printability performance final

SUMALATHA.G.S -100935008

PRINTABILITY PERFORMANCE OF

BIOBASED MATERIALS

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PRINTABILITY PERFORMANCE OF BIOBASED MATERIALS

1. INTRODUCTION

2. LITERATURE REVIEW

3. METHODOLOGY

CONTENTS

- Current scenario- Advantages of biobased materials- Main challenges- Producers & manufactures- Objective of the study

- Biobase materials- Evolving biobased materials- Polylactic Acid – production, properties, degradation, application

- Designing- Ripping- Plate making- Surface treatment for the substrate,- Printing- Testing & measurement

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4. RESULT ANALYSIS

5. CONCLUSION & SCOPE OF FUTURE WORK

6. REFERENCE

CONTENTS

- Dot gain

- Tone reproduction

- Optical/reflective density

- Dyne levels

- Type quality

- Dot shape

- Specular gloss

- Rub resistance

- Ink adhesion

- Runnability

- Tensile strength

- Dirty print

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INTRODUCTION

Public concern is growing on two fronts- Life cycle of packaging products

Reduce, Reuse And Recycle !!

No one wants a landfill in their neighborhood….

FORCAST: Use of plastics & its disposal may grow in future (10 times by 2030).

“Bio plastic” packaging products have emerged as a viable alternative to

traditional plastics.

Awareness of bio-based packaging materials, is having a significant increase.


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INTRODUCTION (continued….)

Use of bio-based films in packaging industry is increasing in food and

beverage markets as these films are used for pouches, shrink and roll-fed labels,

flexible packaging and food trays.


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ADVANTAGES being: Made from agricultural feed stocks, 100% bio

degradable, high surface energy, clarity, flexibility, heat resistance, can be re-

engineered to form any shapes, easy processing techniques, easily

disposable, recyclable, minimum pollution to the environment.



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The use of these bio-based products will likely accelerate in the short term because of:

1. Regulation- especially in countries like Europe, USA, INDIA, etc.

2. Cost reduction as supply of bio plastics increases coupled with rising

oil prices.

3. Marketing by brand owners around carbon footprint reduction.

4. Consumer demand for environmentally-friendly products.

5. Mass marketers requiring a supply base which incorporates

sustainable materials.


Source: Energy cure flexographic inks for PLA films, Andrew Seecharan


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Growth estimates for bioplastics are typically 20% to 30% year by year

But it is dependent on the rate at which the supply chain is developed.

However, consumer adoption of the relatively new technology will depend

a great deal on how well convenience, safety and cost compare to

the established petroleum-based products.

CHALLENGES????




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Main Challenges:

1. A possible draw on food resources which causes food prices to

increase.

2. Infrastructure for optimal disposal of bio-based films.

3. Suitability for microwaveable, hot-fill and extreme storage

conditions.

4. Shelf-life of a packaging material which decomposes – especially in a

heated environment.

5. Possible equipment and ink modification to accommodate the new

substrates.

6. Differences in functional properties.




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Producers and Manufactures:

1. NATURE WORKS –INGEO, Nature works PLA,

2. P & G - NODAX

3. TEIJIN - BIOFRONT

4. BIOTEC- BIOPLAST

5. TIANAN- ENMAT

6. EASTMAN – EASTAR BIO

7. DUPONT - BIOMAX


Source: Product overview and market projection of emerging bio-based plastics- Report 2009


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To review the literatures about biobased materials.

To study the basic properties, production & application of PLA.

To perform printability on Polylactic Acid using water based inks.

To analyze the performance of Polylactic Acid in comparison with

Poly Ethylene Terephthalate (PET) , OPP & OPS

Objective of this study:

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BIOBASED MATERIALS:

Biobased packaging materials are materials derived from renewable

sources like CORN, POTATO, PEAS, WHEAT, SUGARCANE & WASTE

FOOD.

These materials can be used for applications like for food packaging,

garbage, bio implantation, drugs, bio fuels, industrial products,

electronic goods, cosmetics packaging, etc


Source: Biobased Packaging materials for food Industry

LITERATURE REVIEW

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LITERATURE REVIEW (continued….)

