Section D. New Consumer Packaging Trends & Major Topics · New Consumer Packaging Trends & Major...

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New Consumer Packaging Trends & Major Topics

D.1 ACTIVE PACKAGING AND SMART PACKAGING

1. Active Packaging

There are several types of active packaging categories.

1) Oxygen absorbers (Oxygen scavengers)

2) Ethylene absorbers

3) Moisture controllers

4) Anti-microbial packaging

5) Edible films

This section highlights oxygen scavengers.

1.1 Oxygen Scavengers Market

In Japan, oxygen scavengers have been commercial for about 30years. Oxygen scavengers are used widely in Japan, especially in foodpackaging. The total Japanese production of oxygen scavengers isestimated at 18.5 billion (based on 100ml oxygen absorption) in 2003.

Packaging Strategies Japanese Packaging Innovations - 47

Mitsubishi Gas Chemical Company holds approximately 70% of theoxygen scavenger market in Japan. The second largest producer isToppan Printing Co., Ltd., which has a market share of approximately12%.

1.2 Oxygen Scavenging Technology Developments

1) Oxygen scavengers for retort food packaging

Ajinomoto Co., Ltd. has developed and commercialized itsRetort Foods Packaging (Retort Pouch) incorporating anoxygen scavenger. The oxygen scavenger is made ofpolypropylene-combined iron powder and eliminates residualoxygen in the package. The retort pouch consists ofPET(12)/AL(7)/modified PP(10)/oxygen scavenger(30)/CPP(30)and improves the food taste compared to a conventional retortpouch consisting of PET(12)/AL(7)/modified PP(15)/CPP(60).( ): thickness (µm)

This oxygen scavenging technology came into Dai NipponPrinting’s possession by the acquisition of Ace Packaging Co.,Ltd. (Packaging Division Company of Ajinomoto Co., Ltd.).

2) Oxygen scavenging film

Mitsubishi Gas Chemical has developed an oxygenscavenging film called Ageless® Omac.The oxygen scavengingfilm has an oxygen absorbing layer between the barrier layerand the sealant layer in multi-layered packaging film. Activatediron powder as the oxygen scavenger has been mixed, blendedand dispersed in the oxygen absorbing layer.


Fig. 30 Market Share of Oxygen Scavengers in Japan

Source: The Japan Food Journal, P8, July 9, 2003

Mitsubishi GasChemical

(71%)

Others(17%)

Toppan Printing(12%)

There are two types of the Ageless® Omac oxygenscavenging film.

3) ”Oxyblock”

Toyo Seikan Kaisha, Ltd. has developed “Oxyblock,” whichcontains both active and passive oxygen barrier materials. Thebarrier material consists of PA (MXD-6) and a proprietaryoxygen absorbing agent.

The “Oxyblock” material can be applied for beverages suchas hot-filled tea in multi-layer PET bottles composed ofPET/barrier/PET/barrier/PET.

For more information, see Section E.32 Toyo Seikan.

2. Smart Packaging

There are several types of smart packaging.

1) Indicators: temperature, oxygen, etc.

2) RFID smart labels and tags

3) Steam vents for microwaveable foods

4) Self-cooling and self-heating packaging

This section highlights indicators.


Fig. 31

Outer Layer

Barrier Layer

Oxygen Scavenging Layer

Sealant Layer

(PET, OPA etc.)

(AL, MXD-6, EVOH, Ceramic-coated)

(Polyolefin + iron-based Oxygen Scavenger)

(Polyolefin)

Type Base Resin Applications

Omac R PP Retort foods

Omac B PE Boiled foods, Hot filled foods

Table 14 Types of Ageless® Omac Oxygern Scavenging

2.1 Temperature Indicator

Nichiyu Giken Kogyo Co., Ltd. is the leading producer oftemperature indicators in Japan. Nichiyu Giken Kogyo has developedan indicator label called Retomark™, which shows a color changeduring retort-sterilizing, boil-sterilizing, etc. There are four types ofRetomark™ labels.

The Retomark™ technology can be applied to a retort pouch. Inthat case, the temperature indicator is printed between the PET filmand the AL foil.


Fig. 32

Before After

Fig. 33 Color Change by Retort-sterilizing

Indicated markafter retorttreatment

TypeTemperature of

Color Change (°C)Time (Min.) Application

R1 110-134 5-30 High-retort sterilization

R2100-120 5-15 Retort sterilization

90-100 30-120 Boil sterilization

R3 70-100 3-60 Boil sterilization

R4 60-100 3-60 Low temperature boil sterilization

Table 15 Types of Retomark™Labels

2.2 Oxygen Indicator

Toppan Printing Co., Ltd. has developed an oxygen indicatorpackage by using oxygen sensitive ink. The package has theadvantage of visibility of the oxygen content in a pouch through acolor change of the indicator.

The package consists of a high-barrier film, and an oxygenscavenger and indicator, and will be marketed for monitoring oxygenin a pouch. Typical applications are for medical use (IV bag, etc.) andoxygen-sensitive foods.

Please see also Section E.27 Toppan Printing.


D.2 BIO-DEGRADABLE PLASTICS

1. General Review

In Japan, the market size of plastic resins is approximately 15 million tonsper year, and the production of bio-degradable thermoplastics is estimated to be15,000 tons in 2003. It is projected that the bio-degradable plastics segment willgrow and replace about 10% of all plastics by 2015. Poly-lactic acid (PLA),polybutylene succinate (PBS), and starch-based plastics are the top threecategories among the bio-degradable plastics in the market.

In regards to PLA, Mitsubishi Plastics, Mitsui Chemicals, and Unitika, havemade a supply contract with Cargill Dow and have been improving the PLAresin to develop a range of applications. PBS has been developed mainly byShowa Highpolymer and has found applications mostly in the non-food sectorssuch as agricultural.

The Biodegradable Plastics Society (BPS) wasestablished in October, 1989 to promote the technologydevelopment of bio-degradable plastics (GreenPla) and tolead extensive, commercial use of GreenPla.

More information about BPS and the list of itsassociated companies is available athttp://www.bpsweb.net.

Recently, TOYO INK and Dainichiseika developed a bio-degradable gravureink, which can be applied to bio-degradable films.

In Japan, food hygiene was one of the obstacles facing the use of PLA in thefood segment for many years. To help bio-degradable plastics facilitate into thefood service market, the Ministry of Agriculture, Forestry, and Fishery (MAFF)has been conducting in-field testing of tablewares made of bio-degradableplastics since November 2003 to collect various data and consumers’responses.

Following the Food & Drug Administration’s (FDA) approval of PLA inJanuary 2004, the Japan Hygienic Olefin And Styrene Plastic Association(JHOSPA) recognized the poly-lactic acid (PLA) on its independence standardon June 1, 2004. Now each company can attach a “PL mark” to the packageusing PLA-based plastics on the individual registration system. This is the firsttime that a bio-degradable plastic made from agricultural renewable resourceshas been authorized.

The resin number for its independence standard is “2-50,” and its symbol is“PLA.”

Various types of bio-degradable food containers and packages will be testedand introduced at World Expo AICHI JAPAN 2005, from March until September,2005. It aims to establish and operate a new recycling system as well as a new


energy system in which bio-degradable plastics are utilized and an effectiveuse is found for decomposable waste. At the Expo, 1,600,000 90-liter-sizebio-degradable garbage bags are going to be used.

In the Fall of 2005, Toyota Motor is planning to work on the actual pilotplant in Indonesia where it will produce PLA made from sugarcane. It isgoing to supply a broad range of plastic products besides auto-parts.

2. Applications for Packaging

The latest applications using bio-degradable plastics, including examplesexhibited at Tokyo Pack 2004, are as follows:

2.1 Non-food Packages

1) Blister package for dry battery cell

Matsushita Battery Industry adopted PLA for its blisterpackage for a next-generationsingle three-type dry battery cellcalled the “Oxyride Dry Cell.”Including its application for itsalkaline dry battery cell, whichstarted in June 2003, theapplication will amount in total to100 tons for 25 million packsannually. Moreover, an easy-to-open mechanism and universaldesign are considered in thispackage. Mitsubishi Plastics’PLA “ECOLOJU” is used.Umeda Vacuum Package jointlydeveloped the package as acontract-packer.

