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New super barrier films target pharmaceutical, nutraceutical and device packaging |
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Barrier film has managed to capture a market share in the medical sector for pharmaceutical, nutraceutical and device packaging.
Plastic film demand in the US is forecast to increase 2.6% pa to 15.2 bln lbs in 2010, valued at US$12 billion (resin cost only) as per a report by Freedonia. Total plastic film demand (including resins, additives, and processing and other costs) will expand 4.5% pa to US$28.6 bln. Advances will result from cost, performance and source reduction advantages over rigid packaging. Global demand for pharmaceutical packaging will rise 5.3% pa to more than US$47 billion in 2013 as per Freedonia. The developed countries of Western Europe, the US and Japan will continue to account for nearly three-fourths of this amount. However, China will provide the strongest growth opportunities based on rapidly expanding pharmaceutical manufacturing capabilities and the phasing-in of an extensive government program designed to upgrade the quality and integrity of nationally produced medicines. Among other major developing economies, India and Brazil will also evolve into fast-growing pharmaceutical packaging markets as drug-producing sectors are upgraded and diversified, especially in the area of generic ethical drugs. Comprising more than 22 billion units, sterile medical-packaging demand in the US is expected to grow 6% pa to reach US$4.4 bln in 2010, as per Freedonia Group. Sterile medical trays and pouches will post below-average gains but will remain important segments, combining for demand of more than US$1 bln in 2010. Pouch sales will grow from US$415 mln last year to US$515 mln or about 4.4% pa. Improved strength, puncture resistance and barrier protection properties will keep sterile pouches the leading container for medium- to large-sized medical and dental devices and supplies, including catheters and related tubing apparatus, face masks and IV administration sets. Cost advantages will continue to favor the use of pouches over thermoformed trays in these applications. Plastic bags will remain the leading competitive container to pouches in the packaging of large medical supplies and devices with lower barrier protection requirements. Sales of sterilization wrap will climb from US$340 mln in 2005 to US$420 mln in 2010�rising about 4.3% pa. Plastic resins�particularly polyvinyl chloride, polyethylene, polypropylene and thermoplastic polyesters�will continue to dominate the market for sterile packaging raw materials.
Some of the new developments according to Tony Deligio in super barrier films in the medical sector for pharmaceutical, nutraceutical and device packaging include:
PCTFE- and PVdC-powered barrier
Kl�ckner Pentaplast has introduced four-layer PVC/EVOH-PE/ACLAR/PVC to meet the extremely high oxygen- and moisture-barrier requirements of pharmaceutical and nutraceutical blister-packaging applications, extended its line of Pentaphram ACLAR structures at Pack Expo, saying the latest offerings extend gas-barrier performance. This film, which sandwiches barrier materials EVOH and ACLAR polychlorotrifluoroethylene (PCTFE) between layers of vinyl, is also designed for good lay flat and machinability on standard form/fill/seal packaging lines.
The company has also expanded its line of Pentapharm kpMkax films for the most oxygen- and moisture-sensitive products. The four-layer structure here consists of PVC/PVdC/ACLAR/PVC, with polyvinylidene chloride replacing EVOH to combine with and augment the barrier properties of PCTFE.
Sealant-free, FDA compliant
Rollprint Packaging Products Inc has developed Triad high-barrier solventless overwrap. The sealant layer of a new high-barrier overwrap can bond to foil without the use of solvent- or water-based materials, helping satisfy FDA requirement that items like inhalants be delivered in solvent-free packaging. Triad is an extrusion-coated lamination of polyester, aluminum foil, and metallocene polyethylene (PE). The key feature of the product is an extrusion laminator that applies the PE sealant at a thickness of only 0.5 mil with a downstream sealing rate of 30 meter/min. In a typical overwrap product, each side has 1.5 to 2 mils of sealant, which doubles to 3-4 mils once the package is joined. For Triad, max sealant thickness is only 1 mil, which helps speed sealing since less material needs to be heated.
ExxonMobil Chemical has introduced BOPP multilayer which uses vacuum deposition of film business also touted barrier properties and seal strength with its line of Metallyte multilayer biaxially oriented polypropylene (BOPP) films, which use vacuum deposition to add aluminum, instead of a laminated aluminum foil. By using vacuum deposition, weight can be reduced by 30-50% and o at the same time offer stronger barrier. ExxonMobil uses the proprietary vacuum deposition process resulting in aluminum that doesn�t break down when the package is crinkled.
Mitsubishi Plastics Inc has introduced a superhigh-gas-barrier film called X-Barrier that enables the production of flexible roll-to-roll plastic electronics and reliable protection for medical products. This film has water-vapor transmission rate of only 10-4 g/m2/day which is essential for this industry.
X Barrier film is metal-free and instead has silicon dioxide (SiO2) vacuum-coating. This film blocks out gases like hydrogen, oxygen and carbon dioxide, with the barrier properties reportedly maintaining high performance in the long-term presence of high temperature and humidity. Mitsubishi anticipates potential X-Barrier markets in high-performance medical, pharmaceutical, and industrial packages, especially for products like catheters, surgical sutures, contact lenses, tablets, capsules, liquid prenatal nutrition and dialysis treatments � all items that require oxygen- and high water-vapor barrier.
Other potential applications and markets include packing material for humidity-sensitive products like polymers, amino acids, chemicals, semiconductors components, flat-panel displays, and building materials, as well as working as an encapsulation material for electronic devices.
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