Forecast : Future biodegradable plastic market


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Source: Polylactic Acid: Synthesis, Properties and Applications, L. Avérous


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Evolving biobased plastics suitable for films are:

1. PLA – Poly Lactic Acid

2. PHA’s – Polyhydroxy alkanoates

3. TPS – Thermoplastic starch

4. Starch blends



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PLA – Poly Lactic Acid

Evolving biobased plastics suitable for films are:

1. PLA – Poly Lactic Acid

2. PHA’s – Polyhydroxy alkanoates

3. TPS – Thermoplastic starch

4. Starch blends


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Polylactic Acid : Bio polyester

- Derived from lactic acid.

- History – Since 1845– Dupont 1954, Cargill dow 1997 .

- Carbohydrate feedstock: Maize, Corn, Wheat, Whey, etc,.

- Has been received well in medical and packaging industry.

-Due to its ability to be hydrolyzed, it has been studied for bio

absorbable medical device, surgical implantation, Sutures, drug

delivery system application, etc.

- In packaging they are used for loose-fill packages, compost bags,

food packaging, disposable tableware, etc.

- It has been researched for its adaptability to many applications.



19PLA growth trends by geography, 2009 to 2016



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Number of works published since 1960 based on

Scholars Portal SearchSource: Poly(lactic Acid): Synthesis, Structures, Properties, Processing, and Application by Rafael et al.


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Polylactic Acid : Synthesis


Manufacturing Of Poly Lactic Acid (PLA) at Cargill Dow LLC Source: Wikipedia – Poly Lactic Acid


Catalyst: either syndiotactic or a heterotactic stereocontrolOr tin chloride

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Source: Wikipedia – Poly Lactic Acid


Life Cycle of Polylactic Acid

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Polylactic Acid : Properties

- Processing, crystallization and degradation behavior of PLA

depends on structure and composition of polymer chains.

- It can be semi crystalline/ amorphous in nature

- Crystalline – 37%, Blend PLLA & PDLA – High crystalline.

- Glass transition temperature – between 60 to 65 °C.

- Melting temperature – between 173 to 178 °C.

- Tensile modulus – between 2.7 to 16 Gpa.

- Heat resistant PLA temp - 110 °C up to 190 °C.

- Similar mechanical properties to PET.

- It can be processed like most thermoplastics in to fiber and film.



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Polylactic Acid : Properties continued….

- Surface Energy 38 to 36 dyne level.

- Film heat seal-ability 80 °C

- Chemical resistance Good solvent & grease resistance

- Optical Properties Gloss at 20 degree – 90%; Haze – 2%;

- Biodegradability Under real landfill – 15 months

Under real waste water treatment – 15 months

Under Compositing plant condition – 30 days

- Recycling 98% accuracy in separating, using NIR detection

technology. Thermal depolymerization – Cradle to Cradle recycling


Source: Product overview and market projection of emerging bio-based plastics- PRO-BIP 2009


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Polylactic Acid : Degradation


Degradation under Compositing plant condition

Degradation under waste water treatmentDegradation under real landfill


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Polylactic Acid : Applications

- Containers, pressure-sensitive bottle labels, candy wraps, Carry bags, Cold

beverage cups, clamshells, bottle cap, etc,.

Woven shirts, microwavable trays, tissue engineering,



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DESINING the Test Target

RIPPING

PLATE MAKING

SURFACE TREATMENT FOR THE SUBSTRATE

PRINTING AND DRYING

TESTING AND MEASUREMENT

ANALYSIS

METHODOLOGY

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METHODOLOGY continued….


1. Designing the test target:

- Was designed using an Adobe Illustrator.

- The image contains vector and raster images

a solid strip,

slur targets,

multiple point sizes (font),

regular and reverse print,

1 through 100 percent density patches,

greyscale images, white and black image

and some gradient strips.

TEST TARGET

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2. RIPPING:

- The file was ripped through Esko's Cyrel Digital Imager (CDl) Spark

System using Esko's Suite 7 workflow.

- Machine was calibrated before processing.


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3. PLATE MAKING:

- Plate was set at 150 line screen ruling

- Circular dot shape

- 68 degree angle

- The vertical distortion scaling was set to 96.751 percent.

