What is PVA Polymer: Production, Use, Recycling and Environmental ImpactA polymer now omnipresent in the production of commonly used and technically relevant objects, but with difficult environmental implicationsIntroduction to PVAVinyl polyacetate (PVA) is a synthetic polymer with excellent water solubility properties, making it a material of choice in several industrial and commercial applications. Its versatility comes from its ability to form transparent films, its resistance to organic solvents and oils, as well as its non-toxicity, making it safe for use in medical and food applications.PVA ProductionProduction processThe production of PVA begins with the polymerization of vinyl acetate in the presence of a catalyst. The process can vary, but commonly includes initiation, propagation and termination steps, leading to the formation of PVA polymer chains. Subsequently, the polymer is purified and transformed into various forms for commercialization, such as powder, granules or aqueous solutions.World Production DataGlobal PVA production is influenced by several factors, including demand in key sectors such as packaging, textiles, construction and agriculture. Asia is the largest producer of PVA, particularly China, which alone contributes significantly to global production capacity. Other Asian countries such as Japan, South Korea and India are also major producers of PVA.Main PVA Producing CountriesChina: China is the leader in PVA production, with estimated production varying widely, but which can exceed one million tonnes per year, depending on domestic demand and exports.Japan and South Korea: These countries are known for their high quality PVA, with combined production reaching hundreds of thousands of tons per year.India: India is emerging as a major PVA manufacturing hub, with growing production capacity, aiming to cater to both the domestic and export markets.Growth TrendThe growth trend in PVA production reflects the increase in demand in various application sectors. Production is expected to increase in the coming years, with a compound annual growth rate (CAGR) that may vary based on various economic, technological and environmental factors.Applications and Uses of PVAPolyvinyl Alcohol (PVA) is a versatile polymer with a wide range of applications and uses in different industrial sectors, thanks to its unique properties such as solubility in water, biodegradability (under certain conditions), chemical and mechanical resistance, and l 'non-toxicity. Below, we delve into the main applications and uses of PVA.Textile industryIn the textile industry, PVA is used as a softening and finishing agent to improve the strength and flexibility of yarns and fabrics. It also serves as a support fiber that can be easily removed after the weaving process, thus improving production efficiency.PackagingPVA is widely used in the packaging industry, in particular in the production of water-soluble films and biodegradable packaging, such as liquid detergent capsules. This packaging dissolves completely when in contact with water, reducing plastic waste.Building and ConstructionIn construction, PVA is used as a component in mortars, plasters, and sealants to improve their adhesive properties, flexibility, and moisture resistance. It is also used in paints and coatings to increase their durability and resistance to chemicals.Paper IndustryPVA improves the mechanical strength and gloss of paper and cardboard, finding application in the production of high-quality printing paper and food packaging. It also acts as a binding agent in inks and paints, improving print quality.ElectronicsIn the electronics field, PVA is used in liquid crystal display (LCD) components and other electronic devices for its optical and insulating properties. It serves as an alignment layer for the liquid crystals, which is essential for image quality.Pharmaceutical and Medical SectorPVA finds use in medical and pharmaceutical applications, including the manufacture of capsules and soluble films for controlled drug release, as well as in soft contact lens materials and hydrogels for biomedical applications, due to its biological compatibility and non-toxicity.AgricultureIn agriculture, PVA is used to produce biodegradable agricultural films that help conserve soil moisture and reduce herbicide use. These films degrade naturally, reducing the environmental impact of intensive agriculture.Personal Care ProductsPVA is used in the production of personal hygiene products, such as shampoos and shower gels in solid form, which dissolve in water, offering a sustainable solution and reducing the use of plastic.PVA recyclingRecycling PVA presents challenges due to its solubility in water, but there are both physical and chemical methods for its treatment. The research focuses on improving recovery techniques and developing biological processes to degrade PVA more efficiently and sustainably.Recycling TechniquesMechanical Recycling: This method involves grinding or shredding used PVA to reuse it directly in the production of new items. However, its effectiveness is limited by the quality of the recycled PVA, which can be compromised by thermal or mechanical degradation.Chemical Recycling: This technique transforms PVA into monomers or other chemical compounds through processes such as alkaline hydrolysis or alcoholysis. These monomers can then be reintroduced into the production cycle. Chemical recycling has the advantage of being able to recover PVA from mixtures and composites, overcoming some of the limitations of mechanical recycling.Biological Recycling: Uses microorganisms capable of degrading PVA into simpler compounds, such as water and carbon dioxide, or into other useful intermediates. Research in this field is focused on the identification and engineering of specific bacterial strains or enzymes that can carry out this transformation efficiently.Solubility in Water and BiodegradabilityPVA's water solubility is both a blessing and a curse. On the one hand, it facilitates its removal from fabrics or other materials in industrial processes; on the other hand, it makes waste management more complicated, especially in contexts where PVA enters aquatic environments.The biodegradability of PVA varies depending on its degree of hydrolysis and composition, with certain grades of PVA degrading more easily under specific environmental conditions.Environmental impactThe environmental impact of Polyvinyl Alcohol (PVA) in wastewater deserves in-depth analysis, considering both the chemical properties of PVA and the dynamics of water treatment plants.PVA, although generally considered less harmful than other synthetic polymers, presents specific difficulties once it enters the water system, mainly due to its solubility in water and its variable biodegradability.Water Solubility and Wastewater TreatmentPVA is highly soluble in water, meaning it can easily leach into aquatic ecosystems through wastewater. This characteristic, while on the one hand facilitating the use of PVA in applications such as soluble detergent capsules, on the other hand makes its removal from wastewater discharges more complex than insoluble polymers, which can be filtered or sedimented with processes standard physiques.Biodegradability of PVAThe biodegradability of PVA varies depending on the degree of polymerization and hydrolysis. Some forms of PVA are more easily degraded by microorganisms present in water treatment plants or natural environments. However, the biodegradation process can be slow and incomplete, leading to the accumulation of PVA residues in water, with potential negative effects on aquatic organisms.Effects on Aquatic EcosystemsThe presence of PVA in wastewater and water bodies can affect water quality and the health of aquatic ecosystems in various ways:Oxygen Reduction: The biodegradation of PVA by microorganisms consumes dissolved oxygen in the water, potentially leading to hypoxic (low oxygen) conditions that can harm aquatic life.Effects on Aquatic Flora and Fauna: PVA and the intermediate products of its degradation can have toxic effects on some aquatic organisms, influencing the growth, reproduction and survival of fish, invertebrates and aquatic plants.Interference with Treatment Processes: High concentrations of PVA in wastewater can interfere with biological treatment processes, reducing their effectiveness and increasing operating costs.Mitigation StrategiesTo reduce the environmental impact of PVA in wastewater, a combination of approaches needs to be taken:Improved Treatment Processes: Develop and implement advanced water treatment technologies that effectively remove PVA and other organic contaminants.Innovation in Product Design: Design products that contain PVA with greater biodegradability or that release less PVA into wastewater.Regulation and Monitoring: Establish strict limits for the concentration of PVA in industrial wastewater and regularly monitor wastewater to ensure compliance with regulations.The case of PVA detergent capsules for washing machinesThe environmental impact of PVA (polyvinyl alcohol) detergent capsules focuses primarily on their water solubility and biodegradability, as well as production and disposal. These aspects directly influence aquatic and terrestrial ecosystems, waste management, and the consumption of natural resources.Environmental Impact of PVA Detergent CapsulesBiodegradability: Although PVA is technically biodegradable, the speed and efficiency of this process can vary greatly depending on environmental conditions, such as the presence of specific microorganisms and temperature. If not managed properly, capsules can contribute to microplastic pollution in aquatic ecosystems.Water Solubility: The main characteristic of PVA is its solubility in water, which allows the detergent capsules to dissolve completely during the wash cycle. However, this also means that PVA residues can end up in wastewater, where their complete biodegradation is not always guaranteed, potentially affecting water quality and aquatic life.Resource Consumption: The production of PVA capsules requires natural resources, including oil and gas for the production of vinyl acetate monomer, and energy for the polymerization and packaging processes. This contributes to the carbon footprint of the product.Waste Management: Even if the capsules themselves dissolve, secondary packaging can generate additional waste, especially if it is not recyclable or biodegradable.ConclusionsPVA plays a crucial role in multiple industries due to its unique properties. However, it is critical to address issues associated with its production, use and disposal to mitigate environmental impacts.Promoting recycling and developing sustainable alternatives will be vital to ensure the use of PVA remains sustainable in the long term.
