BARRIER ENHANCING TECHNOLOGIES FOR PET

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BARRIER ENHANCING TECHNOLOGIES FOR PET PP
CONTAINERS
SPE Blow Molding Division Fall Technical
Conference
October 2, 2002
PRESENTED BY BUSINESS DEVELOPMENT ASSOCIATES, INC.
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INTRODUCTION

• OVERVIEW OF TECHNOLOGIES
• COMPARATIVE COSTS
• FORECAST POTENTIAL VOLUMES

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BARRIER ENHANCING TECHNOLOGIES

• MULTI-LAYER
• COATINGS
• IMPROVED BARRIER MONOLAYER
• COMBINATIONS

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MULTI-LAYER PET

• O-I
• KORTEC
• S-L
• PPP
• DEVTECH LABS

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O-I SURSHOT

• Process
• Sequential Shooting pots 48 Cavity G line
  Index
• 2M 3L 3M 5L
• Materials
• X-312 Surshield PCR
• Status
• Food Beverage Beer
• Licensing

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KORTEC

• Process
• Simultaneous Discontinuity of B Layer 48,
  96 Cavity G line Index
• 2M 3L 3M 5L
• Materials
• Various PCR
• Status
• Open Ball CSD Beer Constar Beer Bev.
  S-L CSD, JJD China Beer JJD

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AMCOR PET (EX S-L)

• Process
• Simultaneous 48 Cavity
• 2M 4L
• Materials
• MXD6 Bind-OX
• Status
• Europe JJD, Water, Beer

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PPP (EX ANC)

• Process
• Simultaneous 48 Cavity
• 2M 4L
• Materials
• EVOH
• Status
• US Ketchup, JJD. Europe Beer, JJD, FAB
• Low profile

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DEVTECH LABS

• Process
• Hybrid Secotech 16, 48 Cavity
• 2M 6L
• Materials
• Various PCR
• Status

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MULTI-LAYER PP

• COEX BLOW MOLDING
• CO-INJ. STRETCH BLOW MOLDING
• ISBM COATING

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COEX BLOW MOLDING

• PROVEN, MATURE TECHNOLOGY
• FLEXIBLE
• LOW COST
• EVOH BARRIER MATERIAL

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CO-INJ SBM

• 3 MATERIAL CAPABILITY REQD
• CLARITY ?
• ADHESION ?
• NOT READY FOR PRIME TIME

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ISBM COATING

• CLARITY OK
• BARRIER LEVEL ?
• SPRAY APPLIED (PPG)
• CVD
• COST lt BARRIER PET
• DEVELOPMENTAL

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BARRIER MATERIAL DEVELOPMENTS FOR USE IN M/L

• PASSIVE
• ACTIVE/PASSIVE

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PASSIVE MATERIALS

• EVOH EXCELLENT BARRIER RH ADHESION
• MXD6 COST/PERFORMANCE CSD
• NANOCOMPOSITES
  
• IMPERM MELT COMPOUND COST/PERF.
• CLARITY
• AEGIS NC POLYMERIZATION
  COST/PERF. CLARITY
• POLYGLYCOLIC ACID (PGA)
• DEVELOPMENTAL

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ACTIVE/PASSIVE MATERIALS
Nylon-matrix EVOH-matrix Oxbar Dareval X
-312 Surshield EMCM-Matrix Bind-Ox OSP Amaz
on Aegis OX
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BARRIER COATINGS

• SPRAY COATINGS
• VACUUM BASED CHEMICAL VAPOR DEPOSITION (VCVD)
• ATMOSPHERIC BASED CHEMICAL VAPOR DEPOSITION
  (ACVD)

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SPRAY BARRIER COATINGS

• BAIROCADE
• COMMERCIAL
• SIPA
• PRE-COMMERCIAL

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VCVD BARRIER COATINGS

• COMMERCIAL
• ACTIS
• PRE-COMMERCIAL
• PNS (EX DLC)
• GLASKIN
• BESTPET ( TOPCOAT)
• DEVELOPMENTAL
• VPP
• HICOTEC

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ACVD BARRIER COATINGS

• DEVELOPMENTAL
• MICROCOATING TECHNOLOGIES

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IMPROVED BARRIER MONOLAYER

• PEN
• AMOSORB DFC/PET BLEND

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COMBINATIONS

• AMOSORB DFC/PET BLEND COATING

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MFG. COST ANALYSES COMPARISONS

• BASIS
• 3 CONTAINERS/END USE PRODUCTS
• CSD, JJD, BEER
• MFG. COSTS NOT NSP
• BDA MFG. COST MODELS

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BOTTLE SPECS
CSD JJD BEER 12oz 28mm 16oz 43mm 16oz
28mm 2-3xCO2 2-3XO2 3X CO2 10X O2
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DISCLAIMER
Manufacturing cost estimates contained in this
presentation are intended for use in assessing
the relative cost/performance of the various
technologies rather than establishing absolute
costs for any specific combination of container
and technology. Further, they are representative
of costs based on full-scale, high-volume (i.e.,
hundreds of millions to billions of units per
year) production of bottles. Finally, they
should not be used to attempt to establish the
price any converter may charge for these kinds of
containers.
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OUR APPROACH

• DIVIDE TECHNOLOGIES INTO 4 TYPES
• M/L, COATING, MONOLAYER, COMBINATION
• SORT BY END USE
• CSD, JJD, BEER
• USE RANGE OF INPUT VALUES
• USED, /LB, COAT THK., ETC.

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SAMPLE OUTPUT GRAPH
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RESULTS PET
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RESULTS PP VS PET 16oz JJD

• COEX-BM
• PP _at_ 10-15 LOWER WT.
• 1 EVOH
• 30 LOWER COST
• ISBM COAT
• PP _at_ 10-15 LOWER WT.
• BAIROCADE COATING
• 16 LOWER COST

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PET BARRIER CONTAINERS UNIT VOL. BY TECHNOLOGY
2001 MM UNITS
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POTENTIAL BARRIER CONTAINERS 2004 US MM UNITS
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CONCLUSIONS

• TECHNOLOGIES EVOLVING
• ECONOMICS COATING BEST?
• MONOLAYER APPROACH COMING
• LARGE VOLUME POTENTIAL

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