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1 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Renewable Xylan-based Barrier for Packaging
Presented by:
Lisa BindgårdTitle:
Xylophane AB
13TH TAPPI
EUROPEAN PLACE CONFERENCE
30 May - 1 June 2011 Bregenz, Austria
Xylophane
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2 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Structure
• This is Xylophane
• Xylan – the raw material
• Material properties
• Process of application
• Multi-layer structure
• Results from customer projects
• Status
• Conclusion
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3 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Xylophane = xylan-based barrier againstoxygen, grease and aroma
Xylan-based coating
Xylan‐based coatings can provide oxygen barrier, aroma barrier and grease barrier properties.
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4 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Xylan – natural polysaccharide
Molecular structure of arabinoxylan
Xylan is a natural polysaccharide present in wood and agricultural residues. Xylan belongs
to the group of hemicelluloses. The molecular structure shown relates to arabinoxylan
which has a backbone of xylose units and substituents of arabinose.
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5 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Xylan content in barley husks
Xylan40-50%
Cellulose15-25%Other
Starch10-25%
5
The results in this presentation relate to arabinoxylan derived from barley husks. The xylan
fraction in barley husks is about 40‐50%. Apart from xylan barley husks contain e.g. starch
and cellulose.
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6 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Feed stock for xylan production
• Availability of husks/hulls
• 70 000 – 100 000 tons/year in Sweden
• > 5 000 000 tons/year in Europe
• Low value by-product – no competition with food
• Alternative end-use of feed stock:
• animal feed - not ideal from nutrition point of
view
• incineration – inefficient due to high ash content
The availability of xylan in agricultural by‐products is huge. More than 5 000 000 tons of
husks and hulls are generated in Europe every year. Husks and hulls are today a low‐value
by‐product which is not competing with food. Alternative end‐uses such as animal feed and
incineration for energy extraction are limited. Husks and hulls have limited nutrition value
and are therefore not ideal from an animal feed point of view. Incineration of husks and
hulls is inefficient due to high ash content.
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7 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
From agriculture by-products to xylan-basedbarrier in multilayer packaging
Grains are peeled and the husks and hulls goes into the process. The grain itself goes for
food production. Xylan is isolated by extraction and a powder is generated. The powder is
mixed with additives and dispersed/dissolved in water. Dispersion coating is used to apply
the barrier layer onto paper, cardboard or plastics. The material can then be further
coated, converted and filled to form complete packages with barrier properties.
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8 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Comparison oxygen barrier properties
OTR (cc/m2/day)
Aluminium foil << 1
Xylan-based barrier < 10
EVOH < 10
PVdC < 10
PA MXD6 50
OPET 250
LDPE 10 000
5 µm, 23°C, 50% RH
The table shows a comparison of barrier properties of xylan‐based coatings and
commercially available barrier materials. A xylan‐based coating of 5 g/m2 gives rise to
oxygen barrier properties below 10 cc/m2/day. This is in the same range as the synthetic
barrier plastic EVOH.
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9 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Excellent grease barrier properties foradvanced applications
Coated side
Reverse side
• KIT-level 12 can be obtained onto
suitable paper and board substrates
• Xylan-based barrier resists penetrationof aggressive substances such asetheric oils
Xylan‐based coatings also exhibit excellent grease barrier properties. KIT level 12 can be
obtained onto paper and board based substrates. It can also resist penetration of
aggressive substances such as etheric oils.
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10 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Example of end-use applications
Exemple of suitable end‐uses for xylan‐based barriers are board and paper based
packaging for dry and greasy foods such as snacks, dehydrated soups and sauces, coffee,
spices and petfood. In the future xylan‐based coatings could potentially also be used in
liquid packaging board.