SEE MORE
RFID Labels, NFC Tags, and Compostable Freshness Indicators: Frontiers and Sustainable Innovation for Food and Pharmaceutical PackagingTowards intelligent and fully compostable packaging: challenges, solutions and perspectives for the integration of sustainable electronic devices into organic waste collection flows by Marco Arezio In recent decades, the packaging industry has undergone a veritable revolution . While packaging was once simply a means of containing, protecting, and transporting goods, today it has become a vehicle for information, security, interaction, and, increasingly, environmental sustainability. The advent of the Internet of Packaging (IoP) has enabled the packaging of food, pharmaceutical, and consumer goods to be enhanced with smart labels: RFID, NFC tags, and freshness indicators are now well-established features on the production lines of global companies, offering new levels of traceability, authenticity, and quality control. However, this push toward digital innovation is accompanied by an even more pressing challenge: managing the end-of-life of packaging containing electronic components without increasing environmental impact, integrating these devices into the virtuous cycle of the circular economy. Thus, smart packaging today finds itself at a crossroads: become truly sustainable, or risk becoming a new disposal problem. Smart Packaging and New Traceability and Safety Needs The spread of smart packaging arose from the need for ever-increasing information on a product's life cycle: where it comes from, how it's stored, and whether it's been handled correctly throughout the supply chain. RFID labels and NFC tags allow for unique product tracking, facilitating both logistics and inventory management, while freshness indicators and environmental sensors can detect any changes in temperature, gas, or humidity in real time, flagging alterations that could compromise the safety or quality of the food or drug. These technologies are now essential for companies seeking to reduce waste, ensure consumer safety, and meet market demands for transparency. However, the very presence of electronic components, if not properly designed, can compromise the packaging's ability to be recycled or composted, contaminating organic waste streams and posing a potential environmental risk. Environmental issues of traditional electronic devices The enthusiasm for smart packaging still faces limitations imposed by the use of conventional materials in the manufacture of electronic labels. These devices are typically constructed using plastic substrates such as PET or PP, conductive tracks made of copper, silver, or aluminum, silicon microchips, and synthetic adhesives. None of these materials can be considered truly biodegradable or compostable; in fact, they often release microplastics and heavy metals. If dispersed in organic waste streams, they can degrade the quality of the compost produced, posing a risk of contamination for soil and crops. For this reason, European (EN 13432) and American (ASTM D6400) regulations are imposing increasingly stringent criteria not only for packaging materials , but also for all functional components, including electronics, requiring complete compostability for everything accompanying the product at the end of its life cycle. The architecture of a compostable smart label: innovative materials and production processes Scientific and technological research has responded to these new environmental challenges with unprecedented effort, leading to the development of a new generation of labels and sensors that are designed from the ground up to be compostable. The foundation of these solutions lies in bio-based substrates, i.e., supports made from renewable raw materials such as PLA (a polymer obtained from the fermentation of plant sugars), regenerated cellulose, or PHB, a microbial biopolymer . These materials are not only compatible with modern electronic printing techniques, but also degrade safely both in industrial composting facilities and, in some cases, even in domestic environments. The second revolution concerns the materials used for conductive tracks and circuits: instead of traditional heavy metals, carbon-based inks, graphite, or carbon nanotubes, and organic conductive polymers such as PEDOT:PSS or polyaniline, all capable of degrading during composting, are gaining ground. "Green" versions of metal conductors—such as encapsulated silver nanoparticles—are also finding application, albeit with some limitations in terms of cost and durability. The real quantum leap, however, is in eco-friendly microchips and sensors : today, work is underway on organic transistors on cellulose substrates, fully biodegradable thin-film devices, and transient memories that dissolve upon contact with moisture. Although their performance is limited compared to traditional silicon chips, these solutions are already sufficient for short-cycle NFC and RFID tags, ideal for timely monitoring and disposable packaging. Finally, freshness indicators can be made without electronics , using reactive films based on natural substances such as pectin, alginates or plant pigments, capable of changing colour depending on the presence of gas or temperature variations: safety information immediately usable by the consumer and, above all, completely biodegradable. Industrial production and integration techniques Innovations in materials have also driven rapid evolution in manufacturing processes. Compostable smart labels are now produced through inkjet printing with conductive inks on bio-based substrates or paper, screen printing to create thicker and more robust circuits, and low-temperature lamination or bonding to avoid altering the properties of compostable materials. Great attention is also paid to adhesives, favoring natural starch- or dextrin-based ones to avoid any risk of contamination in organic flows. The goal is to integrate these technologies into existing production lines, ensuring scalability, efficiency, and cost competitiveness. Current limitations and technical challenges Although the results are promising, the road to full adoption of compostable labels is not without obstacles. The first limitation concerns durability: these devices are ideal for products with a short shelf life—such as fresh food or single-dose pharmaceuticals—but less suitable for long-term logistics. The communication range of passive RFID or NFC tags, for example, is still lower than that of traditional metal circuits, especially at higher frequencies. On the economic front, production costs, though declining, remain higher than conventional solutions, although growing demand and industrialization are rapidly closing the gap. Finally, there are some compatibility issues with standard reading systems, often optimized for metal labels, which will require technological updates and adaptations by logistics and industrial operators. Real-world applications and case studies Despite these limitations, numerous success stories demonstrate that the compostable smart label revolution is already a reality. In the food sector, for example, some companies are experimenting with packaging for ready-to-eat salads, meat, and dairy products equipped with freshness indicators and compostable NFC tags, capable of monitoring the cold chain and ensuring quality all the way to the end consumer. In the pharmaceutical sector, too, blister packs and "smart" packaging are being equipped with compostable NFC tags, offering secure traceability and facilitating sustainable disposal. In logistics and e-commerce, compostable bags and boxes with integrated smart tags enable product authentication and tracking throughout the supply chain, without increasing the residual waste fraction. Regulations and standards: a race towards compliance Regulatory compliance represents a crucial step for the widespread use of smart and compostable packaging. The EN 13432 and ASTM D6400 standards are now the benchmark for certifying the compostability of materials, establishing precise limits on biodegradability, disintegration, the absence of heavy metals, and ecotoxicological safety. Certification bodies are updating their protocols to include electronic devices, paying particular attention to food safety and the environmental impact of the compost produced. The direction is clear: only devices that comply with these requirements can be fully integrated into organic waste collection flows. Research perspectives and future scenarios Research continues unabated; in fact, it accelerates on multiple fronts. The move toward transient and disassembled electronics , devices designed to dissolve spontaneously or be easily separated from compostable materials, is gaining traction. On-demand circuit printing on biodegradable materials is becoming increasingly popular, useful for customizing information throughout the supply chain. Solutions are being explored that integrate traceability with blockchain and IoT without compromising environmental compatibility. Finally, great attention is being paid to consumer education: clear instructions and intuitive symbols are essential for proper disposal and to avoid the risk of contaminating organic waste streams. This revolution is supported by a strong collaboration between academia, industry, and regulators, with the aim of standardizing new technologies and accelerating the transition to smarter, more sustainable, and environmentally friendly packaging. Conclusions: the future of smart packaging is compostable Never before has packaging innovation faced such a crucial choice: continue to grow by focusing on intelligence, traceability, and interactivity, or stop to avoid increasing environmental pressure. The integration of RFID labels, NFC tags, and compostable freshness indicators represents the synthesis of these needs, demonstrating that it is possible to combine advanced technology and respect for the environment. Advances in materials, production processes, and regulations have paved the way for truly smart packaging that is simultaneously fully compatible with organic waste collection and the principles of the circular economy. Technical and economic challenges remain, but the industry's direction is clear: the packaging of the future will be increasingly integrated, interactive, and sustainable. The challenge now lies in the speed of this transition and the ability to work collaboratively between research, industry, and policymakers to build an innovative, transparent, and truly green supply chain, without compromising the health of the planet. © Reproduction Prohibited
