Patent Application
20250145339
The present invention relates to an induction heat sealable closure liner or lidding that is configured to be fully recyclable in a paper recycling stream.
Liners or seals have been used on containers for many years to prevent leakage or contamination and to increase the shelf life of the substance or product held within the container. For example, liners are used on containers for cosmetics, foods, drinks, medicines and other items in the form of liquids, creams, gels, particulates, powders and other substances. Liners for this purpose are typically placed over the opening on the container or, in some instances, within the cap on the container before placing the combined cap and liner over the opening (mouth) of the container.
It is common practice to attach the liner to the mouth (surrounding the opening) of the container by the process of induction heat sealing. This requires that a metal foil layer be present in the liner structure to transfer heat to a lowermost heat sealant layer for bonding the liner to the container mouth. The bonding is temporary, allowing the customer (user) to remove the liner by peeling it off the mouth of the container. The liner thus serves multiple purposes, providing a tamper-proof seal, as well as preventing leakage, contamination, or spoilage of the product in the container.
Induction heat seal liners require a metal layer for heat transfer, and in prior art liners this metal layer prevents recycling of the liner in a paper or plastic recycling stream. The heat sealant and the use of various types of plastic film or resin extruded layer(s) and other layers in the liners such as coatings and wax in a mixed composite structure, also prevents recycling of the liner in a single recycling stream. As a result, the liners generate non-recyclable trash even if the cap and/or container can be recycled. Also, prior art liners may delaminate during the peeling step, leaving residue of the liner on either or both of the cap and/or container, further impeding recycling of these structures.
Thus it would be desirable to provide a fully recyclable induction heat sealable liner or lidding structure, suitable to recycling in a paper recycling stream, while also providing the desired characteristics of providing tamper evidence, barrier properties to resist spoilage of the product, and leak resistance, while resisting delamination during removal from the container mouth.
The liner of the present invention provides a simple, cost-effective solution that will allow consumers to recycle the entire liner in a paper recycling stream. As a result, manufacturers currently selling products without liners will now be able to include liners on their containers and provide a totally recyclable container package, including the container, cap and liner (each recyclable in a respective plastic or paper recycling stream), while providing the benefits that liners provide, including maintaining product integrity and barrier properties, extending shelf life, providing tamper evidence, preventing leakage, preventing products from being contaminated and/or damaged by consumers sampling the products, and/or otherwise creating an un-saleable product due to leakage, contamination or damage.
In one embodiment of the invention, an induction heat-sealable closure liner or lidding configured for recycling in a paper recycling stream, the liner or lidding having a composite layer structure comprising: a paperboard layer; a metal foil layer for inductive heating; and a heat sealant coating; wherein the paperboard layer is white paperboard or brown paperboard, for white paperboard the paperboard layer has a pulp weight of at least 85% by weight based on the total weight of the composite layer structure, and for brown paperboard the paperboard layer has a pulp weight of at least 90% by weight based on the total weight of the composite layer structure, the remaining weight percent comprising the metal foil layer and heat sealant coating are configured for repulping of the composite layer structure to achieve a pulp yield of at least 80% by weight of the paperboard layer for white paperboard and at least 85% for brown paperboard, such that the total composite layer structure is recyclable in a paper recycling stream.
In one embodiment of the invention, the heat sealant layer comprises one or more of: a solvent-based heat sealant coating, a water-based heat sealant coating, or a resin-based heat sealant coating that is melted to form the coating.
In one embodiment of the invention, the heat sealant coating is a solvent-based heat sealant coating having a basis weight in a range of 2.5 to 4 pounds per ream where a ream comprises 3000 square feet.
In one embodiment of the invention, the heat sealant coating is a resin-based heat sealant coating having a basis weight in a range of 14 to 20 pounds per ream where a ream comprises 3000 square feet.
In one embodiment of the invention, the metal foil layer has a basis weight in a range of 10 to 55 pounds per ream, where a ream comprises 3000 square feet.
In one embodiment of the invention, the metal foil layer has a thickness of 1 mil or less.
In one embodiment of the invention, the metal foil layer has a thickness of no greater than 0.5 mils.
In one embodiment of the invention, the paperboard comprises white paperboard having a basis weight in a range of 90 to 350 pounds per ream where a ream comprises 3000 square feet, and the heat sealant coating is solvent-based.
In one embodiment of the invention, the composite layer structure comprises:
In one embodiment of the invention, the paperboard comprises brown paperboard having a basis weight in a range of 150 to 550 pounds per ream where a ream comprises 3000 square feet, and the heat sealant coating is solvent-based.