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11 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Process of application: dispersion coating
• Several coating techniques possible e.g. blade
coating, air knife, curtain coating, roll coating
• Application onto paper, board and plastics
• Coating trials in industrial and pilot scale have
showed
– Good processability
– No blocking
– No blistering
Coating trial at UMV Coating
Systems, Säffle
Xylan‐based coatings are applied by dispersion coating. Several techniques could be used
such as roll coating, air knife, curtain coating and blade coating.
Application onto paper and cardboard is advantageous since this type of substrates lack
barrier properties by the nature. In addition dispersion coating is an available technique in
paper and cardboard production and barrier properties can thus be applied online or
offline. A further advantage is that a renewable barrier coating is added onto a renewable
base substrate.
Coating trials have shown that the processability of xylan‐based coatings is good. The
material has a low tendency to block and form blisters.
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12 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Viscosity of dispersion
Viscosity for slurry with (top curve) and without (bottom curve) filler.
T=45°CT=30°C
The xylan‐based slurry shows a shear thinning behavior. The viscosity is strongly dependent
on the xylan concentration which limits the maximum dry content. The dry content could
thus be increased by addition of inorganic fillers. The viscosity decreases with increased
temperature. Application in elevated temperature , e.g. 45 °C, can enable a higher
coat weight and reduce the amount of water that needs to be dried off.
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13 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Effect of precoating
13
Precoating
Xylan-based coating
Board / Paper
Board / Paper
Xylan-based coating
• Reduced coat weight of barrier coating
• Improved properties
• Cost-efficient solution
In order to get good barrier values, the substrate needs to be homogeneous and not too
porous. By applying a precoating onto the paper or cardboard, a more even surface is
created.
Also the water penetration into the hydrophilic paper or board is reduced by precoating. If
the water‐based xylan coating is absorbed into the paper or board, an uneven xylan‐based
coating layer is obtained resulting in deteriorated barrier properties. Absorption of the
water‐based xylan coating into the paper or board can also result in fiber rising which
penetrates the barrier layer and creates pinholes.
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14 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Effect of precoating
Cardboard
Precoating
Xylan-based coating
Cross section SEM picture of a multilayer material consisting of cardboard, precoating and
xylan‐based coating.
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15 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Effect of precoating
Board with / without precoating Xylan-based coating
#Pre-coating
type
Coat
weight
[g/m2]
Precoating
Water
absorption
COBB
[g/m2]
Surface
roughness
Bendtsen
[ml/min]
Coat
weight
[g/m2]
Grease
barrier
KIT
Oxygen
barrier
OTR
[cc/m2/day]
1 - 0 29.8 ±0.6 414±34 10 8 ±0.6 >100
2 A 6 8.7±3.0 222±40 10 12 ±0 3.5
3 B 6 8.2±3.5 235±39 10 12 ±0 8.6
4 C 6 11.8±2.9 269±38 10 12 ±0 6.9
The table illustrates the effect of precoating on the oxygen barrier properties of the xylan‐
based coating. The water absorption and surface roughness have been measured on
precoated and non‐precoated board. The grease and oxygen barrier properties obtained
when subsequently applying the xylan‐based coating onto these boards are also presented.
The oxygen barrier properties are clearly improved for samples with precoating compared
to the sample without precoating. The precoating formulation can be optimized for the
current paper or board substrate. However as can be seen in the table, the use of different
precoating types in this study only had a slight effect on the oxygen barrier properties
obtained from the xylan‐based coating.
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16 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Precoating: Prevention of blocking byadding filler
Subtrate Amount of filler Time
min
Load
kg
Temp. Level o f b lock ing
MG, 50 g/m2 non 20 10 23°C 4
MG, 50 g/m2 low 20 10 23°C 4
MG, 50 g/m2 medium 20 10 23°C 1
MG, 50 g/m2 high 20 10 23°C 1
MG, 50 g/m2 non 50 4 105°C 6
MG, 50 g/m2 low 50 4 105°C 6
MG, 50 g/m2 medium 50 4 105°C 2
MG, 50 g/m2 high 50 4 105°C 1
Qualitative evaluation of blocking :Level 1= no blocking and Level 7 = fiber tear
Precoating chemicals have shown high tendency to block. The effect of the addition of
inorganic filler on blocking tendency was studied.
