APPLICATIONS OF UV CATIONIC COATINGS FOR FOOD METAL PACKAGING
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1 APPLICATINS F UV CATINIC CATINGS FR FD METAL PACKAGING Authors: Dr Gianni Mirone Dr Francesco Veltri Presented by: Dr Gianni Mirone Technical Manager Radiation Curing Technology Company: Ce.Ri.Tec srl (Metlac group) S.S 35 Bis dei Giovi Bosco Marengo (AL) - Italy Tel Fax gianni_mirone@metlac.com info@metlac.com
2 Abstract This paper will discuss applications of UV radiation curing technology, mainly within the food metal packaging sector. The focus will be on cationic UV systems based on cycloaliphatic diepoxides. Development of these systems involves optimising the formulations to meet more stringent end-use requirements, to provide flexibility, hardness, abrasion and sterilisation resistance. Future developments for different types of containers will be considered. Introduction The market for metal decoration has undergone considerable changes and innovation during recent years; one of these is the use of UV curing technology. Among the main reasons permitting a wider use of this technology in Food Metal Packaging, we can number the solution to environmental matters concerning the emission of organic substances, the increase of application line speeds, the reduction of start-up investments and the subsequent reduction in running costs for conventional drying ovens. INTRDUCTIN UV VARNISH FR METAL DECRATING 1970 Introduction of UV technology for Metal Decorating 1980 Introduction of UV inks (about 10% on total). UV varnishes not yet under use Some interest for UV varnishes 1995 First trials on line of Multicolor UV inks with UV varnish 2000 Success and growing of UV technology Fig. 1 Short history on introduction of UV varnish for Metal Decorating 1
3 UV Varnish technology Two different technologies with different reaction processes have been developed as follows: - Free radical systems based on the use of monomers, modified acrylic oligomers and photoinitiators like aromatic ketones (i.e. benzophenone) and amines. - Cationic systems based on the action of a photoactive salt which is a catalyst for epoxy-based resins. UV TECHNLGY free radical cationic RESINS CRSS-LINKERS PHTINITIATRS Rheological modifiers Lubricants Additives Pigments Acrylated oligomers A crylic ester A romatic ketons / Amines Epoxy cycloaliphatic polyols Lewis acids (solfonium and/or iodonium salts) Similar for both technologies Both types of UV varnishes are used for Metal Decorating. Fig. 2 Different technology for UV varnish 2
4 UV RADIATIN CURING : CHEMISTRY UV CATINIC EPXY RESINS UV ray R HPF 6 R-H H UV RADICALIC/ACRYLIC A) START B) PRPAGATIN C) END R UV light R* R. free radical. C C + R. R C C ACRYLIC RESINS. R C C. + C C R C C C C Fig. 3 Simplified chemical reaction of different UV technologies The two technologies are applied in the can coatings market, even if, for many applications in this field, the UV cationic technology is preferred as it allows users to obtain a more flexible film, with good adhesion to the metal substrate and good resistance to sterilisation. Properties of UV cationic systems The application of UV systems in food metal packaging concerns the use of lithographic inks and protective varnishes for the external decoration of the container. The external protective varnishes generally require properties such as hardness, flexibility and resistance to heat treatments (for example sterilisation in H2 or steam at C for 1 or 2 hours) which the UV cationic technology is able to satisfy. The UV cationic varnishes used for the external protection of the container are applied under the same conditions as the solvent-borne conventional varnishes, 3
5 without any problem of transfer of odours and/or flavours for "reverse side contact" - i.e. transfer onto the internal side of the sheets during their stacking (tests carried out on the sheets from industrial production have confirmed the same performance as solvent-borne conventional varnishes). UV CATINIC VARNISHES FR METAL DECRATING The cationic technology allows to obtain a more flexible film-weight compared to the acrylic technology with high adhesion to metal subtrates and resistance to sterilization similar to the conventional varnishes. For this reason, the use of UV cationic varnishes is particularly suitable for those applications in Metal Packaging requiring very good chemical and physical properties Fig. 4 UV cationic system for metal decorating The UV cationic systems during polymerisation have a very slight "shrinkage" which gives the coatings a better adhesion to the different substrates. The substrate has a very delicate role for this kind of UV varnish application; the substrate can be either the blank metal-sheet or the metal-sheets coated with a solvent-borne basecoat and/or size used as a prime coat. The interfilm adhesion between inks, prime coats and substrate is of great importance in the use of UV varnishes. The curing process of UV cationic coatings, once it is started, goes on after the UV exposure ("dark cure effect) and the process can be increased and accelerated by 4
6 further heat treatment. This can be helpful in giving to the polymeric film special physical and mechanical properties. ne of the characteristics of UV cationic systems is the sensitiveness of the system to the humidity (high or extremely low levels of humidity can affect the polymerisation speed) and to the substrate contamination (the presence of amines, for example, can inhibit the curing process). End-use of UV cationic varnishes in Metal Decorating Listed in the slide below, (fig.5), are the end-uses of UV cationic varnishes in Metal Decorating. END-USE SUITABILITY F UV VARNISHES FR METAL DECRATING AERSL CANS & GENERAL LINE 3-PIECE FD CAN BDIES AND ENDS CAPS & CLSURES CRWNS MNBLC CANS AND TUBES RIM CAT FR BEER AND BEVERAGE DWI CANS Fig. 5 End-use suitability of UV cationic varnish for metal decorating 5