2) Home electronics

Sony utilizes PLA for the body of its “Walkman.” Thistime, Sony has added a non-contact IC card utilizing PLA,produced jointly with Mitsubishi Plastics, on September 1,2004. Fujitsu has already adopted PLA for its personalcomputer. NEC will adopt bio-based plastics for the “dummycard” part of the memory card for its PC. NEC said it plansto convert 10% or more of its plastics used for its personalcomputers by 2010 to bio-based plastics.


Fig. 34 Blister Package

Source: Mitsubishi Plastics

3) Bionolle

Bionolle (aliphatic polyester),developed by Showa Denko andShowa Highpolymer, is used fornon-food applications. ToyoChemical (Kochi-city) developed itslow-temperature shrinkable filmusing Bionolle. Its printability andheat-seal strength are said to beexcellent. Okura Industrial alsodeveloped transparent shrinkablefilm by blending a variety of bio-degradable plastics.

Besides packaging applications,bio-degradable films are mostlyused for window film for envelopesand also recently for pillow packages for the handlingdescription of cellular phones.

2.2 Food Packages

1) Packages for produce

PLA films are used for produce such as asparagus,tomatoes, and green peppers. Mitsubishi Plastics’ PLA“ECOLOJU” enjoys wide applications in this field. Recently,“ECOLOJU” has been adopted as a package for bean sprouts(Fig. 36) and mandarin oranges.

Tohcello has been manufacturing its bi-axially oriented filmusing PLA called “LACEA” supplied by Mitsui Chemicals.LACEA is also adopted as the lid material for trays for a beansprout product called “alpha & flax,” which is printed with a bio-degradable ink (Fig. 37).


Fig. 35 Bionolle Products


Fig. 36 Bean Sprouts


Fig. 37 Bean Sprouts “Alpha & flax”

Source: Tohcello

2) Shrink films

Bio-degradable films are used for the cap seal ofAjinomoto’s seasoning bottle.

3) Bowls

Unitika’s PLA called ”TERRAMAC” is adopted forthermoformed bowls and features high heat resistance upto 140°C. The bowls are available for bento boxes.

4) Zipper pouches

Seisan Nipponsha has developed zipper pouchesutilizing bio-degradable plastics.

2.3 Bag-making Machines

Totani has developed a bag-making machine using bio-degradablefilms with its proprietary “pre-blocking system.” PLA film is moredifficult than other films such as PE and PP film to make bags withoutwrinkles or creases. PLA film generally has loose parts on its surfaceand easily gets wrinkled or creased when welded. Totani’s “pre-blocking system” solves this problem of PLA film creasing. The PLAfilm is pre-heated gently by the pre-blocking system to make the looseparts flat and welded without wrinkles or creases.


Fig. 38 Ajinomoto’s seasoning bottle


D.3 MICROWAVEABLE PACKAGING

1. Market Trends

The first market entry of microwaveable foods was “House RenjiGourmet” from House Foods Inc. in 1985. This new product recordedincredible sales. Due to the success of this product, many companies havecome to sell many different kinds of microwaveable foods. Mineral-filled PPcontainers with barrier properties were used in the early days ofmicrowaveable packaging. Most of the microwaveable foods were retorted atfirst and then were frozen later. In 1995, more than half of all frozen foodsand more than 70% of new food products were categorized asmicrowaveable foods in Japan.

For microwaveable foods, the use of the pouch has been increasing dueto the need for source reduction. When microwaveable pouches firstappeared, they had to be opened before microwave heating. Later, amicrowaveable pouch with an auto-vent mechanism, which features anautomatic opening at a pre-determined inner pressure, was developed. Thismicrowaveable pouch was first adopted for frozen foods in 1995. It was afour-sided pouch with a vapor exit on the side-seal part.

More than 20 companies developed similar microwaveable pouches andcontainers. They are now being sold and used for mainly frozen and retortfoods. For microwaveable pouches, rupture resistance and uniformity ofheating due to the steaming effects on the contents is required.

For auto-vent openings:

1) By giving easy-peel properties to the heat-seal part of the pouch, the seal part opens due to the increased inner pressureupon microwave heating. For this method, unique techniques are applied for the sealant film, sealing position and sealing shape.

2) A hole is made in the front surface, and it is patched by small pieces of sealing film. Thus, upon microwave heating, the innerpressure breaks the sealant film, resulting in a vapor exit. For this method, a unique mechanism can be seen on the hole andsealant film selection.

3) For this part of the pouch, porous material for the vapor exit is used. Porous material such as non-woven fiber or Tyvek is typically used.

In 2003, a retorted curry sauce packed in a microwaveable pouch waslaunched. This pouch has an auto-vent port which remains unopened duringthe retort process. This pouch passed Japanese regulations for foods using


the retort process. This is a four-sided pouch called the “Renji DO! T-shape”from Sun A .Kaken Co., Ltd. A four-sided pouch and a stand-up pouch whichare both sold under the trade name “Quick Deli/Retort Pouch” from KyodoPrinting Co., Ltd. are two other examples of microwaveable pouches usedfor retorted foods.

2. Microwaveable Pouch

2.1 Sun A. Kaken Co., Ltd. “Renji DO!® T-shape” Pouch

Retortable, four-sided microwaveable pouch

Shape:

The fin sealed convex part, which acts as a vapor exit, ismade on one side of the four-sided pouch.

Features:

Sun A. Kaken is well known for its proprietary sealantfilms. The sealing strength required for a retortable pouch,23N/15mm, is achieved at 23°C for this film. In case of<90°C during microwave heating, seal strength such as>12N/15mm is achieved for this film. The convex portion onthe fin-seal part faces up during microwave heating, theinner pressure is concentrated on the convex part and thevapor exit opens. In addition, the pouch expansion iscontrolled and the vapor exit of the pouch can be openedeasily.

Film composition example:

Transparent-deposited PET(12µm)/ OPA/high retortableCPP (60µm). Transparent-deposited PET is used for bothbarrier properties and microwaveability. For the sealant,high retortable CPP featuring thermal resistance to endurethe retort process is used. This proprietary CPP film wasdeveloped by Sun A. Kaken to achieve a high retortableCPP film.


2.2 Kyodo Printing Co., Ltd. “Quick Deli™/Retort Pouch”

Retortable and microwaveable pouch

Shape:

The “Quick Deli™/Retort Pouch” is available in threetypes of pouches: a stand-up pouch, a four-sided pouchand a four-sided customized-shaped pouch. The stand-uppouch can be heated in a microwave oven standing up.

Features:

A special processed sealing part is provided. Thissealing part has passed both the sealing strength regulationof 23N/15mm required for a retortable pouch, and the retortprocess for 30 minutes under 120°C. Upon microwaveheating, this sealing part gradually opens to controladequate air exhaust. Due to this controlled exhaustmechanism, the pouch does not burst. In addition, due tothe adequate vapor exhaust, a stable inner pressure ismaintained and water vapor in the foods is controlled,resulting in a steaming effect.

“Quick Deli” series:

Other than this pouch, the company also sells a pouchexclusively for boiled foods and a pouch exclusively forfrozen foods.


Fig. 39 Kyodo Printing’s “Quick DeliTM

/Retort Pouch”

2.3 Tachibana Packaging Co., Ltd. “Chef pack” Pouch

Tray with microwaveable lidding

Shape:

A vapor exit (steam vent) is created on both sides of thetray’s flange part. The top seal film is double-sealed aroundthe vapor exit and the outer side of each hole. Then, with itstop sealed, the tray can be heated in a microwave oven.

Features:

Upon microwave heating, the sealing part around thevapor exit of the top seal is first peeled off, while the outersealed part of the top seal remains. While the outer sealingof the top seal stays, vapor can exit from the vapor exit onthe tray’s flange part. Thus, the same cooking effects asthat of a pressure cooker can be achieved with the “Chefpack.” The inner pressure in the tray allows foods to becooked in a short time and the inner temperature can beraised up to 103°C. In addition, with this double-sealedmechanism, the controlled water evaporation allows foodsto retain 10-15% more water than those packed inconventional containers.