Three different filler levels were added (low, medium and high) based on dry content of
precoating dispersion. Stripes of MG‐paper 7x29 cm were cut and coated using K‐Control
Coater 202. The samples were dryed in oven at 105°C for 2 minutes. Two samples were put
together topside vs coating and were covered with a metal plate and a weight of 10 or 4 kg
in ambient temperature or 105 °C. After 20‐50 minutes the metal plate was removed and
blocking was evaluated by tearing the samples apart from each other. The level of blocking
was graded at a 7‐grade scale were 1 relates to no blocking and 7 relates to fiber tear.
The results show that a medium or high filler level in the coating formulation strongly
reduces the blocking tendency of the coating.
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17 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Paper board
Further conversion – Extrusion coating ofmoisture barrier
• Extrusion coating of moisture barrier onto
paper board with xylan-based coating
• Xylan-based barrier could withstand the
extrusion coating process
• Adhesion measured with Y-peel
Machine setup for Y-peel test
Pre-coatingXylan-based coating
LDPE
To achieve a multilayer material with moisture barrier properties as well as heat sealability
xylan‐based coating could be combined with extrusion coated plastics. The xylan‐based
coating can resist the extrusion coating process and a good adhesion could be obtained
between the xylan‐based coating and the extrusion coated plastic. In this project the
adhesion was measured with Y‐peel. In the Y‐peel test, the board is fixed in a 3‐clamp
arrangement were the free ends are fixed at a constant angle 90°. The method has got a
better repeatability than e.g. T‐peel.
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18 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Adhesion
Good adhesion
Y‐peel test was used to measure the adhesion between the xylan‐based coating and board,
between the xylan‐based coating and pre‐coating, and between the xylan‐based coating
and LDPE. Uncoated board with LDPE was used as reference. When measuring the
adhesion between the xylan‐based coating and board, the fracture was cohesive which
means that the fracture was within the board. Fibers could clearly be seen on the fracture
surface.
The adhesion between the xylan‐based coating and LDPE (precoating+X/LDPE and X/LDPE)
was lower than the adhesion between the uncoated board and LDPE (Board/LDPE). This
may depend on better mechanical interlocking due to the higher surface roughness of
uncoated board compared to xylan‐based coating onto uncoated board and pre‐coated
board. The adhesion between LDPE and the xylan‐based coating on uncoated and on pre‐
coated board were similar.
There are no standard values to rank the adhesion results since it depends on application.
According to a board manufacturer, WDdesc > 0.3mJ/mm means excellent adhesion,
WDdesc ≈ 0.3mJ/mm means good adhesion. The LDPE adhesion can be improved by
further corona treatment of the substrate and also by ozone treatment of LDPE in the
extrusion nip.
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19 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Customer project: Xylan-based barrier asgrease and aroma barrier in industrial sacks
• Development project in cooperation
with two customers
• Three problems to solve which were all
related to penetration of etheric oils:
– Grease stains on sack paper
– Labels fell off
– Loss of weight during storage (up to 5%)
An industrial test to verify xylan‐based coating as grease and aroma barrier in industrial
sacks for spices was performed in cooperation with sack manufacturer Jonsac AB and spice
producer Bodén & Lindeberg. had three problems related to the current barrier function of
their paper sacks:
1.Grease stains were formed on the outside of the sack due to penetration of etheric oils.2.Labels fell off due to grease penetration.
3.The weight of the sacks was drastically reduced during storage due to e.g. penetration of
etheric substances.
