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Moisture barrier solutions for PET food and beverage containers
Background

Amcor Rigid Packaging (ARP) is a leading producer of rigid plastic containers for food, beverage, health care, and home/personal care markets. ARP has a substantial presence throughout the Americas and produces packaging from several plastic materials and utilizes many molding processes including injection molding, injection-stretch-blow molding, and extrusion blow molding to produce sustainable consumer packaging. 

 

Traditionally, moisture-sensitive products like dry goods have been packaged in non-PET formats. This is due to the fact PET inherently lacks the desired level of moisture barrier needed to reach the targeted shelf-life for these product types. These products include dry goods such as coffee, baby formula, nuts, spices, powdered milk, etc. Due to the high moisture barrier requirements these products are generally packaged in containers made from metal, glass, polyolefin plastics materials [high density polyethylene (HDPE); Polypropylene (PP)], or laminate structures including foils or other high-barrier materials. 

 

The heightened societal and consumer expectations for more eco-friendly, recyclable packaging has driven a growing interest in packaging these products in containers made from PET. This is driven by the facts: 1) PET is easily recycled and introduced back into subsequent packaging; 2) PET recycling is broadly available; 3) the manufacture of PET containers results in production of less Green House Gas (GHG) emissions vs. competing alternatives. 

 

Unfortunately, PET lacks the desired level of moisture barrier required to meet targeted shelf life for these products. Often times, the existing package formats have moisture barrier performance of greater than 20x that of PET. Conventional solutions for improving the moisture barrier of PET containers have several limitations. Generally, these limitations are in the form of high cost, incompatibility with the PET recycle stream, or limited barrier performance.

What we're looking for

We are seeking improved moisture barrier solutions for PET containers that meet requirements for performance, cost, and recyclability.

Solutions of interest include:
  • An additive to the PET material prior to processing
  • A coating applied to the preform or end PET container
Our must-have requirements are:
  • Effective passive barrier to moisture. Solution should ideally improve H2O barrier by a factor of 5x or more (< 0.8 gH2O @ 36 mos.) based on 6oz canister with 207.4 cm2 surface area and average wall thickness of 34 mils. (Current PET: 6oz canister with 207.4 cm2 surface area and average wall thickness of 34 mils. Calculations at 23°C/50%RH in air (delta RH = 50%) - for 24g PET monolayer container: gH2O@ 36mo = 4.33)
  • For an additive, processing temperature range compatibility with PET extruder processes (240 to 300 C)
  • Final product is compatible with existing PET recycling stream
Our nice-to-have's are:
  • Capability of receiving regulatory approvals for FDA food contact and similar international equivalents
  • Compatibility with common manufacturing processes for PET packaging
  • Clarity of the end product is comparable to glass (Haze < 2%)
  • An added cost to the barrier of no more than $10 per 1,000 containers based on 25g PET container (or potential of reaching this threshold)
What's out of scope:
  • Materials that do not meet food contact requirements or materials containing BPA, PFAS, TMPP.
  • Solutions not compatible with existing PET recycling stream.
What we can offer you
Benefits:
Sponsored Research
ARP is willing to invest funding for high potential research & proof of concept (typically ranging from $25k-100k USD with potential follow-on) based on value proposition of technology proposed.
Expertise
ARP possesses industry leading experts in packaging design, engineering, materials science to provide guidance in development, prototyping, & testing and exposure to world's largest consumer brands.
Tools and Technologies
Amcor can provide access to state of the art R&D facilities & pilot equipment for designing, prototyping, & evaluating performance of injection & blow molded containers.
Facilities and Services
ARP R&D pilot facilities include variety of manufacturing platforms, lab testing equipment, simulation capabilities.
Who we are

We solve packaging challenges, around the world every day. We develop differentiated products, services and processes to protect your products and the people who rely on them, all around the globe. Drawing on unrivaled heritage in design, science and manufacturing, more than 1000 R&D experts are innovating new materials, formats and technologies to better protect your products.

In 2018 we pledged to develop all our packaging to be recyclable or reusable by 2025. On our journey to our 2025 pledge we are innovating across various sustainability options, delivering you more sustainable packaging solutions under the new EcoGuard™ brand.

 Learn more
Reviewers
GC
Gregory Carpenter
Senior Scientist
FB
Frederick Beuerle
Sr. Director, Innovation & IP
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