Packaging composition:

Tray : mineral-filled PP

Lidding (top seal) : OPA/PET/easy-peel film


D.4 RESEALABLE BOTTLE CANS

1. Can the “Bottle Can” Be the Rebirth of the Beverage Can?

According to the estimate by Beverage Japan Inc., theconsumption of drink cans in 2003 reached 30.97bn cans (95% to2002), consisting of 13.28bn steel cans (86% to 2002) and 17.69bnaluminum cans (102% to 2002). The upturn in aluminum can usagedespite a continuous decrease in steel cans was due to the marketacceptance of resealable Bottle Cans.

According to the estimate by Daiwa Can Co., the pioneer of the“Bottle Can” concept which launched its “New Bottle Can” for beer inMay 2000, the total shipment of Bottle Cans in Japan wasapproximately 2.3 bn cans in 2004, which is a 50% increase from2003. It is also estimated that the shipments by each of the threeexisting producers of Bottle Cans is 1.1 bn cans by Daiwa Can, 0.9bncans by Mitsubishi Materials Corp. (including Takeuchi Press Co.),and 0.3bn cans by Toyo Seikan Kaisha, Ltd. Expecting the rapidlygrowing popularity of the Bottle Can concept in the beverage market,all producers are now rushing to increase their supply capacity for2005.

For the past several years the beverage can market has beendecreasing due to a growth in PET bottles. PET bottles’ penetrationcan be summarized in its two biggest attributes of transparency andre-seal capability. On the other hand, the Bottle Can market has alsobeen expanding to various products ranging from carbonated andnon-carbonated drinks to alcoholic drinks, because of its shelfdifferentiation, general novelty, higher gas and light barrier property,refreshment image, and vending machine availability.

As a result, the Bottle Can has been establishing its presence asan entirely new drink container for brand owners and consumers aswell, not only as an alternative to PET bottles or SOT cans.

2. Features of the Bottle Can and its Evolution

• Excellent gas and light barrier property

• Re-seal capability

• General novelty and refreshment image

• Lighter weight than PET bottles

• Superior recycling including can-to-can recycling in the case of the aluminum Bottle Can. It can be easily put in the existing recycling system. The recycling rate reached 87.5% for steel cans


and 81.8% for aluminum cans in 2003.

• 38mm wide-mouth opening available

For PET bottles, a 28mm opening is popular, but a 38mm wide-mouth opening is not. This provides another point of differentiationfrom PET bottles such as a better sensory perception of flavor.

• Vending machine availability

It became possible to sell the Bottle Can products through vendingmachines by adjusting the height and volume of the Bottle Cans.

• Capable of retort sterilization

The technology innovation, including the development of a qualityassurance system, made it possible to utilize Bottle Cans for retortapplications for such low-acid products as milk tea and milk coffeedrinks, which is economically unfeasible at the moment for PETbottles.

• Excellent visual decoration available

By direct printing on the body as well as by the aid of full-bodyshrink labels with multi-color gravure printing, eye-catching decorationis available for more differentiation on store shelves. A foamed shrinklabel also helps its thermal insulation to keep the contents warm orcool.

• Food hygiene safety

There is no fear of the migration of any chemical materials fromcoatings applied on the interior surface if the aluminum or steel canstock is laminated with polyester film. Additionally, the flavor of thecontents can be well preserved by the plastic laminate on the interiorsurface.

3. Features of the Bottle Can by Each Can Supplier

3.1 Daiwa Can

It was Daiwa Can that created the “Bottle Can” concept known as theNew Bottle Can and launched its first commercial application for beer(450ml, 28mm finish) in May 2000. Basically its construction is a three-piece aluminum can with a reclosable aluminum roll-on cap and thealuminum stock is laminated on both sides with polyester film (Fig. 40).After its first launch, Daiwa has been enjoying market expansion tovarious drink segments including beer, carbonated drinks, sports drinks,juice, and also coffee drinks which require retort sterilization. It is alsoavailable in a wide range of sizes and finishes, including 300, 350, 400,450, and 500ml with a 28mm mouth opening and 300ml with a 38mm


wide-mouth opening.

In 2004 Daiwa added the 100mlMini-Bottle Can (28mm, two-piece) forhigh-value functional and health drinks.

In respect to the global popularity ofthe “Bottle Can” concept, the New BottleCan crossed the Pacific Ocean inJanuary 2003 as Kraft Foods beganusing Daiwa Can’s 16.5fl.oz can for itsnew “Capri Sun Island Refreshers” juicedrink. Two months later, Ball Corp. andDaiwa announced an agreement inwhich Daiwa granted Ball exclusiveNorth American sales and distributionrights. Depending on consumer reactionand market demand, a New Bottle Canmanufacturing facility could eventually beestablished in North America.

3.2 Mitsubishi Materials

By first receiving manufacturing rights from Takeuchi Press Co.,Mitsubishi Materials Corp. (MMC) started its version of the Bottle Canin July 2001 — an alternative can structure than that developed byDaiwa Can — with a 38mm wide-mouth“gulpability” opening and a two-piecealuminum can (vs. Daiwa’s 28mm openingand three-piece aluminum can). (Fig. 41)

MMC’s Bottle Can is said to provide abetter sensory perception of flavor,particularly in applications for coffee drinks orflavored drinks.

After its initiation, MMC launched the firstBottle Can capable of retort sterilization byan aid of injecting a small amount of liquidnitrogen into the can just before capping.

Due to its success in a range ofbeverage categories including retort, MMC isenjoying its representation in two-piece BottleCans and has increased its supply capacityto 1.5bn cans from 1.2bn cans annually in2004.


Fig. 40 New Bottle Can

Fig. 41 Mitsubishi

Materials’ Bottle Can

with the Wide-mouth

Glupability” Opening

3.3 Toyo Seikan

In February 2004 Toyo Seikan entered into the Bottle Can marketwith its new version of “TEC200” – the Toyo Seikan Environmental,Evolutional Can and Efficient Filling System 200ml. This systemproduces a two-piece steel Bottle Can with a 38mm wide-mouthopening.

TEC200 basically utilizes the same can stock as the TULC can,which is laminated with polyester film on both sides, and wasdeveloped as an alternative container to an existing SOT can forretort drinks such as high-value coffee and tea drinks. As TEC200shows, vacuum pressure after retort can be applied and then thealready-established tapping inspection system can be utilized forquality assurance (Fig. 42). Toyo claims that all features of the TULCcan such as environmental friendliness, less energy consumption, aswell as less carbon dioxide emissions are also featured in theTEC200 can.

To meet the growing demand, Toyo decided to increase its supplycapacity to 0.9 bn cans in 2005.


Fig. 42 Toyo Seikan’s TEC200

Bottom configurationcapable of tappinginspection

After roll-on capping

D.5 PET BOTTLE TECHNOLOGIES

1. PET Resin Market

The PET resin market for bottles increased from 251,729 metric tons in1997 to 470,731 metric tons in 2003.

The soft drinks category is its major application and has jumped from194,748 metric tons in 1997 to 412,970 metric tons in 2003 due to the strongmarket demand for green tea-based beverages and mineral water.

Cosmetics are also a growing application and have doubled in volumebetween 1997 and 2003 due to the replacement of glass containers withPET.

On the contrary, detergent and shampoo are dramatically down from12,807 metric tons in 1997 to 3,674 metric tons in 2003 due to itsreplacement by flexible packages and polyolefin bottles.

2. PET Polymerization Catalyst

Japanese PET resin manufacturers, including Mitsui Chemicals, Inc.,Teijin Limited, Mitsubishi Chemical Corporation, and TOYOBO Co., Ltd. havedeveloped a new catalyst for PET resin. This catalyst is partiallycommercialized. The catalyst was developed to meet customers’requirements to avoid the use of heavy-metal-based catalysts which havebeen used thus far.