- Carbon masked plate was used.

- Main exposure – using Esko's Cyrel Digital Imager (CDl)

- Back exposure, washing and post exposure – using Dupont Cyrel

FAST Exposure Unit .

- The finished Plate was measured using BetaFlex334 system for dot %


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4. SURFACE TREATMENT FOR THE SUBSTRATE

- Ink adhesion test was performed.

- The surface energy of PLA was tested using Accudyne test solution.

- Requirement of dyne level (surface energy) for substrates:

For most of the Solvent based inks – 36 to 40 dynes/cm of substrate

For water based inks – 40 to 44 dynes/cm of substrate

laminating and coating – 50 & above dynes/cm of substrate

- Surface tension of water based inks – 36 dynes – PET & PP plastic

- Surface energy of PLA – 36 to 38 dynes.


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4. SURFACE TREATMENT FOR THE SUBSTRATE

- Solution for low surface energy of PLA: Surface treatment

- Corona or plasma treatment – to get higher surface energy.


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5. PRINTING

- A draw-down test with the anilox-roll hand proofer was used to test

ink adhesion.

- Once dried, a crinkle test determined that the adhesion was

acceptable to print on press.


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5. PRINTING

- Conventional methods were performed to setup the press.

- Manual deck settings

- Constants that can be controlled include: viscosity, pH, anilox roll,

speed, dryer, and tension.

- Prior to running the ink on press, a Zahn cup was used to measure

the viscosity of the ink.

- Result of Viscosity testing of ink: 50.9 sec

- PH Level for water based was: 8 to 9.5

- About 700 feet of film was printed.


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5. PRINTING

- Press Speed: 50 feets per min

- Dyer positioned at 3rd stage with 167 degree F.

- Tension was set up to 20 psi

- Order of printing: white PLA, clear PLA, PET, OPP, and OPS .


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5. TESTING AND MEASUREMENT

- dot area,

- tone reproduction,

- optical/reflective density,

- specular gloss,

- dot shape,

- visual tests,

- rub resistance,

- adhesion, and tensile strength


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RESULT ANALYSISPRINTABILITY PERFORMANCE OF BIOBASED MATERIALS

1. DOT GAIN

2. TONE REPRODUCTION

3. OPTICAL/REFLECTIVE DENSITY

4. DYNE LEVELS

5. TYPE QUALITY

6. DOT SHAPE

7. SPECULAR GLOSS

8. RUB RESISTANCE

9. INK ADHESION

10. RUNNABILITY

11. TENSILE STRENGTH

12. DIRTY PRINT

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RESULT ANALYSIS (Continued….)


1. DOT GAIN

- The largest dot gain occurred between 35% to 55% for all the films.

- Measurement using : Xrite 528 system 29.3% gain at 40 % dot

24.7% gain at 40 % dot

29 % gain at 40 % dot

27.9% gain at 40 % dot

31.2 % gain at 40 % dot

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2. TONE REPRODUCTION

- No difference between the materials, hard to compare.

- White PLA- smooth curve- helps in compensation of dot gain in

prepress.


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3. OPTICAL/ REFLECTIVE DENSITIES

- Density standard is 1.4 for black ink on film products using narrow

web. Instrument: Xrite 528 Spectrodensitometer

- All of the densities printed had higher densities than the standard.


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4. DYNE LEVELS

-Natural dyne level of clear PLA is about 38 and the white PLA had a

dyne level of about 36.

- PET had about 39 dynes,

- OPP had about 37 dynes,

- OPS had about 37 dynes.


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5. TYPE QUALITY

-Quality images – visual comparison

- Using ImageXpert system.

- White PLA, PET, OPP, clear PLA and OPS films.

BEST.................................................WORST


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6. DOT SHAPE

- To determine the roundness of the five percent dots on each film.

- The dot roundness was defined by the ratio of the circumference of

a circle with the same average radius to the perimeter length of the

dot.

- Ideal number to achieve is 1.

- PET- highest dyne level corresponding to 1.

White PLAClear PLAPET OPP OPS


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7. RUB RESISTANCE

- TMI Ink Rub Tester.

