Tagged in mould labels barrier EVOH and three-dimensional coatings

Wolfgang Czizegg, CEO of Waldorf Technik describes the present of the company in the following way: "We design and manufacture equipment for the handling of articles of consumption of the médico-técnica industry, such as contact lenses;" of laboratory equipment, such as pipettes, containers, pens for application of insulin and plates of Petri… virtually any piece of plastic that large quantities are needed. "In the packaging industry we have opened new markets with innovative engineering and design solutions that allow you to replace the cans and containers of glass for new plastic solutions of precision".

In comparison with the rigid packaging materials more conventional and widely accepted, as glass jars and cans (both have been part of daily life throughout the world during the last 200 years), plastics are still considered relatively new materialsespecially by more conservative packaging manufacturers. Thanks to the considerable benefits and advantages of plastic raw materials and their production, the use of polymers as an ingenious, durable and reliable alternative to the 'classic' materials, as the glass (jars and bottles), metal and other substances (cans)It has come to stay, especially in the industry of food packaging and médico-técnico sector.

The use of injected plastics offers endless alternatives of ingenious packaging and attractive design (different shapes, sizes and thicknesses), which can be adapted perfectly to every product, without attracting the attention of consumers. In addition, the plastic containers are much lighter than the glass and, unlike the cans, its content is fully visible and can be preserved inside safely for longer periods. Its weight and volume are beneficial in terms of transport and storage (due to the possibility of stacking larger volumes), which decrease carbon emissions and can protect the environment.

On the other hand, the security in the handling is an important aspect: the plastic containers do not produce wounds by breakage, as the glass, or by contact with the edges, as in the Tin. In addition, almost the majority of the most common plastics can be recycled easily. Most importantly, however, is that they have become and will continue to breakthroughs in the search for biodegradable plastic containers to help solve the widespread and growing problem of waste disposal throughout the world.

Waldorf Technik makes time that actively participates in the research and the practical implementation of packaging of cutting edge technologies and offers plastic solutions of precision that will benefit not only consumers but also to manufacturers in the industry. In this way, has not remained passive waiting for a change of attitude in the packaging industry or other actors to lay the foundations of the market.

During the last seven years of intense development in this field in particular, the team of Waldorf Technik research has improved three methods for semi-rigid and rigid barrier packaging solutions, in accordance with the criteria of innovation, reliability, accuracysystematic quality, high-speed and high-volume, efficient production and, especially, a great respect for organic production. On the other hand, the plastic containers outperform conventional solutions thanks to its low weight and low transport costs.

This process, which primarily offers options for low- and medium-scale production, has already been effectively tested, is in operation and allows placing wrap label and at the bottom, slightly overlapping all seams of label. The barrier tag is composed of a) a section ultrathin multilayer with Evoh, b) a film barrier coated SIOx or c) foil barrier.

All these components offer a retortable solution. The excellent properties of sealing provide protection in both directions from the migration of oxygen or water vapor. So far, it is possible to achieve extremely attractive designs and solutions in various ways with a process of production of 8 cavities or 2 x 6 cavities as maximum. In this way, it is possible to package aseptic way, often in white rooms, a wide variety of products such as soups, fruits, vegetables, cheeses, coffee, sauces, baby food, products for body care, medicinal products, food for pets and other preserves. The Evoh (etileno-alcohol vinyl) is a formal copolymer of ethylene and alcohol vinyl that is commonly used in food applications.

This process of production, adapted especially to high-volume packaging and applications, as a result, more oriented to the market of packaging, is currently introduced in the market in which glass and Tin containers are traditional rivals. In this case, the coinyección of ultra-thin returnable structures of 3 layers (PP-Evoh-PP), which includes a bonding agent, allow to achieve a process repeatable which has no influence on the cycle time by applying the barrier in moulds with large numbers of cavities, for example in a mold of 32 or 64 cavities-story configuration. This is a process of injection that is known for years, but in the past there was no evidence that Evoh barrier is inyectara complete and evenly throughout the body of the container. However, this obstacle is gone thanks to the newly developed system Check´n Pack Evoh, unique in the world.

Achieved a remarkable difference in the constant and precise thickness of the edge of sealing. However, it is possible that some applications require Automation of the phase of secondary treatment, for example 64 cavities/6 seconds, to achieve control 100% online all the Evoh layer, extract 100% rejected parts online and a process and a 100% automated logistics system. The use of Evoh in the injection molding has been unusual due to the lack of traceability or reliable testing methods; one of the critical factors is that the standard inspection systems do not detect the Evoh.

The inspection and visualization of Check module ' n Pack Evoh allows the inspection in 360 degrees of the edge, walls, the Fund and the injection point. This module is an exclusive brand of Waldorf Technik. In addition, the levels of O2 and H2O vapor barrier are very high and allow (according to Kortec Inc., provider of molding technology) a useful life of storage up to 2 years.

In this way, packaged in aseptic form or with sterilization by autoclave numerous high-volume products such as fish, meat, fruits and food for pets. The adoption of this technology usually results in savings of between 30% and 40% in production and logistics in comparison, for example, with the costs of packaging cans. In addition, conical, easy to stack, forms offer great advantages in terms of space and weight.

This process consists in the total coating in line with various substrates of Cavonic coating, which offers a choice of extremely low output, a solid barrier and watertight properties similar to the glass vacuum. One of the main advantages is that it can be used in existing processes of injection, along with a complete and secure protection against migration of plasticizers to the contents of the container. "To date, the laboratory tests have been successful;" in other words, confirm the preparation for the aseptic process with the aim of achieving a total sterilisation. Currently, the barrier against the permeation of oxygen amounts 99.15% (130 → 1.1 O2TR) after sterilization. "In addition, the combination of the performance of the thin-walled, the superb barrier properties and the low prices of production make this technology, which can be adapted to biodegradable polymers, in a very attractive commercial proposition", concluded Czizegg.

Thanks to this level of specialization and innovation in the three technologies, Waldorf Technik has achieved a prominent position. "These partially exclusive collaborations with Cavonic GmbH, specialist in the technique of coatings of barrier for packaging of consumer products, or Kortec, Inc. offer a clear advantage to our clients and, possibly, revolucionarán the market of canned", says Czizegg about the reactions of customers.

These solutions, combined with others that are in the phase of project, are the Waldorf Technik direct response to the growing demand for manufacturing processes increasingly safer, faster and more productive with cutting-edge engineering. With its 100 employees, the company has activity mainly in the central region of Europe, Scandinavia, the European Union, Middle East and North America, where it opened a subsidiary in 2008. The recent distinction as the 'Top 100 company' recognizes the company for the second time by their level of innovation between medium-sized enterprises of Germany.