SEE MORE
HDPE Recycled Bottles: How to Manage Surface DefectsHow to solve aesthetic problems in the production of recycled HDPE bottles: porosity, streaks, detachment and holesThe production of bottles for detergents , for industrial and agricultural liquids, until recently were produced with virgin materials despite some shapes and colors allowed the use of a recycled HDPE granule. The media impact of plastic pollution dispersed by humans in the environment, has moved the conscience of consumers putting pressure on states, which deal with environmental legislation, but also producers of substances contained in bottles that cannot, for commercial reasons, to lose the consent of its final customers. The demand for regenerated HDPE for blow molding has had a strong surge in the last years, surely finding, a part of the producers, not totally prepared to manage the recycled granule in their machines. It was not just a question of the type of granule that may differ slightly, from a technical point of view, from virgin raw materials to machine behavior, but problems with color shades, stress cracking and seal welding had to be addressed. , to micro holes and other minor issues. In previous articles we have addressed the genesis of recycled HDPE in bottle blowing and the correct choice of recycled raw materials, while today we see some aesthetic aspects that could occur using recycled HDPE granules at 100%. There are four aspects, from an aesthetic point of view, that can negatively affect the good production result: 1) A marked porosity called “orange peel” which is formed mainly inside the bottle but, not infrequently, is also visible on the outside. It appears as an irregular surface, with the presence of continuous micro-cavities that give a rough appearance to the surface. Normally the problems are to be found in the granule, where a possible excessive presence of surface humidity does not allow a perfect laying of the HDPE wall coming out of the mold. In this case the problem can be solved by drying the material in a silo so that it reaches such a degree of humidity that it will not negatively affect the surfaces. In general it is always a recommended operation when you want to produce using 100% regenerated material. 2) Streaks on the bottle are another aesthetic problem that occurs for different reasons, especially if an already colored granule is used. The causes may depend on a different percentage of plastic inside the HDPE granule , even in minimum percentages, between 2 and 4%, since, having the different plastic melting points , the aesthetic behavior on the wall of the bottle can be slightly different, influencing the color in the dough. It is important to note that you should not confuse the streaks of shades with the streaks of structure, which are normally created by the mold of the bottle due to wear or dirt that accumulates by working. Another reason may depend on the heat resistance of the master that is used, as it is not infrequent that at too high temperatures, both in the extrusion phase of the granule and in the blowing of the element , a phenomenon of color degradation can be created with the creation of small streaks on the walls of the bottle. 3) Perfect weldability in a bottle is extremely important as any detachment of the walls, once the bottle has cooled and filled, causes serious damage with costs to be incurred due to the loss of the packaging, the substances contained and the replacement of the material with important logistics costs. The bottle just produced normally does not present the possible defect because the exit temperature from the machine “hides” the problem a little, but once the bottle has cooled, filled and subjected to the weight of the pallets that are stacked above it, a welding defect can present itself in all its problems. The cause of this problem normally must be sought in the percentage of polypropylene that the HDPE granule can contain due to a selection of the raw materials upstream of the non-optimal granule production. A poor selection of the bottles between them, but above all from the caps that they contain, can increase the percentage of polypropylene in the granule mixture. There are commercially available machines with optical selection of the washed ground which help to substantially reduce this percentage, being able to bring it back below 1.5-2%. When buying the recycled HDPE cargo it is always a good idea to ask for a DSC test to check the composition of the granule for production. The effect of an excessive percentage of PP has as a direct consequence the prevention of an effective welding of the contact surfaces that form the bottle. In addition to working on the granule, it would be a good idea if you wanted to use 100% of the recycled raw material, slightly increase the overlap thickness of the two sides of the bottle to favor the correct welding point. 4) The presence of micro or macro holes in a bottle , directly visible through an inspection or, for smaller ones, through the air tightness test, may depend on the presence of impurities inside the granule , when the washing and the filtering of the raw material was not done in a workmanlike manner. Another reason may depend on poor cleaning of the screw of the blowing machine which can accumulate residues of degraded polymer and transport them, subsequently, to the mold. Especially if you use recipes with mineral charge, you may have the problem immediately after changing the recipe between one without charge and one containing it. The use of mixed recipes between virgin and regenerated material can mitigate some of these points but not completely solve any problems if you do not have the foresight to follow the supply chain of the recycled granule.Related articles:HDPE: PRODUCTION OF BOTTLES WITH RECYCLED PLASTIC | SOME ADVICES Automatic translation. We apologize for any inaccuracies. Original articles in Italian.
SEE MORE
Packaging Corrugated Cardboard: Dimensions and Direction of the FibersThe quality and resistance of a corrugated cardboard for packaging depends on the correct arrangement of the fibers and their size How many times have we received, delivered at home, the products we bought on the internet enclosed in a box of cardboard, how many times in our company we use boxes, more or less large, to pack our products for sale, how many times we order by putting our things in cardboard boxes. A type of convenient packaging, simple to use, long-lasting and also circular, as we easily handle corrugated cardboard boxes made with mainly recycled and recyclable paper. In a more professional environment, therefore in the company, the quality of the packaging, whatever they may be, is of substantial importance, not only to present our products to customers, but to protect them during transport and storage in the warehouse. How is recycled corrugated cardboard produced? To create the finished product we start from its origin, so let's see how the sheets that will make up the recycled corrugated cardboard are made >, taking a step back to the paper mill. In fact, it is there where the story begins, using, as raw material, the cardboard that comes from separate collection, which makes up the preeminent part of the recipe, then adding a small part of virgin paper fibers, to increase the quality of the finished product. The type of recipe described does not exhaust the possibilities of finding other blends, as a corrugated cardboard can also be produced 100% with recycled material or with lower percentages of it. Once the raw material has been inserted into the processing plant, water and other substances suitable for the treatment are added, thus starting a mixing of the raw material which leads to the creation of a fluid paste, in which we find an element of crucial importance for the quality of the future finished product which is fibers. In fact, both the recycled cardboard and the natural raw material, which comes from trees, contain different types and form the backbone of future boxes in corrugated cardboard. Once the paper pulp is made, it is spread out, in thin layers, which vary according to commercial requests, on work surfaces to then be sent to the drying of the sheets. Once the correct drying has been achieved, the flat sheets are placed between a corrugated one, specially made through the use of a mechanical folding action assisted by steam. The various layers will then be glued together using vegetable glues derived from potato starch or corn starch. How the direction of the fibers is formed and why it is so important During the creation of the pasta, the most important game regarding future quality is played through the movement of the machine and the presence of water of the cardboard, in fact, with this operation the direction of the fibers is formed which, together with their length, will determine the qualitative result of the product. The fibers are, as mentioned, an armor for the sheet of paper or cardboard, the bearing tool of the product and, their arrangement determines their one-way or two-way mechanical strength. In fact if the fibers are oriented in a parallel way it is possible to tear the sheet in the direction of the same, but it is difficult and irregular in the opposite direction. Furthermore, if the fibers do not have a parallel pattern but unevenly distributed, the mechanical resistance is obtained in both directions of tearing. This does not only apply to the division of the two flaps of the cardboard or paper, but also to its ability to be folded, in fact if we do not consider the arrangement of the fibers, during the folding of a wing of the box, for example, this will be imperfect and difficult, both manually and using the packing machines. What are the differences between using long fibers and short fibers Not all fibers are the same: there are those that are thinner, longer, more irregular, very porous, not porous at all, with knots, of pointed or cylindrical shape and many others. To simplify, with regard to which fiber would be better to use to produce a corrugated cardboard box, we can say that long fibers are the ones most suitable for purpose, as they have greater resistance and hardness, having to create a surface that is as rigid as possible. For completeness we can indicate the short fibers are an excellent solution for creating soft and yielding papers, which are used for multiple uses. Using recycled paper to produce recycled cardboard As we have seen, a good quality paper for making packaging boxes must use a pulp that contains a sufficient amount of fibers long to reinforce the structure. In order to arrive at the correct recipe, to contain costs and to contribute to the use of paper and cardboard waste that we produce every day, the production uses a good part of recycled cardboard. The recycling operations involve, over time, a certain leaching of the fibers, with the consequence that their contribution in the recipe for the production of packaging cardboard, with the various treatment cycles, could decrease. In this case it becomes necessary to resort to the addition of virgin fibers in order to balance the decrease caused by recycling. Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
