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Eco-Efficiency Analysis: Water-based Adhesives for Flexible Packaging AIBO Seminar – Desenzano June 23rd 2016 Andrea Sergio, BASF Italy 01 WATER-BASED LAMINATION ADHESIVES Water-based adhesives combine long polymer chains with good coatability Solvent-based / solvent-free adhesives vs. Water-based adhesives Short-chain components dominate Long-chain polymers Reactive system: Long polymer chains develop between films Chemical reaction already took place at BASF Adhesion increases over time Good adhesion right from the start 3 High molecular weight from the very beginning reduces migration risk Molecular weight distribution of typical lamination adhesives Potential zone of migration 4 High initial peel strength gives process speed Time dependence of peel strength (PETink/PE, 2.5 g/m²; peel at 300 mm/min; with cross-linker) N/15mm MB > 5N 5 4 3 2 1 0 Water-based adhesive Peel 1 min Peel 1 h Peel 2 h Solventless adhesive Peel 4 h Peel 6 h Peel 8 h Peel 24 h 5 No primary aromatic amines from water-based adhesives Risk of toxic migratable components with solvent-based and solventless systems if not fully reacted Film / foil Monomeric MDI Adhesive Film Food Primary Aromatic Amines (PAA) Suspected to be carcinogenic Storage time up to 2 weeks can be necessary between lamination and filling with food to avoid PAAs + H2O - CO2 6 Water-based adhesives contain no monomeric diisocyanates Solvent-based and solventless adhesives contain up to 20% monomeric diisocyanate (MDI) Diisocyanates are increasingly under attack by authorities due to e.g. occupational respiratory diseases European Chemical Agency (ECHA) thrives for additional regulation / use restrictions of such substances Water-based adhesives are not concerned Source: http://echa.europa.eu/registry-of-current-restriction-proposal-intentions/-/substance-rev/10698/term 7 No solvent retention with water-based adhesives Risk of migratable organic solvents if not dried carefully in SB systems Film / foil Adhesive Organic solvents Film Food Organic solvents Very intensive drying of solvent-borne adhesives required (ppm level) slow down of coating speed may be necessary 8 Only with water-based adhesives immediate laminate processing possible Multi layer laminates Printing Laminating Storage 3-6 hours with solventborne and solventless adhesives More frequently changing product designs Smaller packaging units Slitting Storage Filling with Food 2-14 days with solventborne and solventless adhesives Brand owners demand shorter lead times 9 Water-based adhesives work well together with digital printing Customized printing HP Indigo 20000 Digital Printing Press Fast changes From file to pouch making in 24h Fast curing required Instant slitting Fast set-up with low waste Excellent lamination quality and transparency + Comexi Nexus L20000 Laminator 10 Water-based adhesives also need a risk assessment Risk assessment of water-based laminating adhesives Polyacrylate dispersion ISEGA Polyurethane dispersion ISEGA Residues of monomers Approved monomers (10/2011) Info about SML Approved monomers Info about SML Extraction tests for amines and isocyanates VOC Info about VOC content Info about VOC content Oligomers Assessment in FCN Overall migration Assessment in FCN Overall migration Biocide Approved biocides Info about content Approved biocides Info about content ISEGA … ISEGA certificate for typical application 11 Water-based adhesives as a solution for sustainable flexible packaging Benefits of water-based adhesive technology Cost reduction No off-spec resulting from telescoping and mixing errors Reduced bonded capital Time saving / increased flexibility Direct slitting, lean production No interim storage Shortest lead times Improved safety No aromatic isocyanates No organic solvents, low VOCs Very low residual odor / taste 12 4:3 PowerPoint Template 13 Eco-Efficiency Analysis to compare the different adhesive technologies Eco-efficiency analysis considers environmental (life cycle analysis) and economic (life cycle costs) impacts Impacts on environment Life cycle costs Eco-Efficiency methodology validated by TÜV Rheinland (2002), TÜV Rheinland do Brasil (2008) and NSF International (2009, 2013, 2016) Impacts on environment and costs 14 4:3 PowerPoint Template 15 4:3 PowerPoint Template 16 Whole life-cycle of packaging was considered 17 Various ecologic factors are considered in eco-efficiency analysis Freshwater overfertilization Marine overfertilization 18 Climate Change Also referred to as global warming potential (GWP) and carbon footprint (CF) This category reflects the climate change impact of air emissions of greenhouse gases (GHGs). Increased GHGs in the troposphere result in warming of the earth’s surface. The impact of greenhouse gas emissions – such as carbon dioxide (CO2), methane (CH4), and nitrous oxide (N2O) – is assessed over a fixed time period of 100 years. Climate Change The climate change category takes into account that different gases have different climate change impacts on global warming. The total impact is described in CO2 equivalents. 19 Human Toxicity Health & Safety The human toxicity potential takes into consideration all substances handled at any time during the life cycle of a product. Only toxicity potentials are assessed, not actual risks. Substances are assigned toxicity points based on their hazard phrases (H-phrases) of the Globally Harmonized System (GHS). The H-phrases indicate human health hazards associated with exposure to specific substances. These toxicity points are multiplied with the amounts of substances used and report life cycle human toxicity potentials expressed in terms of dimensionless toxicity points. The method is described in detail in R. Landsiedel, P. Saling, Int. J. LCA 7 (5), 261-268, (2002). In cooperation with toxicologists, toxicity points were assigned to each H-phrase. For example, the classification H330 (fatal if inhaled) was assigned 750 toxicity points and the considerably less critical category H312 (harmful in contact with skin) 300 points. 20 Critical Panel Review Statement 21 Aggregated Results Solventless and water-based adhesives are more eco-efficient – base case 22 Solventless and water-based adhesives are more eco-efficient – differential approach 23 Contributions from environmental impact categories – Base case 24 Solvent-based adhesives have a less favorable environmental fingerprint Relative results – smaller values indicate better performance. All product systems are normalized between 0 and 1 by the product system with the highest impact per impact category 25 4:3 PowerPoint Template 26 Conclusions The purpose of the present study is to investigate the differing environmental and economic impacts originating from different adhesive systems for producing a two layer flexible packaging for general-purpose and medium-performance applications by lamination. The results of this study show that under the given conditions and chosen assumptions the three adhesive product systems, the solventless PU, the water-based PU and the water-based acrylate system, are about equally eco-efficient and have a clear advantage over the solvent-based PU adhesive system. The main driver of environmental differences among the alternatives is the production of the solvent of the solvent-based PU adhesive system. The main economic differences originate from the additional costs for the solvent of the solvent-based PU system and from differences in the adhesive production costs. The environmental differences between the four alternatives are larger than their economic differences. 27 4:3 PowerPoint Template 28