polymers, the range of
adhesive and sealant formulations exploded.
Except for the case of self-adhesive materials, the raw materials used for adhesives are
either reactive monomers or polymers formulated in such a way that they can be easily
coated on various substrates.
The ability to bond a wide range of raw materials (ceramic, polymer, glass, metal,
composite, skin, etc.) and allow assemblies of various shapes and dimensions;
The ability to allow the distribution of stress on the adhesive joint over all of the
bonded surface;
Economical processing; and
Ease of use (the technology should be usable by anyone).
Adhesive Technologies
Today’s adhesives and sealants may be classified in many different ways, such as by
cure (bonding) mechanism, chemistry type, and even application (e.g. structural vs.
non-structural).
Low viscosity is essential for spreading the adhesive on the surface to achieve the most
complete bonding interaction. Then, a physical process (solvent evaporation,
temperature cooling) or a chemical process (chain- or step-growth polymerizations,
vulcanization, or mild cross-linking) controls the transformation of the adhesive into a
bonded joint.
The mechanical strength of the formed joint is then related to both the chemical
structure of the polymer backbone and the molar mass between physical entanglements
or chemical cross-links.
PHYSICALLY HARDENING
Physically hardening adhesives are adhesives which, on application, are already
present in their final chemical state. Only polymers that can be liquefied can be used for
this category of adhesive, namely thermoplastics that can be melted, soluble
thermoplastics or elastomers, or polymer dispersions. Physically hardening adhesives
provide a wide range of adhesive properties, generally good bond flexibility, and are
used in a variety of applications.
Hot Melts
Organic Solvent Adhesives
Plastisols
Water-Based Adhesives
HOT MELTS
Hot melt adhesives are generally 100% solids formulations based on thermoplastic
polymers. They are solid at room temperature and are activated upon heating above
their softening point, at which stage they are liquid, and hence can be processed. After
application, they retain the ability to wet the substrate until they solidify. Upon
solidification, they return to a physical state that has structural integrity and can function
as an adhesive.
A feature of hot melts is that on cooling they very rapidly build up their internal strength
allowing rapid assembly and further processing. Because they are based on
thermoplastic polymers, hot melts can be repeatedly heated to melt and cooled to
solidify.
Hot melts are used in industry for a wide range of applications. The packaging industry
is one of the major users. Hot melts are also used in the printing industry for bonding
the spines of books.
PLASTISOLS
Plastisols are single-component adhesives that are applied as a paste to the substrate.
The paste consists of solid polyvinylchloride (PVC) particles dispersed in plasticizer. In
order to form a bond, the applied adhesive is heated so that the thermoplastic PVC
swells and can take up the plasticizer. This process occurs at a temperature between
300 and 360°F (150 and 180°C) and results in an adhesive film consisting of a
plasticized polymer.
WATER-BASED ADHESIVES
This category of adhesives includes a wide variety of polymeric materials (usually
thermoplastics or elastomers) dispersed or dissolved in a continuous aqueous phase.
One of the major advantages of water based (or waterborne) adhesives is the absence
of volatile organic compounds (VOCs). A feature of these materials is the ease of
cleanup of liquid adhesive. Water can be used to clean application equipment and
excess adhesive off substrates.
For many water based adhesives, it is a requirement that at least one of the substrates
be permeable to allow water to escape from the system. It is not surprising, then, that
these materials have found wide use bonding wood, paper, fabrics, leather and other
porous substrates.
1. Solutions
Water-based solution adhesives are based on natural and synthetic polymers that
can be dissolved in water. Bonds are formed by the evaporation of water or by
absorption of water into the substrate. These adhesives are used in bonding paper
and paper products as well as in moistenable adhesives such as those used on
stamps, envelopes, labels, and packing tape.
2. Polymer Dispersions/Emulsions
Water based dispersion adhesives are typically formulated from compounds
including vinyl acetate polymers and copolymers (PVAC), ethylene vinyl acetate
(EVA), acrylics, styrene-butadiene rubber (SBR), natural rubber latex and synthetic
elastomers, and polyurethane (PUR).
CHEMICALLY CURING
Chemically curing adhesives are reactive materials that require chemical reaction to
convert them from liquid (or thermoplastic) to solid. Once cured, these adhesives
generally provide high strength, flexible to rigid bond lines that resist temperature,
humidity, and many chemicals. They may be classified into two groups:
PRESSURE SENSITIVE
The special feature of pressure sensitive adhesives is that they do not solidify to form a
solid material, but remain viscous. As a result, they remain permanently tacky and have
the ability to wet surfaces on contact. Bonds are made by bringing the adhesive film in
contact with the substrate and applying pressure. If inadequate pressure is applied or
the processing temperature is too low, bonding faults such as bubbles or detachment
can occur.
They are typically formulated from natural rubber, certain synthetic rubbers, and
polyacrylates.
Adhesives are used in a wide variety of paper bonding applications ranging from
corrugated box construction and the lamination of printed sheets to packaging material
used for all types of consumers products to the production of large industrial tubes and
cores used by manufacturers of role goods and other materials. They can also be found
in the products used by consumers everyday such as bathroom tissue, paper towels,
and books.