Applications 1997 1998 1999 2000 2001 2002 2003 2004(E)

Designated

representation

products

Soft drinks 195 259 308 339 381 391 413 417

Soy sauce 13 13 13 13 11 12 13 13

Liquor 11 10 11 10 11 9 11 11

Sub-Total 219 282 332 362 403 412 437 441

Others

Detergent andshampoo

13 11 10 9 6 5 4 4

Edible oil 1 2 2 2 3 3 2 2

Seasoning 11 11 14 14 13 13 14 14

Cosmetics 4 5 6 7 7 6 8 8

PharmaceuticalsAnd others

5 4 6 7 11 7 7 7

Grand total 252 314 370 401 443 446 471 475

Source: Japan PET Bottle Association (numbers based on the calendar year)

Table 16 PET Resin Market for Bottles (As of March 2003) Unit: 1,000 tons

3. Barrier PET Bottles

There are two approaches to enhancing barrier properties of PET bottles.

1) Passive Barrier

2) Active + Passive Barrier

Recent developments and the current market status of barrier PETbottles are shown in the following table:


Company name Catalyst Present Developments and Applications

Mitsui Chemicals Ti-base

• Shipments of non-thermal resistant PET resin has taken place since 2002. Some beverage manufacturers adopt this PET and its shipment volume is constantly increasing.

• Thermal resistant PET resin has also been developed. The company completed its development by March 2004.

The new catalyst will be used overseas, Indonesia, and Thailand.

Teijin Ti-base• Teijin developed a thermal resistant PET resin. Container manufactures are

now evaluating the PET performances.

Mitsubishi Chemical Ti-base

• Mitsubishi introduced non-thermal resistant PET resin in 2004.

• Mitsubishi is also developing a thermal resistant PET resin.

• The PET resin using the new catalyst is planned to be produced in Indonesia.

TOYOBOYO AL-base• TOYOBO started the sales of the catalyst. The main part of this catalyst

business lies in its technology licensing.

Source: CMC Research Report “Polyester Resin 2004” P52, 2004

Table 17 Developments and Applications of PET Polymerization Catalysts

Aluminum Antimony Titanium Germanium

PET color tone � � � �

Influences forenvironment

� � � �

Cost � � � �

�: Excellent �: Good �: Fair ��: Poor

Source: CMC Research Report “Polyester Resin 2004” P52, 2004


Type System Company Developmental Status in Japan

PASSIVEBARRIER

ACTIS (UsingPlasma CVD,amorphous carbonthin film isformedinside the bottle)

Sidel

*Hokkai Can Co., Ltd.1. Introduced “ACTIS20” with 20 stations in 2000.At present,

9 systems are installed. ”ACTIS-LITE”has a thinner thickness than that of amorphous carbon thin film, and was marketed in 2000.Beverage-use PET bottle round type (280ml),square type (350ml) and thermal resistant type(350ml) are supplied.

Thin film

Production capacity is 500ml bottles/year.2. New ACTIS series have been developed:

a) ”ACTIS-C” suitable for carbonated beveragesb) ”ACTIS-S” the thinnest carbon thin film suitable for

flavor retention

DLC (DiamondLike Carbon)(formation ofcarbon thin filminside thebottle)

Kirin Brewery Co.,Ltd. Mitsubishi HeavyIndustries, Ltd.

Yoshino Kogyosho:Introduced DLC commercial production machines in2004.DLC can be produced from early August in 2004.DLC is available for thermal resistant square-shaped PETbottles.

PLASMAX (Usingplasma CVD,formation of silicathin filminside thebottle)

SIG CorpoplastSchott-HiCotech (Co-developed by abovetwo)

Hokkai Can Co., Ltd.1. Introduced in 2004. Different from “ACTIS” series,

completely transparent, high-barrier PET bottle can be produced for commercial base.

2. Marubeni Techno-Systems Corp. works for the sales promotion of” PLASMAX” in Japan.

GL-C (formation ofsilica thin filmtoinside bottle)

Toppan Printing Co.,Ltd.

PET bottle for edible oil

SiBARD(Formation ofsilicone polymerthinfilm and silicathinfilm to insidebottle) Toyo Seikan

Kaisha, Ltd.

Showa Sangyo Co., Ltd.This PET bottle can be filled at room temp. is used for edibleoil.Complete transparency and superior recyclability.*See Section E.31 Toyo Seikan.

(ACTIVE +PASSIVE)BARRIER

Oxyblock

Multi-layered PET bottleActive Barrier: Oxygen Scavenger Passive Barrier: MXD-6 PolyamideHot-filled PET Bottle for Japanese green tea* See also Section D.1 Active Packaging,

Yoshino KogyoshoCo., Ltd.

Multi-layered PET bottleActive Barrier: Oxygen ScavengerPassive Barrier: MXD-6 Polyamide is blended into PETSpecialized PET bottle with oxygen gas barrierpropertiesDLC is used when CO2 gas barrier properties areneeded

Source: TOYOBO Packaging Planning Services

Table 19 Barrier PET Bottles in Japan

D.6 FLEXIBLE CONVERTING TECHNOLOGY

1. Environmental Requirements

1.1 Non-chlorine Thermal Shrink Films

The use of non-chlorine thermal shrink films is growing as areplacement for chlorine-containing materials to meet requirementsbased on environmental issues. Polyester and OPS shrink films havepositioned themselves in PVC applications, especially in thebeverage, medical and baby food market. More detailed information isdescribed in Shrink Films/Sleeve Labels, Section D.7.

1.2 Non-chlorine Barrier Film

1) PVA-coated film

As a result of market demands, a non-chlorine barrier film,PVA in-line coated OPP film was launched. It was discoveredthat in-line coated OPP film has higher barrier properties of upto 80% relative humidity (RH) due to a higher crystallinity.

Both gas and moisture barriers are achieved by using OPPfilm for moisture barrier and a crystallized PVA-coated layer fora higher gas barrier.

2) Silica- and almina-deposited film

Silicon Oxide(S), Aluminum Oxide(A), and dual-coating(D)systems have been introduced by Oike(S), Reiko(S, A),Toppan(S, A), Mitsubishi Plastics(S, A), Toray AdvancedFilm(A), Dai Nippon Printing(S, A), Tohcello(A) andTOYOBO(D:S+A) for PET and/or OPA films (See Section D.8Table 21).

3) Hybrid barrier coating

Sumitomo Chemical Co., Ltd and Nihon Ecowrap Co., Ltd.developed SEVIX™ high gas barrier film coated with innovativenon-chlorine hybrid materials that is several hundrednanometers thick. The high barrier is achieved through layers,derived from organic polymers and inorganic nano-compositematerials.

Kureha Chemical Co., Ltd. developed a hybrid barriercoating called “Besela,” available in two grades, “R” and “AR.”These products are produced by using a polyacrylic polymer asthe coating along with inorganic material composites. Thecoating layer is used on the outside of the package. The “R”grade is for general use and the “AR” grade is for retort


treatment.

Daicel Chemical Industries Co., Ltd. developed a hybridbarrier coated film, “Senecci Hop,” which is composed of across-linked high barrier layer which reacts with inorganiccomponents. The hybrid material consists of a molecular-sizednano-composite structure. Therefore, the oxygen barrier levelsremain constant within a wide range of humidity.

Futamura Chemical developed “NCX” nano-composite one-sided barrier coated OPP film. The coating materials arecomposed of organic and inorganic compounds which are non-chlorine aqua-based materials. The oxygen barrier is 2 to5cc/m2. 24 hr.,atm.

4) Coextruded PP barrier with EVOH “ECO FILM”

The need for new barrier films without chlorine haspromoted the development of coextruded biaxially oriented film,which has both moisture barrier from the OPP layer and gasbarrier from the EVOH layer, to replace PVDC-coated OPPfilm.

Both gas and moisture barriers are achieved by the OPPfilm, which provides moisture barrier, and a cyrstallized PVA-coated layer which provides a higher gas barrier property.