In one embodiment of the invention, the composite layer structure comprises:
In one embodiment of the invention, the paperboard comprises white paperboard having a basis weight in a range of 185 to 440 pounds per ream where a ream comprises 3000 square feet, and the heat sealant coating is resin-based.
In one embodiment of the invention, the composite layer structure comprises:
In one embodiment of the invention, the paperboard comprises brown paperboard having a basis weight in a range of 295 to 695 pounds per ream where a ream comprises 3000 square feet, and the heat sealant coating is resin-based.
In one embodiment of the invention, the composite layer structure comprises:
In one embodiment of the invention, the total liner thickness is in a range of 11 mils to 110 mils.
In one embodiment of the invention, the total liner thickness is in a range of 12.6 to 14.8 mils.
In one embodiment of the invention, the paperboard layer has a thickness in a range of 12 to 14 mils; the metal foil layer has a thickness in a range of 0.35 to 0.5 mils; and the heat sealant is a solvent-based heat sealant coating having a thickness in a range of 0.2 to 0.3 mils.
In one embodiment of the invention, the liner further includes an adhesive boding the paperboard layer to the metal foil layer.
In one embodiment of the invention, the paperboard layer comprises wood fiber or other cellulose fiber.
In one embodiment of the invention, the paperboard layer is comprised of greater than 80% cellulosic fiber.
In one embodiment of the invention, the paperboard layer has a thickness range of 10 to 100 mil (0.010 to 0.100 inch); the metal foil layer has a thickness range of 0.25 to 3.5 mil (0.00025 to 0.0035 inch); and the heat sealant is a heat seal coating having a thickness in a range of 0.2 to 6 mil (0.0002 to 0.006 inch).
There is shown in the drawings one or more exemplary embodiments, it being understood however, that the invention is not limited to the specific articles and methods disclosed. Additionally, like reference numerals represent like items throughout the drawings.
Referring to
The liner 100 may be used on a variety of containers for holding various food, cosmetic, confectionery, household and other products in the form of liquid, solid or paste (semi-solid) substances 4. The container is typically made of plastic, but may be glass, molded fiber/pulp, or metal (e.g., aluminum).
The liner 100 has an integral one-piece multi-layer construction having a liner thickness 100t in a direction T transverse to opposing top planar surface 101 and bottom planar surface 103 respectively (as shown in
The container 20 is filled with a product 4 through the opening 22 (or through another orifice of the container that communicates with the chamber 23) and the liner 100 is sealed around the opening 22, allowing the customer to remove the cap 40 and peel off the liner 100 to access the product. The liner 100 can be used with different types of containers 20 and different types of closures or caps 40, such as a threaded cap (
In one embodiment, the paperboard layer thickness 110t and/or metal layer thickness 130t of the liner eliminates any need for a further barrier layer, membrane or material to be laminated to the liner, while preventing access, leakage, and contamination through the liner.
In the present embodiment, the liner 100 is a generally disc-shaped (circular) article having a diameter D, with parallel and opposing top 101 and bottom 103 planar faces each with a matching circular circumference 100c, and a transverse liner thickness 100t which is relatively thin compared to the diameter D (note in
In one embodiment, the liner 100 includes one or more tabs 118 around the circumferential edge 100c (see
The liner 100 is affixed by a heat seal bond (via bottom heat seal coating 140) to an area (here annular lip 22L) around the opening 22 of the container 20, thus completely covering and sealing around the opening. The liner can then later be peeled off (by the ultimate purchaser/consumer) to access the contents 4 of the container. Typically, the liner 100 can be peeled off using a fingernail or, in embodiments having a tab 118, by grasping the tab between the thumb and forefinger to facilitate removal of the liner 100 from the opening 22 of the container 20.
In some embodiments the heat seal bond layer 140 may be limited to a perimeter area of the liner, as this is all that is required for sealing around the opening of the container. In other embodiments, the heat sealant layer may cover additional surface areas and/or the entire lowermost surface 103 of the liner or lidding.
In one embodiment, the thicknesses in the transverse direction T of the paperboard layer 110 and/or of the metal foil layer 130 do not permit venting (the release of gas from within the container to the exterior) to occur through the liner 100. Thus, the liner 100 is a non-venting liner. More particularly, the metal and paper layers area of the liner 100 do not permit a free flow of air or gas from inside the container 20 to the outside of the container 20, or vice versa.
