US-based Packaging Products (PPC) has partnered with Toray Plastics (America) to develop high-barrier, polyvinylidene chloride (PVDC) free packaging for Utz Quality Foods.

The new packaging combines Toray’s Torayfan CBS2 BOPP film, which is a PVDC-free flat sheet designed for use as an inside sealant web, with a co-extruded BOPP print web.

Under the partnership, Toray and PPC conducted extensive trials to compare the performance of CBS2 with traditional PVDC-coated BOPP film.

The results showed that CBS2 provided a high-quality moisture and oxygen barrier and lamination bond, without priming, additives or any changes to PPC’s lamination process.

The film also provided a heat-seal range, oil and puncture resistance, stiffness, yield advantage, and a longer storage life.

PPC has presented the new option and test data to Utz, which successfully tested the material on its own machinery.

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Utz has already used the Torayfan CBS2 BOPP film for its three-ounce party mix, a colourful pouch with a transparent window allowing customers to see the product.

The company will now use the material for the packaging of over two dozen products that don’t require metallised lamination, such as its tortilla and corn chips, and party mix snacks.

PPC sales administration vice president Will Woodford said: "Though PVDC-coated OPP film keeps bakery and snack foods fresh and gives consumers a window to the product inside the package, the film has several drawbacks.

"Reports about PVDC-coated films’ potential negative long-term effect on the environment have made some manufacturers uneasy."

"It yellows as it ages, becoming brittle and prone to flex cracking. It has experienced price hikes that have made end-user costs surge, and it has required many flexographic printer / converters to use EMA additives or other supplemental materials to promote bond adhesion for laminating to PVDC-coated OPP.

"Besides those concerns, reports about PVDC-coated films’ potential negative long-term effect on the environment have made some manufacturers uneasy."

Wolford also stated that several other PPC customers are now testing CBS2 film for their packaging.

Toray developed CBS2 BOPP film with barrier properties using its resin technology and a proprietary, non-PVDC barrier layer, which is designed for heat sealability.

Image: Toray’s Torayfan CBS2 BOPP film provides an environment-friendly alternative to traditional transparent barrier film made with PVDC. Photo: courtesy of Toray Industries.