1.3 Soventless Aqua-based Printing and Non-solvent Lamination

A number of Japanese companies have developed modified OPPfilms for use with aqua-based printing inks. Films in this applicationare as follows:

1) Sun Tox Co., Ltd.: Sun Tox-OP PA20W

Surface-modified OPP film that provides high wettingtension and strictly selected additives.

2) Tohcello Co., Ltd.: Tohcello-OP Aqua Fit

Surface-modified OPP film that provides higher wettingtension and selected additives with hydrophilic segments.

3) TOYOBO Co., Ltd.: TOYOBO Pylen Film AD: P2111

The fundamental concepts of the formulation are as follows:

• Bleed-out control

• Affinity with aqua-based ink

• Affinity of the base polymer with aqua-based ink


4) Futamura Chemical Co., Ltd.: AQ series

Additive formulations are specially designed.

1.4 Stand-up Pouch with Spout for Replacement of Bottles

Many technologies have been employed to obtain the stabilitystand-up pouches need in actual applications. Furthermore, as stand-up pouches with spouts become more popular, they are replacingrigid bottles in many applications.

1.5 Refill Pouch

Kao Co., Ltd. has designed some technological and designadvantages for refill pouches as a part of its promotion to re-usecontainers.

Refill pouches are an effective way to reduce the environmentalburden not only by lessening waste volume when packages aredisposed of, but also reducing the plastic used for packaging. Kaoadopted a pouch with a center opening for the kitchen detergent“More” in 1991. After that, it developed four types of pouches thatwere compatible with liquid inside and featured an opening for eachpouch.

1.6 Bio-degradable Products

Recent activities of the leading Japanese companies involved inbio-degradable products are as follows.


In addition to the products listed in Table 20, blended formulationswere developed to compensate for the drawbacks of the productmade by a single polymer formulation. For instance, PLA/Ecoflex andEcoflex/Bionole blended polymers are utilized to take advantage ofcharacteristics of each polymer. Furthermore, PLA/modified polyesterresin formulation LACEA/Biomax blended products such as Pal sealGE, and Pal seal MP were developed. Mitsubishi Chemical hasdeveloped the GsPla which is made by blending 1,4 butanediol andfatty acid polymers as the main segment with PLA as the blender.

1.7 Thinner Gauge Stretch Label

Conventional stretch labels have a comparatively thicker gaugebecause of the need for expandable elasticity. Dai Nippon PrintingCo., Ltd. (DNP) developed a three-layered coextruded stretch labelwhich was designed utilizing a new resin formulation in order toestablish properties such as excellent optics, scratch resistance andhysteresis.

2. Convenient and Functional Packaging Film


Category Chemical components Product name Manufacturer

Biological

productPolyhydroxybutylate Biogreen Mitsubishi Gas Chemical

Synthetic

resin

Polylactic acidLACIATERRAMACECOLOJU

Mitsui ChemicalsUnitikaMitsubishi Plastics

PlycaprolactonTONECelgreen PH

UCCDaicel Chemical Industries

Polybutylene Succinate

PolybutyleneSuccinate/Adipate

Bionole 1000 series

Bionole 3000 series

Showa Highpolymer/Showa Denko

Showa Highpolymer/Showa Denko

Polyvinyl alcoholPOVALGosenol

KurarayNippon SyntheticChemical Industry

Natural

productCellulose acetate

Celgreen PCALunare ZT

Daicel Chemical IndustriesPlanet Polymer

Table 20 Product List

Source: Toyobo Packaging Planning Services, Inc.

2.1 Easy Open

There are two ways to make an easy-open package, with easycutting and easy peeling properties.

1) Easy cutting package

There is a general market demand for easy cutting andstraight cutting packaging features in the marketplace. Thefollowing are examples of easy cutting technologies.

• One of the easy cutting technologies employs micro-sized pores on a film partially or in whole areas. A large number of punctures makes it possible for easy cutting. “Magic cut” and “Fancy cut” are two proprietary technologies that employ this technology. Another technology is porous film which is processed on whole areas, which allows users to cut along all directions.

• Straight cutting films are also utilized.

Longitudinally and transversely molecular oriented films aresupplied as special types of films. Uniaxially oriented filmprovides an excellent straight cutting property.

Toray Torephan YT has developed its “Torephan YT” seriesincluding YT52A, YT22, YT42, and YT54 which are producedby the combination of a biaxially oriented layer and atransversely oriented layer in a two-stage biaxial stretchingprocess for polypropylene. Usually uniaxially oriented filmproduces many fibrilations at the cutting portion, but YT filmsprevent fibrilation due to the biaxially stretched layer.

The “DP30” biaxially oriented polypropylene film supplied bySuntox Co., Ltd. is another straight cutting film. Denki KogyoCo., Ltd. also produces its transversally uniaxially oriented highdensity polyethylene film called “Carary Yarn Y.”

Recently TOYOBO Co., Ltd. launched its newest polyesterfilm, “TOYOBO polyester film TF,” which provides notch-lesscutting ability.

• Nisseki Plasto Co., Ltd. has developed a new packagingmaterial with an easy-to-open function marketed as an added-valuefeature. In order for consumers to take contents out of the packagewithout any difficulty, a cutting technology that enables users to cutthe opening straight is of great value.

Also, by utilizing non-woven “MILIFE” sheets made by laminatingwebs which are layered with a longitudinally oriented web as the mainmaterial and a transversely oriented web as the auxiliary one, straightcutting ability can be added to such films as OPP which is widelyused for packaging.


2) Easy peel package

Sumika Plastic Co., Ltd. developed easy-to-open films,called “Assist” AE films designed by a polymer alloytechnology for PP, PS and PE containers based on the“cohesion destruction” concept. As a layer-to-layer peelablefilm, the “M series” films are provided for PS and PPcontainers. For a retort type of layer-to-layer peelable film,the M series of films are also provided for PP containers.

Technical methods introduced recently include a “destructive” heatseal layer, which is a PP/PS alloy dispersed into the PP and PSsegments to create strong and weak areas. The seal is thendelaminated along a certain layer of the film. The following are typicalexamples of this “destructive” heat seal layer:

• J Film Corporation developed its ”VMX” and “IMX”films

• Idemitsu Petrochemical Co, Ltd. developed its “MagicTop” film for lids

• Tohcello Co., Ltd.’s “OMPS,” and Santox Co., Ltd.’s“EP Type” are also used in practical applications. RecentlyTohcello Co. introduced its thermal resistant peelablesealant “MS-R” for a transparent polyester “B-PET” cup. Inaddition, Tohcello had already launched peelable sealantfilms for lids called “Sunseal MS series.” These films can beused at 95°C for 30 minutes in a boil and 120°C in a retorttreatment.

• Toray Advanced Film Co., Ltd. launched its “CFFilm” as a cohesive peeling type of film

• Toso Co., Ltd.’s “Melcene” easy peel sealant resinswere also developed. Four grades designed for severalapplications were introduced.

- MX02 High temperature boil treatment, 90°C for 30 minutes

- MX06 Non-boil use

- MX23 Low temperature heat sealable and low temperature resistance in practical use

- MX39 High temperature boil treatment, 100°C for 30 minutes,and easy openability for PP cups

•The following easy peel sealant films were alsolaunched.

- MX102: Single layer film made of MX02 resin

- MX302: Multi-layer film made of MX02 resin


• Show Denko Plastic Products Co., Ltd. developed its“Aromal Film.” This filmcan be used for lids for PPcontainers because polypropylene is mainly used. Severalgrades are produced for various applications including boiland retort treatments.

2.2 Reclosable Packaging

Many reclosable technologies including zippers are increasinglypopular for a variety of uses. A new reclosable technology has beendeveloped which uses adhesive force in the layer that is coextrudedbetween the substrate and heat sealant layers.

2.3 Microwaveable Cooking Pouch

Changing lifestyles are making microwaveable foods more andmore appealing. The key technology in microwaveable packaging is tosafely ventilate steam evaporated by heating. There are manydesigns for ventilating as described in more detail in Section D.3Microwaveable Packaging.

The following are fundamental designs in microwaveablepackaging.