Agricultural crates: the choice of polypropylene or recycled hdpeToughness, visibility, durability, safety, temperature and recycled resistance, this is asked of an agricultural crateIn the countryside, when there is a period of fruit and vegetable harvesting, which still takes place mainly by hand, the containers of agricultural products collected, to be transported to the processing and packaging departments, must have special characteristics. The agricultural casings,called transport because they have the function of receiving the fruit or vegetables removed from the plant or field, are generally plastic elements suitable to contain the product and then transported to processing and packaging centers. In the past all transporting agricultural crates were produced using virgin polymers,and made using bright colors such as yellow, red, white to be easily noticeable in the field. This type of packaging is also used for the containment and shipping of high-weight processed fruit, which must also receive storage at low temperatures. Today the agricultural case is generally produced in recycled material, whether in PP or HDPE,using materials from the separate collection. An attempt was made to give a regulation to the product supply chain that required the use of recycled materials from agricultural coffers alone, but in fact traceability, in the processing phases of plastics through the collection, grinding, washing and possible granulation, does not allow possible contact with other types of plastics or contamination. This is because, although they have packaging from agriculture alone, the processes of processing and recycling in a new raw material,subject the input to the passage into shredding machines and washing and extrusion plants, in the case of granules, which have also worked other raw materials. On the basis of this information, however, it must be said that the product collected in the field already has in itself a degree of protection that can be the peel,also, among other things, subjected spraying insecticides and antifungals during the growth phase of the product, which have a much more important impact than contact between fruit and an inert product such as recycled plastic. The choice of plastic to use depends on the work cycle of the food that will be contained and the type of logistics that you have to use. If the case has a mere function of the mobility of the crop from the field to the processing plant, it is not very important to choose whether to use a polypropylene case or high-density polyethylene case, but if the fruit or vegetables are to be stored in cold storage, the choice falls on HDPE which has a degree of resistance to low temperatures more important than polypropylene. The production of the raw material, of both plastic categories, takes place through the use of the waste of the packaging that the recycling system can make available and through the conversion to new warehouses of beverage or logistics companies, which periodically replace their container fleet. Let’s look at the differences in the production of the raw material: Polypropylene it is generally produced by food packaging waste, agricultural and industrial boxes that are selected by provenance, ground in sizes of about 10-12 mm., deferred, washed in rotating and decanting plants in the tank, densified by packaging gaps and, if required, initiated to extruders for granulation. The fluidity of the product made normally hovers around a range between 6 and 12 to 230-2.16 kg. and can be generally colored with dark colors. The raw material enjoys a certain abundance in plastic markets and generally has a low price for both mince and grain. The cases are robust, as normally the percentage of PP within the recipe is usually around 90, but are not recommended for use in cold storage.High-density polyethylene does not enjoy the same ease of finding on the market as the packaging industry, especially the mineral water and soft drinks industry, has long focused on plastic film packaging, leaving the recycling market without a product.There are still production areas in the world where we prefer to make crates with virgin materials, especially in some food sectors where there is direct contact with unprotected food, and this generates a small recycling market. Other production of crates with virgin raw material are carried out in countries where material separation systems and subsequent recycling are not so developed as to create a sufficient supply cycle for those who build these packaging. In any case, the production of a recycled HDPE for the production of agricultural crates goes from the separation by color of the available crates, so that you can use the raw material without adding dyes during molding, grinding and deferring the grind in HDPE and the subsequent washing with double passage as for polypropylene. The fluidity ranges from 6 to 8 to 190 degrees/2.16 kg, and the grind can be used directly in the machine to produce the case or move on to the granulation phase.See more info about recycling
SEE MORE
If the food is consumable, the new bio film tells youThe new packaging changes color based on the quality of the food it contains University and scientific research in the field of packaging is focusing on the problem of the effective expiration of food, studying bio films that can help us classify, in addition to the label affixed, the real quality of the food contained. The new bio-films are made of bio-plastics, made from the transformation of sugar contained in beets and corn, to which additives are added from waste from the agri-food sector. These additives are, in turn, waste from the agri-food chain such as hemp, flax, coffee waste, various vegetation waste, and other natural products . They have several properties that we can summarize: · Good mechanical properties · Fire resistant · Antioxidant properties · Antifungal properties · Antimicrobial properties Among the additives we talked about earlier, the addition of zinc oxide and aluminum, in the production of bio films, develops antimicrobial properties that can lengthen the expiration of fresh products, thus reducing the waste given by the expiration of the products. While the addition of an additive such as cardarol oil and a particular molecule called porphyrin, they attribute to the film antioxidant and antifungal properties , which in the field of food packaging help to signal the deterioration of the product. But how does this mechanism happen? When the bio film comes into contact with some analytes, such as water, ethanol, ammonia or other products that derive from food degradation, in combination with light, these toxic elements penetrate the polymer of the film creating color reactions . The films made in the laboratory are completely biodegradable and bio compostable , this means that at the end of their life cycle they can become fertilizer and re-enter in full respect of the circularity of the products.Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
Nano Polymeric Coatings with Antimicrobial Properties. Where are We?Polymers containing nanoparticles with the ability to inhibit the proliferation of many microorganisms, in the packaging, transport and hospital sectors. The microorganisms that surround us and that can cause discomfort, disease and even death in some cases, they are invisible to the eye of man but, not only do they keep us company in every place we are, but often we ourselves carry them from one place to another, during our daily life. Scientific research has been studying the phenomenon for years, it is not so much focused on direct intervention to disinfect the surfaces we touch, but rather on avoiding the proliferation mechanism of microorganisms on the surfaces. By surfaces we mean all those objects that, directly or indirectly, can be vectors of contact with our body and, consequently, could cause diseases of rapid diffusion. This is true for the world of packaging, for hospitals, for means of transport, in our homes, for places of social gathering, in short, in all those situations in which microorganisms have an easy time to replicate. From a technical point of view, this phenomenon can be understood in what is called biofouling, that is, biological contamination processes deposited on the surface of materials. This process begins with the formation of a primary film on the surface of the material in the presence of at least two variables, microorganisms and moisture. Among the predominant microorganisms are bacteria and diatoms, which produce a large amount of organic matter, such as polysaccharide acids that form a surface film with many nutrients, which is used for the colonization of other larger organisms. For example, in the health field, it has been discovered that micro-films, composed of microorganisms, can form in medical devices such as vascular catheters, joint prostheses and catheters urinary, which was, at times, resistant to antibiotics. Other areas under observation are for example means of transport or hospitals, whose fight against infectious microorganisms is fought with metal nanoparticles available in many types and quantity. In this way, the nanoparticles Cu, ZnO, Se, ZrO 2, SiO, TiO 2, among others, can be used in all social places and our homes in the presence of high humidity. The carrier for the nanoparticles can be a polymer, of any type, which constitutes the products, for example, silver or copper nanoparticles, are materials interesting that can be used to combat biofouling, as they have broad spectrum antimicrobial properties and are effective against multiple bacteria, viruses and fungi. Furthermore, iron oxide nanoparticles also have antimicrobial characteristics, but their study was less extensive than Ag and Cu nanoparticles, but it is important to note that their biocompatibility is an important reason to implement their use in commercial products such as those for packaging. Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