The container 20 may be composed of any materials capable of providing a tamper evident, removable induction heat seal secured to the container and that are suitable for storage of the substance being sold. It may also provide barrier properties as desired. The container 20 may be composed of a polymer material, for example of polyethylene PE, polypropylene PP, polyethylene terephthalate PET or polyvinyl chloride PVC. In another embodiment, the container 20 is glass, molded fiber/pulp, or metal (e.g., aluminum). Once the liner 100 has been secured over the opening 22 of the container 20, a removable cap 40 is secured to the container 20 over the liner 100.
The barrier properties of the liner 100, measured e.g., in terms of oxygen transmission rates (OTR) or moisture vapor transmission rates (MVTR)) can be controlled by adjusting (reducing or increasing) the materials and dimensions of the various layers in the liner 100. In the present embodiment, the required barrier properties of the sealed container are maintained by the paper layer(s) 110 and metal layer 130.
As used herein, the paper or paperboard layer 110 is a sheet of cellulose material, including those materials typically used in the liner industry and referred to as paper, paperboard, board and pulp. The sheet may comprise wood fiber or other cellulose fibers, and may further include fillers, binders, chemical treatment and surface coatings, and may be made of virgin or recycled materials.
The paperboard layer 110 may be a sheet comprising a heterogeneous mixture of plant material such as cellulose, hemi-cellulose, lignin, etc. and filling material such as china clay, calcium carbonate, etc., chemical additives such as rosin, alum, starch, etc. depending on the grade of the paper. Typically, the paperboard layer is comprised of greater than 80% cellulosic fiber, together with one or more binders, optical brighteners, coatings and/or other chemicals.
In various embodiments, the thicknesses of the respective layers may comprise:
The liner of the present invention provides a simple, cost-effective solution that will allow consumers to recycle the entire liner 100 in a paper recycling stream. As a result, manufacturers currently selling products without liners will now be able to include liners on their containers and provide a totally recyclable container package, including the container, cap and liner (each recyclable in a respective plastic or paper recycling stream), while providing the benefits that liners provide, including maintaining product integrity and barrier properties, extending shelf life, providing tamper evidence, preventing leakage, preventing products from being contaminated and/or damaged by consumers sampling the products, and/or otherwise creating an un-saleable product due to leakage, contamination or damage.
The composition, structure and amount of the non-paper components of the liner are controlled in order to achieve both repulpability and recyclability. In general, these materials are considered contaminants in the paper recycling stream, and may degrade the repulping process (interfere with grinding, rewetting or the filtering process) so as to lower the pulp yield.
The amount of metal foil in the liner structure must be limited. While depending on the overall liner dimensions and other layer thicknesses, a suitable thickness for the foil layer is generally 1 mil or less.
The film layers in one embodiment are limited to the paperboard layer and the metal foil layer. Additional film layers (e.g., either as heat sealant film or barrier film) if used should be of a thickness no greater than 50 gauge (0.0005 mils or 12 microns) and of characteristics that do not negatively impact the repulping operation, i.e., create undue difficulty in grinding the structure and/or difficulty in blending (for pulping). An adhesive coating (e.g., to bond the metal foil layer to the paper board layer) and a heat sealant coating (to bond the liner to the container rim) are allowed, as they are sufficiently thin (as described herein on a basis weight) so as not to substantially interference with the repulping and recycling processes.
A typical solvent-based heat sealant (HS) (known as a universal sealant) can be used as a coating for sealing the liner to bottles made of polyethylene, polyester, and/or polypropylene. Ethyl Acetate (EA) is a suitable solvent carrier, as are Methyl Ethyl Ketone (MEK), and/or a mix of EA and MEK. Depending on the coating chemistry, a suitable solvent carrier is water (aqueous).
Resin-based heat sealant (HS) coatings can also be a universal sealant (i.e., for sealing to various bottles made of polyethylene, polyester, polypropylene, and even glass). The resin-based heat sealant coating can be co-extruded in one or more coating steps (as long as the basis weight remains as required for the repulping in relation to the overall liner basis weight, pulp basis weight, and Al foil basis weight for the liner structure are met). For example, for a 20 lbs./ream basis weight of the resin-based HS coating, this can be a co-extruded structure of 12 lbs./ream of ethyl vinyl acetate (EVA) and 8 lbs./ream of ethylene acrylic acid (copolymer resin) where EVA is the heat sealant contact surface to the bottle and the EAA helps create a stronger bond to the Al foil during the application of the HS coating to the foil by the means of resin extrusion (i.e., known as co-extrusion of two resins). The resin-based coating can be applied by other methods such as slot die resin-coating.