• Weak seal portions are utilized

• Perforations or small vapor exit holes are used

• Ventilating valves are utilized

2.4 Twin Compartment Package

The Japanese company Nissui has adopted a newcompartmentalized package for its product which contains differenttypes of soups. This product allows consumers to adjust to theirindividual taste by mixing two soups.

3. Extended Shelf Life

3.1 Modified Atmosphere Packaging (MAP)

There are two types of fresh foods, one which does not need torespire, and one which needs the transmission of oxygen to stayfresh. The former type usually requires high gas barrier, and the lattertype needs an appropriate transmission of gases. Generally, anti-fogging film was used for various foods. Now, more permeable films


are used for fresh vegetables and fruits.

3.2 Oxygen Scavenging Film

Hagoromo Foods Co., Ltd. has adopted an oxygen scavengingfilm for its fruit packaging to replace its canned package. The packageshelf life is 12 months.

3.3 Light Impermeable Film

UV light and visible light protection are required to preventdeterioration of foods under distribution for a long time. Recently, anew light impermeable film providing both protection and transparencywas developed.

3.4 Aseptic Packaging for Boiled Rice

Shinwa’s rice-cooking and individual tray packing system isdesigned for product safety, stability and higher productivity due to thecontinuous cooking, sterilizing and gas flushing processes. Furtherdetailed information is described in Section E.22 Shinwa Kikai.

4. Functional Packaging

4.1

Metallocene polyethylene film is now used in a wide range ofapplications as a replacement for low-density polyethylene andethylene vinyl acetate. The following are some advantages to usingmetallocene polyethylene:

1) High-speed heat sealable film - Low temperatureheat sealable film

2) Stable seal strength through contamination

3) Lower off-flavor heat sealant

4) Direct handling without powdering

Recently, TOYOBO developed a new type of LLDPE film withoutusing powder which is used to prevent blocking. Easy handling, easyprocessability and easy opening of bags were achieved withoutpowdering.

4.2 Replacement for Three-dimensional Rigid Packaging

Requirements stemming from consumers and environmental


issues such as easy use, light weight and reduced packagingmaterials, and general package conveniences have promoted thereplacement of rigid packaging with various types of stand-uppouches with spouts.

Some examples are as follows

1) Square bottom and flat bottom stand-up pouches

• Plast Co., Ltd. has developed its “EdgeStand,” described inprofile, Section E.20. The EdgeStand features stability, and anexcellent appearance due to its four-corner edge seal.

• Hosokawa Yoko Co., Ltd. developed its square bottom “FBpouch.” At Tokyo Pack 2004, it was revealed that this perfect squarebottom pouch was developed under the collaboration with thepackaging machinery manufacturer. Furthermore, Hosokawadisplayed a three-dimensional bag-in-box type of flexible containercalled the “Cheer-Tainer GZ” at Tokyo Pack 2004.

• Nishibe Kikai and Totani Corporation have already beenproducing pouch-making machines with square bottoms and four-corner edge seals.

2) Stand-up pouch with spout

There are many applications for stand-up pouches including foodsand beverages, sanitary goods, cosmetics, PET foods, and householdgoods packages.


D.7 SHRINK FILMS/SLEEVE LABELS

1. Market Trends

The demand for shrink label film is increasing due the following factors:(1) shrink films offer an alternative to paper labels, (2) the increased demandfor PET bottles, especially smaller-sized, 500ml & 350ml sizes, and (3) newapplications for cans and glass bottles.

Regarding the label material, from the ecological point of view, formerlypopular PVC has been replaced by PS or polyester films. The market sharefor shrink label film material in order by volume is OPS film (approximately63%), polyester film (approximately 32%), PO film (approximately 4%) andPVC film (below 1%). Demand for both OPS and polyester films is projectedto increase 5-8% annually.

From a technical standpoint, PVC film is the most functional film.However, since dioxin gas is created from the uncontrolled incineration ofPVC, the use of PVC and PVDC has been radically decreased in Japan. PSfilm had to be improved both in its shrink prevention in storage and lowtemperature shrinkage. Polyester film, which features transparency andgloss, needed to improve its shrink finish. Each manufacturer has improvedthe performances of these films by improving the resin reform and theorientation technologies.

As a result of the new resin formulations, Space clean® technology fromTOYOBO Co., Ltd. was used for the label for returnable beer bottles in 1998.

Approximately 85% of shrink films are used in the beverage and foodmarkets and approximately 15% is used in the non-beverage and non-foodmarkets. In the beverage and foods markets, shrink film is used mostly forPET bottles. Shrink films are also used for tamper-evident cap seals for soupstock, soy-based dipping sauce, seasoning, wine and whisky. In the non-beverage and non-food markets, shrink films are used mainly for toiletry andcosmetics products.?Among PET bottle applications, OPS film or polyesterfilm is mainly used for aseptically-filled products. OPS film is used for hot-filled products and polyester film is used for products sold in hot venders orwarmers.

Major manufacturers of shrink label films are C.I. Kasei Co., Ltd.;Mitsubishi Plastic Inc.; Gunze Limited for OPS film; and TOYOBO Co., Ltd.for polyester film. Because TOYOBO has obtained a patent for polyestershrink film, it holds a large market share in this field.

2. OPS Shrink Film

2.1 C.I. Kasei Co., Ltd. “Bonset”


C.I. Kasei has the top market share for OPS shrink film in Japan.The company also sells PVC and polyester films.

“Bonset” is styrene-butadiene copolymer-based horizontally-oriented film. This film offers optimal shrinkage speed and stress aswell as has an authentic finish. Six film types are supplied for“Bonset,” according to its five applications.

Applications include

1) General and PET bottle use

2) Glass bottle use

3) Light-weight container use

4) R-seal use

5) Cap seal use

For general and PET bottle use, a single layer and a multi-layershrink film are supplied. The film thickness depends on eachapplication. The thickness range is between 27and 80µm.

2.2 Mitsubishi Plastics Inc. DXL®

Mitsubishi Plastics is a top shrink label film manufacturer in Japan.The company is also ranked at No. 2 for OPS film and polyester filmproduction and at No.1 for PVC film production in Japan. DXL® is astyrene-butadiene copolymer-based oriented film. This film featuresmoderate shrinkage properties corresponding to temperature changeand has an authentic finish. Five types of DXL® films are provided forPET bottle use. All the types of DXL® films which have the best-fitshrinkability to varied bottle shapes are used for the PET bottle’sshoulder part. Various film types such as a steam-shrinkable type, ahot air shrinkable type, and a low-temperature shrinkable type areavailable. The film thickness depends on each type of film used. Thefilm thickness range is between 40 and 80µm.

2.3 Gunze Limited “Fancywrap”

Gunze sells PS film, polyester film, and PVC film. The company isfocusing its business mainly on the production of PS film and iscompeting with other companies to obtain the No. 2 ranking for PSfilm production. Recently, the company developed PO shrink film.

Six film types are sold under Gunze’s “Fancywrap” brand name.One is for general labels and five are for beverage labels. Beverage labels include:


1) Label attached after hot-pack process

2) Label attached before hot-pack process

3) Label attached after aseptic process

4) Low temperature shrink label

5) Glass bottle use

3. Polyester Shrink Film

3.1 TOYOBO Co., Ltd. Space clean®

This is a shrink film using a polyester copolymer which TOYOBOdeveloped. This film has superior low-temperature shrinkability,transparency and gloss. Due to its film stiffness, a thinner gauge canbe used. Due to its dimensional stability, easier storage managementis also achieved. For PET bottles, the amount of impurities containedin recycled products can be decreased because both PET bottles andthis film are made of the same polyester. To further accommodaterecycling, TOYOBO and Dainichi Seika Color & Chemicals Mfg. Co.,Ltd. are co-developing a gravure ink called “Daiecolo,” which can beeasily removed during the recycling process.