7 UV cationic varnishes for Aerosol and General Line cans Aerosol and General Line cans are used for food and other packaging (for example cream bottles, paint and oil cans) and are widely use for cosmetics, chemical products (such as insecticides, lubricants, paints, etc ) The properties of the external protective varnish, (which for this type of application is used on the body of the containers) are the following: very good gloss, resistance to abrasion, hardness and very high surface slip. CATINIC UV VARNISHES FR AERSL CANS & GENERAL LINE CATING PRPERTIES GLSS RESISTANCE T ABRASIN HIGH SLIP GD HARDNESS Fig. 6 Properties of Cationic UV Varnishes for external Aerosol and General Line Cans 6
8 The varnishing system is applied on flat metal-sheets and is composed of a solventborne basecoat conventionally dried, lithographic UV inks and UV cationic finishing varnishing. UV CATINIC VARNISHES FR AERSL CANS & GENERAL LINE VARNISHING SYSTEM SHEET + BASECAT + UV INKS + UV VARNISH PRCESSING SYSTEM Fig. 7 Varnishing and processing systems of Aerosol and General Line cans These packages are made up of three sections: the body (the section concerning the UV varnishing), the cone and the bottom. They are made of tinplate and the body itself does not undergo any particular deformation during the final moulding (see fig. 7) UV cationic varnish for "Easy pen Ends The manufacturing material can be either Tinplate, "Tin free steel or Aluminium. The properties of the UV polymeric coatings for external protection must, in this kind of application, satisfy the requirements of direct adhesion to the metal, resistance to sterilisation, good flexibility and resistance to surface abrasions. 7
9 UV CATINIC VARNISH FR FD CANS EASY PEN ENDS CATING PRPERTIES DIRECT ADHESIN T METAL SUBSTRATE PRCESSABILITY GD FLEXIBILITY RESISTANCE T ABRASIN Fig 8 Properties of UV varnish for external Easy pen Ends The varnishing system (on regular or scrolled sheets), requires the application of UV varnish directly onto the metal, followed by the application, on the other side of the sheets, of a solvent-borne internal lacquer, normally dried for 12 minutes at a temperature of 190 C-200 C. 8
10 UV CATINIC VARNISH FR FD CAN EASY PEN ENDS VARNISHING SYSTEM SHEET (BSG o TFS) + UV VARNISH + VARNISH N INTERNAL SHEET (curing 12 min at 200 C) PRCESSING SYSTEM EE printing from regular and scrolled sheets. crimping Fig 9 Varnishing and processing system of food can easy open ends (EE). The required properties of the coating are affected by the formation process of the easy open ends, which are printed directly from the regular sheets or the scrolled sheets and then "crimped" onto the can. The picture on the right side of fig. 9 shows the section of a crimped EE, where the high level of mechanical stress suffered by the varnish can be easily seen. UV cationic varnish for Caps & Closures, Twist ff Caps and Drawn Systems The closures which are used to seal the containers can be re-useable (as in the case of twist-off caps) or useable only one time (as in the case of crown corks). The twist-off caps are available in a very wide range and normally are classified according to their diameter and height. The small diameters (deep caps) are the most critical for the protective polymeric coatings. 9
11 UV CATINIC VARNISH FR CAPS & CLSURES TWIST-FF CAPS AND DRAWN CANS CATING PRPERTIES EXCELLENT FLEXIBILITY PRCESSABILITY RESISTANCE T ABRASIN Fig 10 Properties of UV varnish for external closures, caps and drawn cans The external protective UV varnish must have excellent properties of flexibility, resistance to sterilisation and to surface abrasion, even during the sealing phase of the cap in steam. The varnishing system (on sheets) is more complex than the previous ones. The first step is the complete lithography of the external side (solvent-borne basecoat dried in a conventional oven) lithographic inks with UV curing, UV finishing varnish. Then there is the varnishing of the internal side (with a solvent-borne product with conventional drying). nce the cap is transformed, the compound is applied on the internal side and it is necessary to make an additional drying in the oven (approx. 2- min. at 200 C). 10
12 UV CATINIC VARNISH FR CAPS & CLSURES TWIST-FF CAPS AND DRAWN CANS VARNISHING SYSTEM SHEET + ENAMEL + INKS UV + UV VARNISH + Varnish for internal sheet (stoving 12 min at 200 C) + compound (stoving 2 min at 200 C) PRCESSING SYSTEM 1- Shell printing 3-Rolling 2-Trimming 4-Curling Fig 11 Varnishing and processing systems for twist-off caps The processing system of the twist-off caps in 5 steps, (plane sheet, "shell" mould, trimming, rolling and "curling" phase) can explain the very high mechanical stress suffered by the coating. Guidelines in the development of a new product The flow chart in the slide here below (fig.12) shows the formulation process in the industrialisation of a new product. 11
13 FRMULATIN PRCESS Customer s request Choice of parameters Setting-up of formulation Re-evaluation of the system Pilot Production Industrialization Monitoring of production quality Fig 12 - Flow chart of a formulation process The choice of the formulation parameters (type of base resin, choice of monomers, photoinitiators, additives, flexibilising resins, curing conditions, etc.) and the setting-up of the formula before the pilot production, is the key point of the varnish industrialisation, which goes through much testing and re-evaluation of the Laboratory and production systems. 12
14 Future development of UV coatings in Metal Decorating UV CATINIC VARNISHES FR METAL DECRATING FUTURE DEVELPMENTS UV WHITE BASECAT Basecoat, inks and UV varnishes for Aluminium tubes INK S and UV varnish for deep drawn cans: DRD Aluminium cans Fig13 - Development projects on cationic UV coating for metal decorating 13
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