Pfas emergency in Plastics and Packaging Is there a solution?Pfas in plastics and packaging: they are chemical compounds not present in nature, not biodegradable and harmful to healthLike all the medals that are respected, also the Pfas, an acronym of the perfluoroalkyl and polifluoroalkyl substances, have their shiny side and their dark side. The chemical compounds of these families, which number about 4700, were created in the laboratory and widely used since the 1950s in the food packaging industry, in pesticides, in non-stick pans, in cardboard containers, in fire foams, in shampoos , in paints, in stain-resistant products and in many other applications. In plastics we find them in the form of elastomers (Vinylidene fluoride, Fluorurates in general, Tetrafluoroethylene) or in polymeric materials (Magnesium salt-sodium-fluoride of silicic acid). The advantages of these substances, applied to finished products, lies in their water repellency, oil-repellency and thermo-resistance , which allow us to make, for example, a waterproof jacket , not to stick an egg to the pan , not to get dirty mayonnaise or oily substances when we eat a sandwich filled with paper and not let our hands get dirty in the cinema when we eat popcorn. Their chemical bond composed of fluorine and carbon makes the resulting molecule an element irreplaceable today in industrial applications, but also makes it non-biodegradable and extremely dangerous, as it is odorless, tasteless and colorless. These characteristics allow it to be easily dispersed in water, soil and air, remaining to damage the environment and human health for a long time. The plants absorb the Pfas through the irrigation water, they give it to the fruits and the animals , of which they feed and thus, magically end up on our tables and in our body. From the health point of view, many studies have shown that the accumulation of these substances in the human body can favor spontaneous abortions, alter fertility, cause testicular, thyroid and kidney cancer. What are the means available today to defend ourselves from the sneaky pollution of the Pfas? At present there are not many: we can count on active carbon filters in which the porosity of the filtering carbon has shown a certain effectiveness in intercepting the Pfas, but it is not an effective system on all molecules. But once again, biochemistry could give us an answer to the problem as a team of American researchers has discovered a bacterium, called Acidimicrobium A6 , which would have the characteristic of breaking the bond between fluorine and carbon in Pfas. The bacterium was discovered in an American swamp and studied for a long time as a result of its ability to split ammonium, exploiting the iron present in the soil, without using oxygen. This named reaction, Feammox , was reproduced in the laboratory, after cultivating new strains of bacteria and subjecting the new families to other tests relating to the substances present in the waste water. After 100 days of cultivation in waters containing, among others, also the Pfas, it was noticed that the bacterium had the ability to break down the two main binders, fluorine and carbon, reducing them by 60%. The discovery could be interesting, not only in the liquid contaminated by Pfas, but also in the soils because the bacterium acts in hypoxic conditions, that is of poor oxygen.
SEE MORE
The Use of Mineral Fillers in the Production of Recycled HDPE BottlesAdvantages and disadvantages in blowing bottles with recycled HDPE granules loaded with Talc or Calcium Carbonate The production of single-layer HDPE bottles has always been competence of virgin polymer until a few years ago, with which colors, thicknesses, finishes, fragrances and shapes were made without worrying too much about the polymer-blow molding ratio. The advent of recycled HDPE in the blow molding world has been gradual and quite complicated, as there was a certain mistrust on the use of rHDPE, motivated by hypothetical doubts on mechanical strength, on the quality of the surfaces, on the seal of the handle, on the smell of the blown packaging, on the realization of the colors and the transparency to see the liquids inside, on the sealing of the welds, on the micro perforations of the surfaces, on the availability of the material and on the small difference in price compared to virgin raw material. All legitimate objections for those used to using virgin polymer, but many of them were general preconceptions about recycled material, which was still seen as synonymous with lower quality general. There is no doubt that the first years in which HDPE recycled in blow molding granules arrived on the market, the quality of the recycling and sorting plants attributed to the raw material some objective limits. The main critical issues were related to some technical factors: • Impurities contained in the granule • Excessive presence of PP • Presence of residual moisture • Persistent odor • Hardly manageable color We do not go into how the recycling sector has technically, over the years, solved the problems exposed, managing to create a recycled HDPE granule that is comparable, from point of overall performance, many times to the virgin one. Perhaps, in some cases and with some machines, the question of the thickness of the bottle is still an open topic, as, at times, it may be necessary to increase in thickness using rHDPE compared to the first choice. The reason why it may sometimes be necessary depends on many factors, such as the shape and size of the bottle, the blow molding machine you use, the quality of the recycled granule, all elements necessary to achieve a correct ratio, between the compressive strength of the bottle and the weight that weighs on it once inserted into a vertical pallet. It is possible to overcome this inconvenience, after verifying and solving the previous problems, through the use of mineral fillers such as talc or calcium carbonate. The function of mineral fillers is to increase the vertical compressive strength of the bottle, without having to increase its thickness, through the use of percentages that do not exceed usually 10-15%, depending on the size of the product to be made. It should be noted, by engaging loaded granules, that the bottle enjoys advantages relating to load resistance and torsion, thus improving portability and economy in the production phase . There are, however, some information to keep in mind when deciding to operate by blowing with an rHDPE granule loaded with talc or caco3: • The screws of the blow molding machine must be cleaned often, as the first stages of using an abrasive mixture, such as loaded HDPE, facilitates the transport of contamination present in the blowing machine with the possibility of creating holes in the bottle. • The presence of mineral fillers can affect the transparency, or semi transparency, of the product. • The creation of colors must take into account a possible different color result compared to a rHDPE without fillers. • The presence of PP, even in low percentages, in a loaded granule, further reduces the sealing and sealing capacity of the bottle, especially in the handles or in points with particular angles. Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
HDPE: Production of Bottles with Recycled Plastic | Some AdvicesHow to solve aesthetic problems in the production of recycled HDPE bottles The demand for regenerated HDPE for blow molding has seen a strong surge in recent years, certainly finding some producers not totally prepared to manage the recycled granules in their machines. It was not just a question of the type of granule which may differ slightly, from a technical point of view, from the virgin raw materials in their behavior in the machine, but problems related to the tone of the colors, stress cracking and the tightness of the welds had to be addressed , micro holes and other minor issues. In previous articles we have addressed the genesis of recycled HDPE in bottle blowing and the correct choice of recycled raw materials, while today we see some aesthetic aspects that could arise using 100% recycled HDPE granules. There are four aspects, from an aesthetic point of view, which can negatively impact the good production result: 1) A marked porosity called "orange peel" which forms mainly inside the bottle but, not rarely, is also visible on the outside. It appears as an irregular surface, with the presence of continuous micro cavities which give a wrinkled appearance to the surface. Normally the problems are to be found in the granule, where a possible excessive presence of surface humidity does not allow perfect laying of the HDPE wall coming out of the mould. In this case the problem can be solved by drying the material in a silo so that it reaches a level of humidity that will not negatively affect the surfaces. Generally speaking, it is always a recommended operation when you want to produce using 100% regenerated material. 