There are three types ofSpace clean® shrink films:

1) A horizontally-oriented type for bottles

2) A biaxially-orientedbalanced type for liddingand tamper-proof applications

3) A biaxially-oriented,unbalanced type for R-seal and tamper-proofapplications

For bottles, five kinds of Space clean® shrink films are available:

1) General type

2) High shrink type

3) Low-temperature high shrink type for aseptic use

4) Collective packaging type

5) Glass bottle type


Fig. 43 Actual Applications of

Space clean® Shrink Label

The film thickness depends on each type of film used. Thethickness range between 20 and 60µm.

4. Thermal Insulation Packages

4.1 Technical Features:

1) Easy handling for hot drinks and hot soups

2) Glossy appearance of label with laminates of film and non-woven fabrics

3) Very tight labeling with shrink film

4) Thermal insulation

4.2 Applications:

Examples were exhibited at Tokyo Pack 2004 including a cup forsoup and beverages packed in metallic cans. The thermal insulationpackages are very convenient for household use and hot vendingmachines which are provided throughout Japan.

5. Functional Shrink Labels

The following are examples of functional shrink labels:

5.1

Ajinomoto Co., Inc. adapted a PLA-based cap seal for itsseasoning product.

5.2

Because functional shrink labels have light-shielding properties, awhite opaque polyester film with surface printing is used for thelabeling of nutritional beverages, such as “Powerade” from Coca-Cola(Japan) Co., Ltd. and “Propio Yogurt” from Meiji Seika Kaisha, Ltd.

5.3

In order to give a Japanese look to green tea, the functional shrinklabel features a laminated “Unryushi,” a typical Japan paper, on itsinner side.

5.4

For carbonated beverage bottles, high shrink polyester film is usedas a shrink film instead of the formerly-used PE stretch film.


Source: The Material Guidebook for Converting 2004

Hisaaki Suzuki, Market Research By Research Company,PACKPIA, P50-52

(June 2002)


D.8 TRANSPARENT BARRIERS & COATINGS

1. Market Trends

For barrier films, PVDC-coated films such as K-OPP, K-PET and K-OPA,used to be widely used. “K” indicated PVDC-coated in Japan. However,since the mid-1990s, the use of these films has sharply decreased becauseof persistent health scares related to dioxin gas emitted from poorlycontrolled incineration of chlorine-containing waste. As a substitute for thesefilms, several new barrier films were developed: PVA-coated barrier OPPfilm, “hybrid” coated film containing horizontally-configurated inorganicparticles in the coated layer, and EVOH coextruded film. For barrier PETfilm, transparent-deposited or acrylic acid-based coatings are mainly applied.For OPA film, MXD-6-nylon, EVOH coextruded film, or transparent-depositedfilm is used as a substitution. As a transparent barrier film, PVA and EVOHfilms are already used. Recently, PVA has gained the industry’s attention dueto its bio-degradability and water-solubility.

The applications for EVOH film are expanding due to its increase ingrade variations.

2. Silica- and Alumina-deposited Films

2.1 Types

There are three kinds of deposited films: alumina-, silica- andblended (alumina and silica) deposited films. Generally, physical vapordeposition (PVD) is used as a deposited method. In contrast, only DaiNippon Printing Co., Ltd. is processing film using a chemical vapordeposition (CVD) method, and CVD film, mainly using OPA film as asubstrate, is sold. CVD is also used in Dai Nippon Printing’s division.Only TOYOBO Co., Ltd. is marketing a blended-deposited film usingalumina and silica. This film is also discussed in TOYOBO Co.’s partof the report, Section E.29.

2.2 Base Films

Transparent-deposited films using PET, OPA and extruded PVA asa base film are also sold. In 1988, PET-based transparent-depositedfilm was first introduced for commercial production. Previously, silica-coated PET films were largely produced, and alumina-coated PETfilms, having high productivity rates, came to be largely produced.From the late 1990s, transparent-deposited film using OPA film as asubstrate was used and Mitsubishi Plastics, Inc. introduced its super-


high barrier film using extruded PVA film as a substrate.

2.3 Silica- and Alumina-deposited Film Suppliers

2.4 Features

Transparent-deposited film, while having superior oxygen barrierand water vapor barrier properties, can provide little change of itsoxygen barrier properties under high temperature and humidity. Inaddition, the film has superior chemical resistance and flavorretention, microwaveability as well as retortablitiy for retort-type film.In the early development stage, the barrier properties were inferiordue to printing, tension in the lamination process, pressure and heat;however, improvements have been made.

3. Barrier Coated Films

3.1Types


Suppliers Product name Coated layerDeposited

methodBase film


GLAluminaSilica

PVD PET, OPA

Dai Nippon PrintingCo., Ltd.

IB-FilmAluminaSilica

PVDCVD

PET, OPA

Oike Industrial Co.,Ltd

MOS Silica PVD PET, OPA

REIKO Co., Ltd. FINE BARRIERAluminaSilica

PVD PET, OPA

TORAY ADVANCEDFILM Co., Ltd.

BARRIALOX Alumina PVD PET, OPA

Mitsubishi Plastics,Inc.

TECHBARRIERAluminaSilica

PVDPET, OPA,extruded PVA

TOYOBO Co., Ltd. ECOSYALTMAlumina/Silica

PVD PET, OPA

Tohcello Co., Ltd. TL Alumina PVD PET

Table 21

As a substitute for PVDC-coated OPP, PVA-coated OPP wasinitially marketed. However, due to low barrier properties under highhumidity, the applications were limited. Thus, manufacturers came toevaluate the development of a new coated film that would performbetter under high humidity conditions and as a result, two films werecreated: a hybrid barrier coated film using nano-composite technology,and an acrylic acid-based resin coated PET. Only this acrylic acid-based film has retortablility among the various barrier coated films.

3.2 Barrier Coated Film Suppliers

3.3 Hybrid Barrier Coated Film

On this barrier film, a coating agent is applied to compose acoated layer. This agent is made from the barrier resin and thedispersed inorganic particles using nano-composite technology.Using this technology, each layered inorganic particle in the coatedlayer is arranged in a horizontal direction against the coated layersurface. These many inorganic particle layers are dispersed in thecoated layer. Because each inorganic particle layer prevents gas fromtransmitting, gas inevitably needs to be transmitted through the resinpart in a coating layer. With this mechanism, it takes considerabletime for gas to pass through the whole coated layer completely whileavoiding inorganic particle layers and then selecting the resin part togo through. As a result, this barrier effect is considered to be thesame as that of a coated film having hundreds of times morethickness. Thus, even with a thin membrane coating, this hybridbarrier coated film has the same barrier performance as that of a


Suppliers Product name Coating agent Base film

Tohcello Co., Ltd. A-OP PVA OPP


OP-M PVA OPP

Daicel ChemicalIndustries, Ltd.

Seneshi® XOP,HOP

PVA, Hybrid OPP

Kureha ChemicalIndustry Co., Ltd.

Besela®Acrylic acid-based resin

PET, OPA

Nihon EcowrapCo.,Ltd.

Sevix® Hybrid OPP, PET, OPA

Kohjin Co., Ltd. Cobarrier Hybrid OPP, PET, OPA

Futamura ChemicalIndustries Co., Ltd.

NCX Hybrid OPP

Table 22

coated film having hundreds of times more thickness. The advantagesalso lie in stable barrier properties such as less change of barrierproperties under high temperature and humidity, less change ofbarrier properties due to the coated layer’s increased flexibleproperties, (compared with that of transparent-deposited film) alongwith the base film stretching in the film processing stage.

4. Other Barrier Films

4.1 Types

As basic barrier resins, PVDC, PVA, EVOH, MXD-6 and PAN areused. Among them, EVOH and MXD-6, having superior processability,are used by laminating with other resins, resulting in enhanced filmfunction; thus the use of these films is increasing.

4.2 Barrier Film Suppliers

The following chart lists major manufacturers of barrier films andtheir products.


Fig. 44 Hybrid Barrier Coated Film Structure


SuppliersProduct

name

Barrier

resin

Film

composition

Extruded

or cast

Asahi-kasei Life &Living Corp.

Saran-UB PVDC Single layer Cast

Kureha Chem. Ind.Co., Ltd.

Krehalon PVDC Single layer Cast

Nippon SyntheticChem. Ind. Co., Ltd.