- 2 x 4 in & 2 ½ x 6 in strips

- four-pound test block on top of the based

- 100 cycles at 42 cycles per minute

- Visual test was performed

- Clear PLA film had the poorest rub resistance.

- Closely followed by the white PLA film.

- The OPS film had the next worse rub resistance.

- The OPP and PET films had the best rub resistance.


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8. DIRTY PRINT


White PLAClear PLA PETOPP OPS

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SUMMARY

GLOSS WHITE PLA

CLEAR PLA

PET OPP OPS

Dyne 4 2 1 3 3

Dot gain 4 1 5 3 2

Tone Reproduction

1 4 3 2 5

Density 1 2 5 3 4

Type Quality 1 4 2 3 5

Dot Shape 2 2 1 3 4

Specular gloss

2 1 4 5 3

Rating: 1- Best to 5 -Worst

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SUMMARY continued

GLOSS WHITE PLA

CLEAR PLA

PET OPP OPS

Rub resistance

4 5 1 2 3

Ink Adhesion 4 5 1 2 3

Tensile Strength

2 1 3 4 5

Dirty Print 1 2 3 4 5

Average Score

2.36 2.64 2.64 3.09 3.82

Rating: 1- Best to 5 -Worst

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It seems that the white and clear PLA films are most comparable to

the PET film.

Even though the ink was formulated for pp and pet, the white and

clear PLA out performed OPP in the majority of the printability and

runnability tests.

The white PLA film out performed the PET film, which was also white.

The clear PLA film performed equally as well as the PET film.

If the PLA films used custom formulated ink, they would have likely

out performed all of the films.

Natureworks recommends using Akzo nobel's hydrokett3000 or

hydrofilm 4000 water-base inks for good ink adhesion.

CONCLUSION

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Given time, PLA may replace some of the most common plastic films

used in the food industry.

It is difficult for a new film to break into a market that has twenty or

more years of established film lines.

Advancements are continuously being made to the structure of PLA to

enable for using in more applications.

The PLA films are already ideal for many of the same applications

other petroleum-derived films are used for today.

CONCLUSION (continued)

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Biobased plastics have experienced fast growth in the past decade.

Numerous factors influence future biobased material technology

developments – political & legislative changes, consumer demands,

global request especially for the food & energy resources.

In India, a biobased packaging material working group can be formed.

That will speed up the process of knowledge exchange between

academic worlds, the industry, government institutions & finally

commercialize the product to reach the end user.

SCOPE FOR FUTURE WORK

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1. J. Jacobson, M. Keif, X. Rong, J. Singh And K. Vorst, (2009) “Flexography

Printing Performance of PLAFilm”,Cal Poly State University

2. Andrew Seecharan (2009) “Energy Cure (EC) Flexographic Inks for PLA Film”

3. Rafael A. Auras, Loong-Tak Lim, Susan E. M. Selke, Hideto Tsuji,(2010)

“Poly(lactic Acid): Synthesis, Structures, Properties, Processing, and

Application” , Wiley publications

4. Dr. Semih Ötles, Serkan Ötles (2004) “Biobased packaging materials for the

food industry – Types of Biobased Packaging Materials”.

5. Walle, van der G.A.M, Koning, de G.J.M., Weusthuis, R.A. and Eggink, G.

“Properties, modifications and applications of biopolyesters In: Advances in

Biochemical Engineering/Biotechnology” Volume 71, Steinbuchel, A. and Babel,

W. (Eds.), Springer Verlag

6. David E. Henton, Patrick Gruber, Jim Lunt, and Jed Randall, (2005) “Polylactic

Acid Technology”.

REFERENCES

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7. http://graphics.tech.uh.edu/courses/3350/materials/Offset_Inks.pdf

8. http://www.accudynetest.com/adt_introduction.html

9. http://en.wikipedia.org/wiki/Soy_ink

10. http://www.ehow.co.uk/list_7476524_properties-soy-ink.html

11. http://en.wikipedia.org/wiki/Polylactic_acid

12. http://www.creativepro.com/article/eco-friendly-inks

13.

REFERENCES

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THANK YOU

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