Development of high barrier multilayer sheets for thermoforming

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This project is about the development of high barrier multilayer sheets to be used in thermoforming. The multilayer structure of interest is PP/tie/EVOH/tie/PP. Since EVOH is expensive and because of sheet trims from the sheet process, its replacement and/or recycling could be highly beneficial both from cost and environmental points of view. The collaborating company in this project is E. Hofmann Plastics Inc., a medium size Canadian company based in Orangeville, Ontario and engaged in the production of multilayer sheets and their thermoforming into containers for food packaging. It seeks reducing the cost of the multilayer structures and better recyclability of its trims. Thus, the objective in this project is to develop PP based multilayer (or monolayer blend) sheet structures with high O2 barrier properties for containers thermoforming. Various strategies will be considered: a. Using an EVOH layer and its minimization in a multilayer structure;b. Blending of PP with EVOH in a mono and multilayer sheet/recyclability;c. Using nanocomposites based on clay dispersed PP or clay in EVOH;d. Using active barrier material in addition to passive barrier material;e. Using a nanoparticulate solution coating process.In addition to barrier properties, the puncture ability of the barrier sheet will be evaluated as a consequence of the above techniques. We will study of the effect of materials parameters (resins, nanocomposites, additives, etc.) and their innovative layout in multilayer or blend monolayer sheet structures on the processability, microstructure and performances of thermoformed packages based on those sheets. It is expected that the results and innovations obtained from this research project will benefit directly to the supporting organisation and the Canadian plastics industry in general. Training of highly qualified personnel and publications will enhance Polytechnique's research edge.