2) Streaks on the bottle are another aesthetic problem that occurs for different reasons, especially if you use an already colored granule. The causes may depend on a different percentage of plastic inside the HDPE granule, even in minimal percentages, between 2 and 4%, since, since the plastics have different melting points, the aesthetic behavior on the wall of the bottle can be slightly different, affecting the color in the dough. It is important to note that the streaks of tone should not be confused with the streaks of structure, which are normally created by the bottle mold due to wear or dirt that accumulates while working. Another reason may depend on the heat resistance of the master used, as it is not uncommon that at temperatures that are too high, both during extrusion of the granule and blowing of the element, a color degradation phenomenon can be created with the creation of small streaks on the walls of the bottle. 3) Perfect weldability in a bottle is extremely important as any detachment of the walls, once the bottle has cooled and filled, causes serious damage with costs to be incurred for the loss of the packaging, the substances contained and the replacement of the material with significant logistics costs. The newly produced bottle normally does not present the possible defect as the temperature at the exit from the machine "hides" the problem a bit, but once the bottle has cooled down, filled and subjected it to the weight of the pallets that are stacked on top it, a welding defect can present itself in all its problems. The cause of this problem must normally be sought in the percentage of polypropylene that the HDPE granule may contain due to a non-optimal selection of raw materials upstream of the production of the granule. A poor selection of the bottles among themselves, but above all from the caps they contain, can increase the percentage share of polypropylene in the granule mixture. There are machines on the market with optical selection of the washed ground coffee that help to substantially reduce this percentage, bringing it back below 1.5-2%. When purchasing a load of recycled HDPE it is always a good idea to ask for a DSC test to check the composition of the granule for production. The effect of an excessive percentage of PP has as a direct consequence the prevention of effective welding of the contact surfaces that form the bottle. In addition to working on the granule, it would be a good idea, if you wish to use 100% recycled raw material, to slightly increase the overlap thickness of the two sides of the bottle to favor the correct welding point. 4) The presence of micro or macro holes in a bottle , visible directly through an inspection or, for smaller ones, through the air tightness test, may depend on the presence of impurities inside the granule, when washing and the filtering of the raw material was not done to perfection. Another reason may depend on poor cleaning of the screw of the blowing machine which can accumulate residues of degraded polymer and subsequently transport them outside towards the mould. Especially if you use recipes with mineral filler, the problem may arise immediately after changing the recipe from one without filler to one that contains it. Category: news - technical - plastic - recycling - HDPE - post-consumer - bottles
SEE MORE
Chemical-Physical Quality of Glass. Comparison with Paper, Plastic and AluminumThe materials for food packaging on the market have different characteristics, quality, disposal costs and recyclability In the world of food packaging we find extremely different raw materials, some of them, such as paper and glass, have a thousand-year history, while plastic and aluminum have a more recent history. We do not want to deliberately enter into a marketing duel on the preference between one material or the other, but we would like to analyze some aspects concerning the conservation of the contained assets, the durability of the packaging, recyclability. In truth, to these analyzes we should add that relating to the compared production costs and the environmental impact on logistics, which will be addressed elsewhere. If we take a look at the past we can say that glass was the main material of the packaging with which liquid foods, milk, wine, spirits, oil were contained and other foodstuffs, while starting from the economic boom of the 1960s, mineral water and soft drinks had also found their share of the market through packaging in bottles. As far as metal food boxes are concerned, we can refer to the 19th century as the beginning in America and England of the first industrial productions, although the costs to make them were very high and canned food was therefore a luxury for the few. To push their diffusion, however, came the world wars, as the armies found it convenient and logistically useful to entrust the soldiers' rations to this type of packaging. With the advent of aluminum cans, a widespread diffusion of food and drinks packaged in soft metal began in the mid-50s of the last century . As far as the use of paper packaging is concerned, we have to get to the mid-50s of the last century to see the start, in Sweden, of the first packaging for food liquids in cardboard and plastic film packages. Since 1973, when the Du Pont company patents PET, we can say that large-scale food packaging was born, with the intention of eroding quotas market to glass ones. If we want to make a comparison of the physical and chemical qualities of the main food packaging, we can list some general comparisons: Possible transfers of packaging substances • Glass: sodium and calcium already present in food • Plastic: components of additives especially if there is fat or alcohol • Paper or Cardboard: additives and colorants • Metal: Tin and lead within the legal limits. Toxic substances from paints (at high temperature) Impermeability to liquids, gases and microbiological agents • Glass: 100% • Plastic: variable depending on the polymer • Paper or Cardboard: only if there are no surface abrasions • Matallo: only if there are no surface abrasions Corrosion of the packaging • Glass: Only hydrofluoric acid and alkaline solutions with a Ph higher than 8 • Plastic: can release microplastics at the bends • Paper or Cardboard: attackable by insects and mice • Metal: generated by any imperfections of the structure Sterilisability • Glass: 100% dry and wet • Plastic: with special bacteriostatic additives • Paper or Cardboard: during packaging with hydrogen peroxide or UV or chemical agents • Metal: 100% even at high temperatures Transparency • Glass: perfect with clear glass • Plastic: depends on the polymer, difficult with recycled HDPE polymers • Paper and Cardboard: no • Metal: no Actinic light protection • Glass: good in the colored vertices • Plastic: good with specific additives • Paper or Cardboard: opaque • Metal: opaque Sanitization • Glass: excellent • Plastic: disposable to be recycled • Paper or Cardboard: disposable to be recycled • Metal: disposable to be recycled Recyclability • Glass: continuous and without degradation. Economical only with returnable vacuum • Plastic: possible a certain number of times with some qualitative degradation. The recycling of polylaminates is difficult • Paper and Cardboard: recyclable with degradation. The recycling of paper-plastic polylaminates is difficult • Metal: good In conclusion, an economic comparison of food packaging will be added to this analysis according to the durability of the product on the shelves and the cost of recycling or disposal of packaging at the end of its life, as well as the environmental impact of both production, logistics and the circularity or otherwise of the waste. Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
The Modern Active Packaging with Millennial RootsStudying how the packaging interacts with the product contained, how time, structure and chemistry make this relationship evolveThe current active packaging is well defined by the EC regulation 450/2009 which states: "... active materials and objects intended to come into contact with food products are materials and objects intended to extend the shelf life or maintain or improve the conditions of packaged food products. They are designed to deliberately incorporate components that release substances into, or absorb into, the packaged food product or its environment ”.It seems to be a conquest of our times to better preserve the products inside the packaging, whether they are food or other products, making them, at times, interact with the packaging that contain them.This means worrying and studying how the packaging interacts with the product contained, how time, structure and chemistry make this relationship evolve, finally verifying the pros and cons, on the product that will be used.In reality, the problem has already been addressed in some way over the past millennia, even without having the multiple packaging available today.There was no plastic, aluminum, Tetra Pack, but wood, glass and ceramic yes, and above all through the wooden barrels, our predecessors sensed that the barrel had a close relationship with the final quality of the wine.In fact, they realized that the fine wood barrels yielded polyphenolic substances to wines and spirits that improved the color, flavor and aroma of the product.Today, with the increase in the types of packaging available to us, the problems that we must consider and solve in order to control adverse reactions between packaging and product and encourage positive ones have also multiplied.Among those unwanted or harmful we can list:Humidity. This favors the proliferation of molds and bacteria in some cases, while in others it is necessary to control the aerobic respiration of plants and microorganisms. For these reasons it is necessary to act in order to be able to control the development of humidity in the packages based on the type of product contained. To do this, it is possible to use bags containing silica gel, calcium chloride and calcium oxide, or multilayer materials containing hygroscopic compounds, such as Pitchit film.Oxygen. Everyone knows that the presence of oxygen facilitates the reduction of the shelf life of stored food products as a result of reactions (chemical and