For a white paperboard-based liner with a solvent-based HS coating the basis weight ranges of materials are:
For a brown paperboard-based liner with a solvent-based HS coating the basis weight ranges of materials are:
For a white paperboard-based liner with a resin-based HS coating the basis weight ranges of materials are:
For a brown paperboard-based liner with a resin-based HS coating the basis weight ranges of materials are:
The entire paperboard-based composite liner structure is subject to a repulping process which includes grinding, blending and disintegration in order to determine a weight percentage of repulpable paper material, i.e., to achieve a pulp yield of at least 80% by weight of the paperboard layer for white paperboard and at least 85% by weight of the paperboard layer for brown paperboard, such that the total composite liner structure is recyclable in a paper recycling stream. Large non-paper components such as aluminum foil and beat sealant are removed by filtering (through a screen). Ink particles are removed by washing and flotation. The pulp yield (accept rate of at least 80% by weight of the paperboard layer) is then measured by weight. The test protocols for repulping and the recycling are more specifically described in the following section.
The following repulping and recycling test protocols can be used in accordance with the present invention. These test protocols were established by a joint alliance of the Fibre Box Association (FBA) and the American Forest & Paper Association (AF&FPA) which issued a “Voluntary Standard For Repulping and Recycling Corrugated Fiberboards Treated to Improve Its Performance in the Presence of Water and Water Vapor” (publicly available at www. Fibrebox.org, revised Aug. 16, 2013). Western Michigan University (WMU) has a WMU Paper Pilot Plant, 4651 Campus Drive, Kalamazoo, MI 49008, USA, which is one of several certified laboratories for conducting the repulping and recycling test protocols.
Disposing of treated corrugated that cannot be recycled can be a financial and logistical burden on the supply chain for these packages. While treated corrugated containers are the most practical and cost-effective way to ship produce, meats, seafood and other items, certain treatments to improve performance in the presence of water or water vapor have made recycling difficult. It is desirable from both increased recyclable fiber availability and environmental standpoints to encourage the development of treated corrugated that may be recycled into other paper products using common mill technology.
The corrugated products industry recognizes the solution to this problem should be industry-wide, primarily because the recycling mills cannot effectively identify all treatments specific to particular companies. Different treatment systems may have different impacts on recycling processes; mill operators have even considered some to be highly detrimental.
To address and evaluate the technical as well as the educational aspects of this objective, a joint committee was formed consisting of the Fibre Box Association and the American Forest & Paper Association (AF&PA) members who represented manufacturers of containerboard, corrugated containers, and others who utilize recovered corrugated container fiber. Their work was to evaluate the repulpability and recyclability of moisture barrier treatments or coatings applied to liners or combined corrugated board in an effort to establish a minimum threshold for moisture barrier treated or coated corrugated that is intended, and labeled, to be recyclable into new containerboard and other paper products.
After numerous meetings, tests, and legal reviews, the committee developed this Voluntary Standard for repulpability and recyclability. The Standard contains a test method and test report. Box manufacturers can register treatments and coated board combinations with the Fibre Box Association if they do the following:
Part 1 determines the repulpability of treated corrugated by determining fiber-on-fiber yield when only the treated corrugated is processed in accordance with this standard (Appendix A).
Part 2 determines the recyclability of the treated corrugated by evaluating its effect on mill operations and finished products when it is added to untreated corrugated in the amounts specified (Appendix B).
Fiber-on-fiber yield is the amount of fiber that remains after the processing action, expressed as a percentage of the fiber present in the material to be tested.
Handsheets are sheets made from a suspension of fibers in water in an operation, whereby each sheet is formed separately by draining the pulp suspension on a stationary sheet mold.
OCC (Old Corrugated Containers) is a grade of waste paper comprised of untreated corrugated boxes that have been used for the purpose for which they were originally purchased and have subsequently been source separated from other waste.
Recyclable means used paper, including in-plant and post-consumer waste paper and paperboard, which is capable of being processed into new paper or paperboard using the process defined in this standard.
Recyclability test sample consists of a minimum of 20% (by weight) of the treated corrugated to be tested and the remainder of the untreated corrugated.
Repulpable means the test material that can undergo the operation of re-wetting and fiberizing for subsequent sheet formation, using the process defined in this standard.
Treated corrugated is the combined board or boxes that have been subjected to a specific treatment for the purpose of improving its performance in the presence of water or water vapor. The level of treatment used in the test must be equal to or greater than the level of treatment to be used in the field.
Untreated corrugated/control is the same combined board or boxes that have not been subjected to any treatment to improve performance in the presence of water or water vapor.
Preliminary Analysis: Before beginning the test protocol, determine the moisture content of the treated corrugated sample.
