Its new packaging is made with Toray's Torayfan CBS2 BOPP film, a clear, PVdC-free flat sheet, as an inside sealant, with a co-extruded BOPP print web.
Superior lamination bond
Toray approached PPC with the film and the companies carried out trials comparing the performance of CBS2 with that of traditional PVdC-coated BOPP film.
The results showed the material offered an excellent moisture and oxygen barrier and had superior lamination bond, said PPC, without the need for priming, additives or changes to PPC's lamination process.
It also provided a wide heat-seal range, oil and puncture resistance, stiffness and yield advantage and a longer storage life, according to the supplier.
Will Woodford, VP for sales administration at PPC, claims food manufacturers have been looking for an alternative to transparent barrier film containing PVdC for a long time.
He said even though PVdC-coated OPP film keeps bakery and snack foods fresh and allows a window to look at the product inside, the film has ‘several drawbacks’.
"It yellows as it ages, becoming brittle and prone to flex cracking. It has experienced price hikes that have made end-user costs rise, and it has required many flexographic printer/converters to use EMA additives or other supplemental materials to promote bond adhesion for laminating to PVdC-coated OPP,” he said.
PPC and Toray Plastics (America) also point out it is understood within the industry that when PVdC-containing materials are incinerated for electricity production or waste disposal, hydrochloric acid fumes may be generated from the chlorine in the PVdC.
“PVdC-coated films' potential negative long-term effect on the environment have made some manufacturers uneasy," said Woodford.
The Torayfan CBS2 BOPP film is chlorine-free, and therefore manufacturers using it would not have those concerns, he added.
Utz stringent barrier requirements
Amanda Whaley, product manager, Torayfan division, Toray Plastics (America), said Toray and PPC presented the CBS2 BOPP film with barrier properties to Utz, who successfully tested the material on its own machinery.
Utz has stringent barrier requirements for its packaging because it has to ship products over long distances - and price increases in PVdC-coated films made CBS2 film more attractive.
Utz first used Torayfan CBS2 BOPP film for its three-ounce party mix, creating a colorful pouch with a clear window. It has now expanded this to include tortilla chips, corn chips, Puff N' Corn and other salty snacks.
"The first application performed beautifully and Utz continues to specify the CBS2 lamination," added Woodford.
"CBS2 BOPP film has given us and our customers a new option for a clear, thin OPP with enhanced oxygen- and moisture-barrier, which is critical to good sourcing practices."
Woodford said several other PPC customers are now testing CBS2 film for their packaging.