enzymatic oxidations, degradation of pigments and aromas) and metabolisms (aerobic respiration, proliferation of aerobic bacteria, molds and yeasts). A widely used system is the preservation of food through vacuum packing, but there are other methods, such as sachets that absorb oxygen, consisting of small elements that, through a chemical reaction between metallic Fe and O2, reduce its presence inside. of the packaging. This methodology is not applicable to all packaging as the chemical reaction is triggered in the presence of a certain degree of humidity and the presence of iron can interfere with the automated logistics systems in the presence of metal detectors.Ethylene. Ethylene is a plant hormone that influences the aerobic process and the ripening of many fruits, therefore its reduction produces a slowdown in the ripening of the product. Substances capable of adsorbing ethylene, such as activated carbon, silica gel and zeolites, can be included in the packaging.Volatile compounds deriving from the degradation of food. Especially the lipid and protein degradation of food produces volatile substances with an unpleasant smell. Volatile aldehydes (hexanal, nonanal, etc.) produced during the oxidation of unsaturated lipids, can be intercepted by chemical compounds inserted in polyolefin copolymers (PE / PP). There are other chemicals, such as hydrogen sulfide (H2S) and volatile mercaptans (R-SH), which are generated by protein degradation, can be sequestered with specific adsorbents.Then there are protective and improving substances that interact with the products contained in the packaging. Taking a quick rundown we can mention:Antioxidants. Contained in the plastic materials intended for packaging production favor a protective action over time. There are also natural antioxidants, such as α-tocopherol, which is added in the production of specific packaging films.Natural Antimicrobials. They are substances responsible for controlling microbial proliferation in food that interact with the humidity and temperature inside the packaging in contact with the fresh product.Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
Can Plastic Bottles Transfer Substances to the Water Contained?Let's find out by checking the water contained in a PET bottle using the electronic noseThe packaging of soft drinks and mineral water has passed, in a few years, from glass to plastic bottles for a series of important factors that have made this bottling system the most used in the world. Around the plastic bottles , especially its primary material, PET , there have been developed support campaigns and campaigns of denigration among the most bitter, played between producers of soft drinks, producers of raw materials, distribution and citizens. The strongly discussed issues are environmental, on the one hand, claiming a sort of polluter license from the public opinion towards the producers of PET bottles, to due to the massive presence in the seas of disposable products. It is obvious to everyone that the producers of plastic bottles have no part in this environmental disaster that is to be attributed to the final consumer, who does not care about give the empty bottle to recycling centers or arrange for its reuse. On the other hand soft drink manufacturers have identified in the plastic bottle , by the way, today, consisting of one part of recycled material, a great advantage in terms of production costs, savings on logistics and a lower environmental impact during production than other packaging materials. But there is another question to consider, and that is the relationship between the plastic bottle and its contents , the 'water for example, a relationship that is a solidarity marriage as long as the water is not used by the consumer. During the permanence of the water in the plastic bottles , between the moment of bottling and the moment of its consumption, the bottle it can receive the effects of light, solar radiation and the increase in temperatures of plastic under the effect of the sun. Any modification of the standard conditions of the plastic, heat, cold, light, life time of the bottle , which can modify the structure of the plastic, could be shared with the water contained that the consumer drinks. How do we know if volatile elements that arise as a result of possible mutations in plastic are transmitted or not in the water? Not tasting it , as some substances that could be released may be tasteless, not looking at it against the light, because some substances may not be visible to the naked eye. Today we have a small but very effective laboratory instrument , called electronic nose, which analyzes volatile elements in a scientific way some materials. By sampling portions of water contained in various plastic bottles, the test tubes are inserted into the electronic nose and, automatically, the samples are heated, creating volatile parts that are intercepted by a gas chromatograph (GC), which communicates with an ion mobility spectrometer (IMS) , which give us a three-dimensional examination of the volatile parts contained in the water, identifying exactly the quantity and chemical type of the compounds contained. What shall we drink then? Water or something? The electronic nose will tell us Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
Recycled LDPE Bags: How to Avoid Quality ProblemsRecycled LDPE Bags: How to Avoid Quality Problems The world of recycled LDPE bags is widely represented by the type we use every day for separate waste collection which, through their different colours, help us to separate waste correctly. The trend in bag production was represented by the maximum reduction in thickness and the use of increasingly lower quality raw materials. All this was part of a market logic in which the bag had to cost less and less, thus creating products that were increasingly less performing from a qualitative point of view. The major problems encountered were the following: • Fragility of the bag under the effect of the weight of the waste introduced with breakage of the walls due to breakthrough • Detachment of the welding points of the lips of the bag with vertical opening of the same • Cutting the bag if there are impurities on the wall • Irregularity of the surface with phenomena called “partridge's eye” • Difficulty in creating colours • Pungent odor from the bags even after a long time • Dryness of the bag due to the use of collected films degraded by the sun, especially the waste coming from agricultural greenhouses All these problems should be analyzed individually as each point has a long story to tell and a clear path to its resolution. In today's article we take a leap, arriving directly at the recipes that can solve all these problems, allowing the production of qualitatively correct bags with an eye on general production costs. Most of the problems listed derive from the 100% use of post-consumer input , from separate collection or agricultural sheets, whose mechanical recycling, although excellent with the new production lines, involves many of the problems mentioned. Certainly, a higher quality of the recycling lines , understood as selection, washing, densification, filtration and extrusion of the granules, corresponds to a lower quantity and importance of problems, but the mechanical recycling of waste coming from separate waste collection or from the agricultural sector, however, has of the qualitative limits that have not yet been resolved to date. For this reason, the attention to the preparation of recipes for compounds, created with attention to the resolution of these problems, gives the possibility of creating LDPE granules, coming from recycling, with superior qualities, remaining in the perspective of the circular economy which requires the consumption of waste that we create every day. The compound should contain a significant part of an LDPE film input that does not come from separate waste collection , not necessarily of post-industrial origin, but from waste that has not been mixed and polluted by other mixed plastic materials. Based on the characteristic of the final product to be made, it will be decided how to compose the input recipe, so as to be able to guarantee the quality expected by the customer. The qualitative indices must solve the problems we have talked about by taking into account some indications: • Allow bag production starting from 20 microns • The elasticity must be greater than a recipe with 100% post-consumer • The sealing strength, even when cold and under the weight of the contents of the bag, must be high. • The absence of small foreign bodies, which are formed due to the degradation of materials other than LDPE during extrusion, which affect the accidental longitudinal cut of the product. • Being able to create a smooth surface, without small corrugations or irregularities. • The recipe must include the possibility of making films with light and dark colours, semi-transparent in smaller thicknesses. • Absence or marked reduction of the pungent odor typical of post-consumption must be possible. On the basis of correct modulation of the material input and attention to the recycling and granulation phases, it is possible to significantly improve the quality of the LDPE bags produced , with a greater contribution margin on production and greater satisfaction of the end customer, always having costs under control. Category: news - technical - plastic - recycling - LDPE - post-consumer - bags - film - quality Related articles: WHAT QUALITY OF FILM CAN BE OBTAINED BY USING RECYCLED LDPE? LDPE RECYCLED FROM POST CONSUMER: 60 TYPES OF ODORS OBSTACLE SALES LDPE FROM POST CONSUMER. HOW TO REDUCE IMPERFECTIONS. EBOOK See more information on LDPE recycling
SEE MORE