Packaging Applications
An extremely high proportion of all industrial products are sold in packaging – either due
to stability requirements for storage and transport or for aesthetic reasons. Although
normal envelopes and paper bags consist of just a single layer of material, most
packaging materials used nowadays are in fact different materials laminated together.
Packaging accounts for one of the largest markets for adhesives. Applications include:
Bags
Carton Side Seam & Closures
Cigarettes and Filters
Composite Containers and Tubes
Corrugated Board
Cups
Disposables (Non-wovens)
Envelopes
Film: Film and Film: Foil Laminates
Flexible Packaging
Labels/Signs/Decals
Remoistenable Products
Specialty Packaging
By laminating cardboard with paper, in particular high gloss paper, it is possible to put
product information on the cardboard and give the product a commercially alluring
appearance. Adhesives based on starch, dextrin and gluten, and also polyvinyl acetate
dispersions, are used for this purpose. Important requirements on overprinted
packaging materials, in particular the various types of packaging materials used for
foods, are their strength, stability to heat and impermeability to moisture, oxygen and
aromas. These properties along with desired appearance can usually only be obtained
by combining different materials.
Frozen Food
It has a long shelf life but is still fresh and on the table within minutes: frozen food is a
permanent fixture on the menus in most homes nowadays. Whether it is pizza, fries,
summer vegetables or ice-cream – steady temperatures below zero are used to
conserve a boundless cornucopia of food. Only adhesives make frozen food possible.
They provide a reliable seal for the packaging and ensure that the low temperatures in
the freezer remain constant and that energy costs are minimized.
Laminated films
Laminated films can be manufactured from polyester (PETP, PBTP), polyamides,
polyethylene, polypropylene, cellophane, paper, polyvinyl chloride, polyvinylidene
fluoride, polyimides, aluminium and a few other materials. Metallic foils are also often
used. Solvent-containing adhesives based on polyurethane are used for laminating
films; the most recent developments in this area however involve solvent-free systems,
so-called high-solid products and adhesives based on aqueous polyurethane disper-
sions.
For application using automatic packaging machinery, high requirements are put on the
constancy of the adhesive properties, especially with regards to its viscosity stability.
Dispersion adhesives and hotmelts are used to seal packaging (e.g. folding cartons,
packets).
Coldseal Adhesives
Coldseal adhesives are designed for use in packaging heat-sensitive food items such
as candy, ice cream, and chocolates. They also find use in some consumer's medical
and industrial applications such as detergents, protective packaging, and labels. The
products are applied to base films or laminates having release lacquers or release films.
They are designed to be sealed to themselves to form packages using only pressure.
Heat Seal Coatings are thermoplastic coatings applied to a variety of films or laminates.
They are designed to adhere to many different substrates using heat and pressure to
form the seal. These products are designed for use in multiple lidding applications
including condiments and dairy, as well as retortable and ovenable containers. Other
uses include in-mold labeling and medical packaging, as well as some industrial uses. A
variety of chemistries are available to meet the myriad of potential end-use applications.
They are supplied in water, solvents, and in some cases as solid resins.
Primers
Primers are used to promote or improve adhesion of a topcoat to a variety of base films
including foil, metalized films, paper, and board stock. Often they are applied and
immediately top-coated. In some cases, however, they may be applied and wound, but
top-coated at a later date. Both water- and solvent-based chemistries are available.
Solventless Adhesives
Solventless adhesives are 100% active products containing no water or solvent carrier.
They are applied to base substrates using smooth roll transfer, solventless laminators
and subsequently nipped/bonded to the secondary film to make the lamination. These
laminations may contain multiple layers and are used in a broad array of food packaging
applications including for snack foods, high performance retort, and microwavable
packaging. These products meet a broad range of regulations for packaging adhesives
and are suitable for most films, foils, and paper.
Water-based adhesives contain water as their carrier which is subsequently dried after
application (dry bond laminating), leaving the active resin system on the substrate to be
bonded to a secondary substrate to make the lamination. These products can be used
on a variety of film substrates as well as foil and paper. End use applications in food
packaging include snack food and bottle labels, as well as microwaveable and boil-in-
bag packages. Other applications include medical packaging and flexible industrial
laminations. These products are typically machine-ready with no dilution needed and
offer fast slit-to-ship turnaround.
A lot of so-called “green” adhesives are derived from the biomass, for example, from
trees and animal fats. Today, these adhesives are typically used for low-cost
applications. However, research based on the chemical modification of bio-
macromolecules should lead to the design of new adhesives to broaden their usual
range of applications. Adhesives derived from the biomass are manufactured from a
complicated blend of molecules found in nature, so their chemical structures are poorly
defined.
