Issue 05/2015

Barrier
PLA and cellulose
based film laminates
NatureWorks and Innovia Films have collaborated to develop
the next big step forward in sustainable multilayer
film materials. By combining the complimentary
technologies of their bio-materials, they have created a biobased
commercially compostable packaging structure that
can be used across a wide range of packaging and lidding
formats. When laminated, the high-barrier properties of cellulose
based NatureFlex combined with Ingeo PLA make
for a truly high-performance packaging film.
Potential Application with NatureFlex & Ingeo
By focusing on the functional attributes of each individual
film, along with the combination of the materials, Innovia and
NatureWorks, in concert with their collaborative partners
Bi-Ax International, H. B. Fuller and Clemson University,
developed one of a kind bio-laminations that not only meet
the functional requirements of packaged products, but also
address renewable content, end of life for flexible materials
and reduce the amount of carbon in the overall package.
Package functionality is paramount. In many cases, these
newly developed structures would be replacing traditional,
petro-chemical derived materials that meet the fit for use
requirements for the product packaged. The bio-laminations
needed to meet the key criteria of appearance, barrier and
sealability. NatureFlex film from Innovia meets barrier criteria
while Evlon film from Bi-Ax International incorporates an Ingeo
sealant layer. During the design phase of the collaboration,
two very common flexible structures were identified as
candidates to compare bio-laminate alternatives. The first
incumbent structure is a widely used secondary package
across multiple segments and package formats; 12 µm PET/
Adh/46 µm PE. The other candidate went to the other side of
the spectrum with a high barrier foil lamination; 12 µm PET/
Adh/7 µm Alu /Adh/46 µm PE.
Compared to all other package formats, flexible packaging
is a sustainable solution. For example, just over the past 20
years, packaged retail coffee has evolved from glass to steel
to rigid plastic and now flexible laminations. Comparatively,
each step throughout the package evolution has resulted in a
more sustainable product than the predecessor. By focusing
on “what’s next?” in the evolution of flexible materials,
Innovia and NatureWorks designed materials that address
the two major downsides of using flexible laminates, namely
Stick pack HFFS VFFS Pouches Sachets Lidding
Dry beverages
(coffee/tea)
Dry goods/breads
Nutritional bars
Salted snacks
Confections
Cultured dairy/
cheese
Pet food/treats
Liquid applications
• Recommended • Evaluation needed • Not applicable
renewable content and end-of-life. Comparatively, the petrochemical
derived materials have zero renewable content,
which essentially means that these materials are using 100 %
finite fossil resources as the primary raw material. Conversely,
the flexible laminates designed by the collaboration of
NatureWorks and Innovia have very-high renewable carbon.
Additionally these bio-laminations provide an alternative
and valuable end of life option. Beyond just landfill which is
the principal final resting place of mixed-material, flexible
laminates in many countries, these bio-laminates offer up
the prospect of carbon-neutral incineration with renewable
energy recovery and they are also designed to decompose in
Industrial Composting facilities where such facilities exist.
Each film used in the construction has been fully certified
(ASTM D 6400) by the Biodegradable Products Institute (BPI)
for compostability.
Advancements in processing within manufacturing of the
base materials has greatly reduced the amount of greenhouse
gas emissions in packaging. Petro-chemical laminates are
already at a very low base compared to rigid packaging but
bio-laminations allow to reduce these levels even further,
especially as the scale and adoption of renewable materials
are commercialized.
The next generation of flexible packaging is here. Innovia
Films and NatureWorks, along with their development
partners, have succeeded in developing individual materials,
when combined, make a sustainable packaging solution for
brands and converters. By meeting the package requirements,
having renewable content and an alternate end-of-life, the
next generation of flexible packaging is here and addresses
the “What’s next?” question for flexible laminates. MT
www.natureworksllc.com - www.innovia-films.com
Raw material
End of life
Raw material
End of life
Conventional pack
12µm PET/Adh/50µm PE
0 % RRM
fossil
derived
Incinerate
or landfill
Footprint
0.3 kg
CO 2
eq/m 2
MVTR ~11
OTR