Recycled EPS (Expanded Polystyrene): Where It Comes From and What It IsHow to recycle a multi-purpose material from the packaging, construction and food sectorsThe EPS or more commonly called expanded polystyrene, is obtained from polystyrene by means of a polymerization process which occurs through a chemical reaction of styrene. In the polymerization phase, expanding additives such as pentane are added to the polystyrene, favoring the birth of EPS, which comes in small balls with a glassy appearance and of different granulometry. By then bringing the balls to a temperature of about 90 °C through the use of steam, the gas contained in them triggers their volumetric expansion equal to 20 - 50 times the volume of the same. After the expansive phase, we move on to the sintering of the balls, which consists, again through the use of steam at 110 - 120 ° C, in their ability to agglomerate with each other, with the possibility of creating monolithic blocks. The EPS thus produced is used in many sectors, such as insulation in the building industry, for the protection of objects during the packaging, and in the food sector for the production of containers of various types. This very large multi-sector use, leads to the creation of a large amount of waste which must be properly managed, sending it for recycling, as EPS can be a circular product. How to recycle EPS with the mechanical system The first criticality encountered speaking of recycling EPS is its volume in relation to its weight , two elements that determine costs for the storage of waste and for its transport. In fact it is a very light material, about 15-25 Kg. /m3 and very voluminous. For these reasons, the first phase of EPS recycling lies in its volume reduction, through shredding mechanical waste, in order to obtain irregular pieces with dimensions from 2 to 10 cm. After the crushing phase, we move on to that of grinding, which consists in using hammer mills or knife mills with shafts counter-rotating, which have the ability to reduce the EPS to the desired size. As an alternative to grinding, the crushed EPS scarts can be compacted with specific presses, so as to monolithically reduce their volume , bringing the specific weight between 300 and 800 Kg/m3. If you opt for grinding waste, you get a raw material that can be used for the extrusion stages, then creating a granular crystal polymer with a high fluidity, around 14-18, usable for injection moulding. To extrude the EPS it is necessary to have a forced feeding system as the material is very light, it is also advisable to have a degassing to remove gases present within the cellular structure. If the ground or compacted waste comes from separate collection, therefore post-consumption, it is advisable to insert a magnet on the conveyor belt that can intercept any metallic elements present in the ground. It is also always advisable to sift the ground in order to eliminate any impurities consisting of wood, paper, non-ferrous elements which are not intercepted by the magnets. There are other non-mechanical recycling systems for EPS which can be listed below: • Thermomechanical molecular cracking system • Microwave and infrared system that generates a controlled pyrolytic process • Liquid dissolution system that allows the recovery of uncontaminated EPS Machine translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
Polymeric Coatings for Metal Food PackagingPolymeric Coatings for Metal Food PackagingMetal boxes for food preservation have a long history but, if in the past, they had deficiencies from the hygienic and toxicological point, especially in because of the welds that were made in Sn-Pb alloy, currently the quality of the manufactured products are much better. Today the protection of food is mainly entrusted to the polymeric layer of inner coating , called coating , which stands between the metal wall and the contained food. The primary function of this barrier is to protect food products from light, oxygen, enzymes, humidity, pollutants and microorganisms that would result in the modification of the structure of the food and its quality. The aim is also to increase the useful life of the food or the drink which in normal, that is, not canned, it would deteriorate more quickly, as the biochemical and enzymatic reactions and the activity of microorganisms would normally run their course. Therefore, to increase the life of the food, the metal packages are normally coated with synthetic resin film applied to the metal sheet again flat, film with a thickness of a few microns. The choice of the type of resin depends on its mechanical, chemical or thermal characteristics based on the content they must host. Below we can list the main ones: • Rosin consists mainly of abietic acid, which is normally added with ZnO to control the chemical reactions that are formed through the sulfur amino acids of proteins. • Vinyl resins are from the family of thermoplastic resins, normally PVC, which have excellent resistance to acids, but have the defect to absorb food pigments. • Phenolic resins are composed through the polymerization of formaldehyde and phenol which have excellent resistance to heat treatments, PH and to fats. Through the formaldehyde content we can identify two families of phenolic resins: Novolacche (thermoplastic) and Resoli (thermosetting). • Epoxy Resins are thermosetting resins consisting of bisphenol A and epichlorohydrin which are the most common coating in canned foods, especially in fish-based foods in oil. • Polyester resins are thermosetting resins obtained from different monomers such as phthalic anhydride, maleic anhydride or fumaric acid, integrated with vegetable oils and pigments. They have the characteristic of flexibility giving this characteristic to the metal wall layer. • Epoxy-Phenolic Resins are the result of the polymerization of epoxy resins with phenolic ones through catalysts. They are used as a transparent coating for many metal cans that contain oil, vegetable or pet food preserves. As regards the toxicological characteristics there are specific legal regulations that place limits on the possible migration of packaging substances into food, in which both specific migration and global migration are considered. However, the scientific community has given new impetus to studies and research on the toxicological aspects relating to plastics used in the food industry, with particular attention no longer to the single element that constitutes the packaging, but takes into consideration the cocktail effect that is given by all the elements that come into contact with food translated over time and with different thermal characteristics. Undoubtedly the food or drink contained in the packaging at the time of packaging has certain characteristics, but over time and in different climatic conditions , the quality of the food that arrives on the table could be different. Therefore it would be advisable to verify it through a chemical analysis, on a sample, with an instrument composed of a gas chromatograph and a spectrometer ion mobility that, in a simple and rapid way, will give the photograph, analytical, of the quality of food or drinks. Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
PVC Films for Food: What Contaminations Are Possible?For many years, food can be portioned through a packaging consisting of a PVC film It is by now it is our habit to buy portions of food that the shopkeeper or large-scale distribution packs in a PVC film. Even in our homes, partial batches of food are commonly wrapped in these films to increase shelf life and safeguard quality. Although there are also several PE films today, the PVC market is still the most important due to numerous techno-economic factors. The use of PVC polymer allows to create a very resistant film, with a low permeability to water and oxygen, with a good resistance to acids and diluted alkalis. Moreover, for a completely practical fact, the PVC food films have an excellent packaging capacity, easily welded to a plate or bowl or on itself. same. From an economic point of view, the presence of chlorine in the PVC compound, essential for its chemical structure, significantly reduces the cost of the finished product. because there is an ethylene saving of about 50% compared to the use of PE for the same product. Using PVC it is possible to insert a series of additives that can modify its performance characteristics, having the possibility of creating, with a single polymer, different products. Let's see the main additives that are used in the packaging industry: • Anti-blocking agents: reduce the tendency to adhesiveness • Anti-fog agents: promote the formation of a homogeneous and continuous veil of liquid • Antimicrobials: prevent the growth of microorganisms • Antioxidants: They prevent the degradation of the film due to the atmosphere • Antistatic: They reduce the accumulation of electrical charges that attract dust • Swelling agents: used to produce foams from plastic materials • Catalysts: they start the polymerization in the production of plastic resins • Dyes: allow the coloring of the films • Coupling agents: favor the coupling between pigments and polymers • Flame retardants: reduce the flammability of materials that are combustible • Heat stabilizers: reduce the degradation of PVC into hydrochloric acid • Lubricants: Reduce adhesiveness between PVC and metal parts • Plasticizers: improve flexibility, workability and expandability All these additives, but especially the plasticizers, are subject to very strict regulations to allow their use in the food sector. It must be considered that there are about 300 types of plasticizers on the market and those approved for food use, are subject to the hygiene regulations of packaging, containers, utensils intended to come into contact with food substances or substances for personal use. The substances that could transfer from the packaging to the food can be divided into three categories: • Added substances: mainly represented by the PVC additives listed above • Residues: represent parts of polymeric material with incomplete reactions (monomers, catalysts, solvents, adhesives, etc.) • Newly formed products: these are substances that originate from the spontaneous decomposition of materials or during operations of transformation into an artifact These substances, defined as neoformations, are very variable among themselves, depending on many chemical-physical factors that can occur and that can affect the possible transfer of substances in the food that are difficult to manage and resolve. Automatic translation. We apologize for any inaccuracies. Original article in Italian.
SEE MORE