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20 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
OXYGEN
GREASE
AROMA
• Dispersion coating of xylan-based
barrier in industrial scale
• Sack production in industrial scale
• Filling with product (spices)
• Storage test and evaluation
Xylan-based barrier
LDPE
Sack paper
Customer project: Xylan-based barrier asgrease and aroma barrier in industrial sacks
A xylan‐based coating was applied onto LDPE‐coated Kraft paper by dispersion coating.
Three layer sacks were manufactured of which the layer coated with xylan‐based barrier
was put in the middle. 200 sacks were filled with each 20 kg of cardamom in an industrial
filling process and those were stored for 6‐8 weeks in a warm storage area. The sacks were
visually evaluated and weighed and the results were compared to three layer reference
sacks without xylan‐based coating.
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21 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Customer project: Grease barrier problemsolved!
Reference With xylan-based barrier
”You have certainly been successful with the barrier. It works very wellfor the packaging of etheric oils and grease containing spices.
We have had problems with fat stains on the outside of the paper sacks
and labels that were falling off due to etheric oils penetrating the bags.With a xylan-based barrier we could eliminate this problem.”
Peter Karlsson, Stores Manager, Bodén & Lindeberg
The results showed that a xylan‐based barrier layer in the sack construction gave rise to
excellent grease barrier properties for the current application. There were no grease stains
on the outside of the package and the labels were still stuck on the sacks containing a
xylan‐based coating. The weight reduction during storage was just one tenth of the weight
reduction of the reference bags (0.5% instead of 5%).
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22 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Customer project: Xylan-based coating asoxygen barrier in crisp bags
• Project performed with packaging
material converter
• Driver: to find sustainable alternatives
to metalized film
• Application: paper-based bags for
potato crisps
In another project crisp bags with a xylan‐based oxygen barrier instead of metalized foil
were produced to obtain a more sustainable packaging solution. The project was
performed in cooperation with a converter and a crisp producer.
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23 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Customer project: Xylan-based coating asoxygen barrier in crisp bags
• Dispersion coating of xylan-based coating
• Extrusion coating of moisture barrier
• Conversion to crisp bags in conventional
bag filling equipment
SampleWVTR
(38 ° C, 90% RH)
g/m2/day
WVTR(23 °̊ C, 50% RH)
g/m2/day
OTR(23 ° C, 50% RH)
cc/m2/day
Paper/pre-coating/xylan-based coating/LDPE 13.6 1.4 3.8
Pre‐coating as well as xylan‐based coating were applied onto MG‐paper using dispersion
coating equipment with two coating stations. The material was further coated with a layer
of LDPE using extrusion coating equipment.
The oxygen transmission rate as well as the water vapor transmission rate (ASTM F 1249‐
05) of the multilayer material were measured. The barrier properties obtained were
suitable for the contemplated application. The multilayer material was further converted
to crisp bags and filled with potato crisps. The conversion was successfully done with the
existing bag conversion and filling equipment.
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24 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Status: Development in cooperationwith customers
• Development projects in lab, pilot and
industrial scale with potential customers
• Strategic development projects with
board and paper producers
• Market entry application projects with
brand owners and converters
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25 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Status: Pilot production plant
• Pilot unit for xylan production
• Optimisation of production
process for further upscaling
• Production of raw material for
customer trials and commercial
material for niche applications
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26 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Customer projects and product/process optimisation will
form base for volume production decision
2009 2010 2011 2012
Start pilot Decision
for volume
production
Customer projects: lab tests, pilot & industrial trials
Product development
Process optimisation
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27 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Summary
• Xylan-based barrier - a renewable alternative to
synthetic plastics and metal foils
• Optimization of multi-layer structure important
• Development of xylan-based barrier in cooperation
with customer to prepare for commercial use
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28 Lisa Bindgård, Xylophane AB 13th TAPPI European PLACE Conference 2011 Bregenz - Session 3 - Paper 1
Thanks for yourattention!
Please
remember
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PRESENTED BY
Lisa BindgårdM.Sc. in Engineering Biology
Xylophane AB
E-mail: [email protected]
Xylophane