A 100% charge of treated corrugated is repulped in a Modified Waring Blender (as shown in
Mix a minimum of 20% treated corrugated and the remainder of the same untreated corrugated in a laboratory-scale pulper at pH 7 (±0.5 pH) and 125° F. (±10°). This is the recyclability test sample. As a control, a charge of 100% of the same untreated corrugated is also pulped using identical conditions. Each pulped material is passed through (in succession) a pressure screen equipped with a basket with 0.062 inch holes, the same screen or a similar screen equipped with a basket with 0.010 inch slots and a reverse centrifugal separator under conditions specified in the procedure Handsheets (3.0 gram) are made from the final stage (cleaner) accepts. For each batch tested, the handsheets are pressed and dried with heat and tested for product performance properties. Properties include slide angle, short span compressive strength (STFI), bursting strength and water drop penetration, using the established TAPPI official test methods. Appearance tests shall be done according to the procedure outlined in Appendix B. The final sheets shall have no more than 15 spot counts, or not exceeding 30% greater counts than the control, with an area of ≥0.4 mm2 area, averaged over 3 sheets. The properties and appearance of the handsheets from the recyclability test sample and untreated corrugated tests will be compared. Detailed procedures for recyclability are given in Appendix B.
Treated corrugated satisfying all of the requirements of the voluntary standard will be regarded as repulpable and recyclable. There are three general performance requirements: fiber yield, operational impact and product requirements.
Fiber yield from the repulpability test must be at least 80% based on the total weight, or 85% based on the bone dry fiber charge to the pulper.
Operational impact is acceptable if:
Note: Conventional wet strength linerboard and corrugating medium, by definition, is considered to be not repulpable/recyclable unless it has passed the tests in this Voluntary Standard. Wet strength containerboard may not be substituted for standard kraft or recycled containerboard without being re-certified at a lab and re-registered with the FBA. Conventional water resistant corrugating adhesives may be substituted for lower grades of moisture resistant or domestic corrugating adhesive; however, the substitution of proprietary or special corrugating adhesives with known extra water resistance would require recertification by a lab and re-registration with the FBA.
However, if a different company purchases treated containerboard or treatment chemicals, or performs production functions on purchased sheets, or markets treated materials under the name of a company that has not registered the use of these treated materials, that company must register their use of these treated materials with the FBA. The same restrictions regarding not exceeding the treatment-to-fiber ratio and the application on standard kraft or recycled containerboard continue to apply. Companies selling registered treatments or treated materials to companies that will be re-selling previously registered treatments or treated materials are required to provide sufficient technical information so that the company purchasing the treatments and/or the treated containerboard for resale can comply with the treatment-to-fiber ratio maximums and that the application is on standard kraft or recycled containerboard. (See the “Option B” registration procedure on pages 13-14 of this document.)
Multiple trade names may be used for the same registered treatment as long as the treatment is applied or the treated materials are combined so that the previously approved, or lower, treatment-to-fiber ratio is not exceeded and the application is on standard kraft or recycled containerboard. All trade names for a given registered treatment or treated material must be reported to the FBA on a continuing basis with additions, deletions, and changes reported within 30 days of implementation. Identical trade names may not be used for different registered treatments or treated materials. However, a common “Family Name” with varying prefixes and/or suffixes is allowed.
The objective of having all sellers of registered treatments or treated materials report all relevant trade names is to allow the FBA to know who is producing treatments and treated materials and how they may be identified in the marketplace. This information is critical to permit the FBA to facilitate tracing any complaints from containerboard mills back to a box plant.
If the repulpable/recyclable certification marking (as shown below) is used, it must clearly appear on the box with the box manufacturer's name and location.
See Appendix D for guidelines on use of this symbol.
To determine the repulpability of corrugated board. (Note that the Repulpability Test must be run at least twice on the treated corrugated board. The sample must pass two out of three tests.)
Percentage of rejects to the nearest 0.1%
Note: Both the Control sample and the sample of Treated and Untreated test material must be tested at least twice and must pass two out of three tests.
2.00 grams÷dry sheet weight×500=mis of slurry to use for test sheets.
The Voluntary Standard (as described above) can be used for both white paperboard-based liners and brown paperboard-based liners as defined herein. The white paperboard structure is also referred to as SBS, which stands for Solid Bleached Sulfate (one of the types of white paperboard). For Part I, the Repulpability Process, a minimum pass/fail limit is 80% accepts, 20% rejects. For Part II, the Recycling Process, the pulper loading is 85% control material (white or brown paperboard itself) and 15% test material (complete liner according to the invention).
While the invention has been described and illustrated in various terms and embodiments, the scope of the invention is not intended limited thereby and other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the scope of the appended claims.