BOVLON® PVA Single layer Extruded

Kuraray Co., Ltd. EVAL® EVOH Single layer Cast

Futamura Chem.IndustriesCo., Ltd.

ECOFX

EVOHPAN

Multi-layer (OPP)Single layer

Cast,Extruded

Gunze Limited HEPTAXEVOHMXD-6

Multi-layer (OPA)Multi-layer (OPA)

ExtrudedCast

Unitika Co., Ltd. EmblonEVOHMXD-6

Multi-layer (OPA)Multi-layer (OPA)

ExtrudedExtruded

TOYOBO Co.,Ltd.OSMMX

MXD-6MXD-6

Single layerMulti-layer (OPA)

ExtrudedExtruded

Mitsubishi Plastics,Inc.

Supernyl MXD-6 Multi-layer (OPA) Extruded

Mitsui Chemicals,Inc.

Zexlon PAN Single layer Cast

Tamapoly Co., Ltd. Hytron BX PAN Single layer Cast

Table 23

Source: Kyoichiro Ikari, The PACKPIA, P.54-67, (Aug., 2004)

D.9 RFID TECHNOLOGIES

1. General Review

Radio Frequency Identification Technologies (RFID) have just entered thefield test stage in Japan, and applications are being made according to eachfrequency band such as 135kHz, 13.56MHz, and 2.45GHz (See Table 24).Although the use of the UHF band is now under deliberation, a 950M—956MHz band is likely to be assigned by the ministerial ordinance revision ofthe Wireless Telegraph Law in March 2005. Once the UHF band isapproved, it is expected that more RFID applications will be offered by manycompanies in various fields.

The Logistics Systems Research Institute began collecting participants tospread the Electronic Product Code (EPC) system and attain arationalization through the whole supply chain from manufacturers to theconsumers, including warehousing, transportation and sales output.

Under this situation, each company or industry starts doing its fielddemonstration test within its own logistics network, or its related distributionchannels. Moreover, the actual in-field testing in each industry is supportedby the government based on an “e-Japan” plan to promote IC tags utilization.The e-Japan plan was a guideline developed in January 2001 by thegovernment that Japan would follow to become the latest IT state in the


Table 24 Application List

world.

The Ministry of Internal Affairs and Communications and the Ministry ofEconomy, Trade and Industry added “the privacy protection guideline aboutelectronic tags” for privacy protection.

It is expected that the economic ripple effect from IC tags will expandthrough 2007 and continue to grow. The report by the Ministry of InternalAffairs and Communications says that the economic ripple effect created bythe use of IC tags depends on finding ways to expand the network.Pessimistically, if items such as standardization, technology, and privacy arenot solved, the economic ripple effect of 9 trillion yen will be expected by2010. Optimistically, however, when a sufficient environment for widespreaduse is ready, an economic ripple effect of 17 trillion yen is projected by 2010.Moreover, when technical hurdles are cleared including low-cost IC tags, it isexpected that the economic ripple effect of 31 trillion yen will be realized by2010.

The Ministry of Economy, Trade and Industry has supported theexperiments of IC tags in home electric appliances, apparel, publications,and the food industry since 2003. The list of actual in-field testing results isshown in Table 25.



For the actual in-field experiments of food distribution through a grocerystore, 13.56MHz RFID was used. NTT, Dai Nippon Printing, and Marubeni, atrading company, participated in the experiment. The test was done in a fooddistribution center for two days, September 24 and 25, 2003, and in agrocery store “Maruetsu Siomi-Ten” for 49 days from October 6 to November23, 2003. IC tags were applied to 30 kinds of perishable foods, and 47 kindsof processed foods.

A monitor was installed in the store for consumers to check and track therecord of the products including the product’s source, processing method,safety, and the producer’s policy for environmental-friendliness. Theconsumers showed a positive interest in them.

As an example of RFID promotion by the government, the Ministry ofEconomy, Trade and Industry launched a two-year investment programnamed “Hibiki Project” of about 1,800 million yen as a national projectrunning from August 2004 to August 2006. Its development targets are asfollows:

• UHF band tag, a passive tag, and a read-only RFID IC tag

• Less expensive, as little as 5 yen or less per tag and micro tag

• Reader/writer based on EPC global “UHF Generation 2”

Hitachi, Dai Nippon Printing, Toppan Printing, and NEC are going tocooperate.

2. Overview at Tokyo Pack 2004

At Tokyo Pack 2004, many companies exhibited RFID technologies and labelers such as DaiNippon Printing, Toppan Printing, Sato Corp., Lintec Corp., Osaka Sealing Printing Co., SealexCorp. and Hitachi Group. A label-type IC tag was the most popular at the show. The antenna partof the IC tag is made by the etching of aluminum foil and copper foil, or screen-printing using silverink.

The other tag makers such as Omron Corp., Toray International Inc., Japan InformationSystem Co., Japanese RF Solutions Co., and Mitsubishi Materials Corp. did not exhibit at theshow.

One of the U.S. observers commented, however, that RFID was conspicuously absent byhis measuring stick and that, with the likes of Tesco, Wal-Mart, and other RFID-pushing big-boxretailers now operating in the Japanese market, one has to believe RFID technologies arecoming soon.

From a packaging standpoint, a Japanese industry expert also said it will take several yearsuntil the RFID packaging applications are as widely used as the bar codes in Japan, becausethe IC tag is too expensive, currently at 40—60 yen, and is too large in size to be used forconsumer packages.


3. Major RFID Technologies from Supplying Companies

3.1 Dai Nippon Printing Co. (DNP)

1) Logistics management of PET bottle preforms

DNP, NTT, and Sun Microsystems have jointly tested theactual field testing of PET bottle performs for soft drinkssince 2003 using an IC tag and the next-generation barcode EPC. Various technology and application informationwas accumulated, including a 99.9% recognition rate, whichproved its usefulness of traceability. The trackinginformation and whereabouts are grasped in real time, andits delivery information, “having been when and where,” isobtained within a short lapse time.

2) Thermo-sensitive RFID Tag

The thermo-sensor field test with Q.P. Corp., the largestegg-products producer in Japan, is scheduled to run fromthe beginning of October to the end of November 2004. Thetemperature tracking system of liquid egg distribution at achilled temperature between factories to the frozen foodsfactory and then the delivery points will be tested. A thermo-sensitive RFID tag is very useful for the quality control byfoods processors and logistics companies. Linkage with atraceability system is expected.

3.2 Toppan Printing Co.

1) Position management system

Two companies, Toppan and Oracle Corp. Japan, havecollaborated to put the position management system on themarket beginning November 1, 2004. For the first year, theinventory control of the raw materials utilizing 13.56MHz istargeted and an initial introduction kit and consulting serviceare offered.

2) Tracking system of returnable packing materials

The returnable packing materials for housing equipmentand components will be tested under the development withAsahi Chemical Industry, where an IC tag of 13.66MHz isutilized. If adopted completely, the packing materialdischarged from the new building construction spot isexpected to be reduced 40%.


3.3 Hitachi Group

Hitachi demonstrated its idea for logistics management by using am-chip. The

Hitachi group and Taisei Lamick Co. developed four kinds of m-chip tags by lamination technologies. Their on-metal tag is offered toattach on metal surfaces. The antenna has a two-layer structure and25cm communication distance is obtained.

3.4 Sato Corp.

Sato Corp., one of the world’s largest RFID solution providers,made a partner contract with the German Metro group and is due toprovide RFID printers and applications. Sato also claims it soldprinters to the companies supplying them to Wal-Mart in the U.S. Theactual in-field experiment is to test for stock control of label printed-rolls within the company.

3.5 Japan Information System Co. (JIS)

Japan Information System Co. has developed thermo-sensitive ICtags which are now being tested for tracking the temperature throughfood distribution. One-chip thermo-sensitive, IP-embedded UHF bandIC tags can report back an environmental temperature periodically ina very short time interval to the host during communication with thescanner. It is suitable for the traceability of foods and/or frozenmaterials. Moreover, JIS also developed laundry-type IC tags andstarted its delivery for cleaning applications.


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