Such adhesives must be designed to perform well and be recyclable while also
satisfying the constraints imposed by forthcoming environmental legislation
Liner-less labeling
This is one of the most recent innovations in packaging and labeling, which will help to:
Reduce waste
Improve weight efficiency, and
Favorably influence packaging cost
For this type of labeling, the entire back is coated with a particular release coating so it
can be wound up like a roll of tape. The adhesive needs to be strong enough to bond to
various substrates including highly recycled content and low energy surfaces but not be
too aggressive, as it can pick the release coatings and result in print voids and variable
unwind properties, which needs a careful balance in the adhesives formulations as well
as innovations at the polymer binder’s end.
Adhesives for Food Packaging
From a customer end, there are even higher demands to maintain the freshness or
product shelf life of the products within the package with same time more long and
complex delivery chains. “Fresh to Table” stands for higher standards of brand
differentiation, shelf appeal and consumer convenience which meet the needs of a
rapidly evolving society.
For the packaging adhesive this trend translates into new materials and surfaces to
bind, partly direct food contact demands and also new application methods to adapt to.
As customers also demand re-closable packaging for their convenience, adhesives
formulators need to develop low-tack adhesive that securely seal repetitively under
greasy or fatty conditions.
From a flexible packaging supplier’s perspective, the relevant demand is for the use of
high speed running machines resulting in higher manufacturing efficiency at the
packaging line. Same time, less adhesive should be applied more precise, to reduce
waste. Thinner, stronger, faster running describes sought after adhesives film
characteristics, which sets higher demands for the packaging adhesive in terms of
rheology and high shear stress resistance.
Failing these demands causes not only loss of production time (cost) but also additional
waste, as the adhesive builds up on the applicator’s cutter and within the print engine.
Recently, the adhesives raw material suppliers focused their innovation effort towards
this problem and provided the adhesives formulators with new polymer raw materials,
optimized for this application.
Natural organic adhesives have been around for a long time. These are easy to obtain,
relatively inexpensive, easy to apply and are known to have a base of sugar, starch or
dextrin, mainly used in paste paper products. Several of these can be edible, especially
the majority of sugar-based glue. Starch based glues are generally derived from the
cooking of seeds with a high starch content (as for example oats, rice, etc.) in water,
often in the presence of acid or base to obtain a paste of varying viscosities. When
aqueous acids are used at around 50⁰C, the formed pulp is neutralized with a base. In
the basic treatment, the starch is heated in an alkaline solution in combination with
additives such as borax.
References
3M.
Henkel AG & Co.
HB Fuller.
Bostik.
Sika AG.
Avery Dennison.
Jowat Corp.
Wacker Chemie.
Ahland Inc.
Paramelt BV.
and Dymax.
There are several adhesive options available for different end uses and thus selecting
the most appropriate adhesive is not always straightforward. The best approach to this
task is to regard the adhesive in the same way as any other packaging component, and
consider the key functions of the finished pack and what part any adhesive(s) will have
to play in meeting those functions. The pack design and development process starts
with a brief and involves the consideration of options for meeting that brief; these
options should always include the adhesives, i.e. adhesives should be considered at the
start of the process and not left to the stage of final specifications. It should be clear by
now that knowledge of substrate properties is essential when selecting adhesives, as
well as a thorough understanding of the conditions to which any adhesives bonds will be
exposed throughout the life of the packaging components and the finished pack.
Closing time or setting time: This is the time during which the adherends and
adhesive must be in intimate contact such that the bond is sufficiently secure that it will
withstand subsequent handling. In most packaging operations, this is determined by the
layout and speed of the packaging line.
Coating weight: This is the amount of adhesive applied, usually quoted as grams per
square metre. Adhesive manufacturers often recommend typical coating weights for
given applications. Applying too little means inadequate bond strength and applying too
much is costly and may lead to an open time that is too long for the machine and bond
failure.
Cohesive strength: This is the strength of the adhesive film itself. Once the adhesive
film has formed, the bond can still fail because the polymer is not strong enough. A self-
seal envelope and a cold-seal bond on a confectionery wrapper are both examples of
bonds where the adhesive strength is higher than the cohesive strength of the adhesive
film.
Fibre tear: This applies only to bonds involving paper and board. A good bond is one
which, when an attempt is made to peel it apart, results in tearing of the cellulose fibres,
i.e. the adhesive is stronger that the inherent strength of the paper.
Green bond: This is the bond achieved prior to drying or curing of the adhesive.
Open time: The maximum amount of time between when an adhesive is applied and
when the substrates can be brought together and still make an effective bond. This
varies from a few seconds in the case of many hot melt adhesives to several minutes
with some PVA or EVA types.
Solids (non-volatile) content: The percentage of the adhesive which will remain once
the carrier has dried off. For example, a hot melt adhesive is described as 100% solids,
because it moves from a liquid to a solid state without losing any of its content. A PVA
water-based emulsion is typically around 50% solids, so the volume of the final
adhesive is half of the volume of the adhesive as applied. When calculating adhesive
costs, it is important to take solids content into account.
Wetting out: The ability of an adhesive to spread across the surface of an adherend
such that it forms a bond with it; failure to wet out will result in uneven bonding.