"This technology is the best one available today on clear barrier polypropylene packaging films“. Gabriel Durana, Product Manager for Special Technologies at Biofilm S.A. in Mexico, has high praise for the coating technology of the Fraunhofer Institute for Electron Beam and Plasma Technology FEP.
Plasma technology of Fraunhofer FEP is enhancing barrier properties of food packaging
© Fraunhofer FEP
In November last year Biofilm commissioned their second plant using the plasma technology from Dresden at its site in Altamira, Mexico. Since starting up the first plant in 2009, Biofilm has supplied the innovative film to manufacturers of snack products and baked goods in North America and Europe.
The film has become so popular amongst customers and has opened up new applications, like high-barrier microwavable packaging to give products a freshly-baked taste and feel, that a second production plant became necessary. The new plant is now fully operational and coats films up to 2.85 meters in width.
The vacuum roll-to-roll plants transport the several kilometers long polymer film at speeds of 36 km/h via roller systems through coating stations. Aluminum wire is constantly fed to these stations and is evaporated in hot ceramic crucibles. The trick for applying transparent barrier layers is accurate control of the amount of oxygen that is mixed with the aluminum vapor.
To achieve an optimum oxide layer, the oxygen requirement is identified directly by optical measurement systems which detect the transparency of the film and adjust the oxygen feed accordingly. In order to deposit a preferably dense layer on the film, and hence achieve an effective barrier, additional energy is introduced into the aluminum-oxygen vapor in a plasma zone before the vapor hits the substrate.
The result is a transparent packaging film with a very thin aluminum oxide layer, which is less permeable for oxygen and water vapor than a conventional film and hence extends the freshness and crispness of foods.
The Fraunhofer FEP developed this technology jointly with Biofilm from the concept stage right through to industrial implementation. Important here was to be able to develop and test the process under industry-relevant conditions in own pilot plants and hence considerably lower the risks associated with the scaling up of the process. The project work was carried out over several years and was funded by the Saxon State Ministry for Economic Affairs, Labor and Transport (SMWA) and the Federal Ministry of Education and Research (BMBF).
The project partners included Applied Materials, Inc. (coating equipment manufacturer), Vacuum Technologies Dresden (VTD) (producer of hollow cathode sources for the plasma activation), and ISA GmbH (provider of the power supply system).
However, it is not only packaging materials that can be improved using this plasma technology. Medical implants, solar cells, flexible electronics, and optical filters can also be refined using vacuum technologies such as sputtering, high-rate deposition, and high-rate PECVD. Dr. Nicolas Schiller, head of the Coating of Flexible Products business unit and deputy director of the Fraunhofer FEP, believes the technology has enormous potential for battery applications: „The special expertise of the Fraunhofer FEP is in using thin film technologies for precision, economical coating of large surfaces. There are certainly opportunities for this technology in the area of electromobility, where battery cost reduction is seen as a key step for commercialization.“For further information please visit Fraunhofer FEP on May 1 – May 2 at the international trade fair on vacuum coating SVC 2012 in Santa Clara, USA, at booth no. 904.
Annett Arnold | Fraunhofer-Institut
Shock-dissipating fractal cubes could forge high-tech armor
08.07.2020 | DOE/Los Alamos National Laboratory
Atomic 'Swiss army knife' precisely measures materials for quantum computers
08.07.2020 | National Institute of Standards and Technology (NIST)
New insight into the spin behavior in an exotic state of matter puts us closer to next-generation spintronic devices
Aside from the deep understanding of the natural world that quantum physics theory offers, scientists worldwide are working tirelessly to bring forth a...
Kiel physics team observed extremely fast electronic changes in real time in a special material class
In physics, they are currently the subject of intensive research; in electronics, they could enable completely new functions. So-called topological materials...
Solar cells based on perovskite compounds could soon make electricity generation from sunlight even more efficient and cheaper. The laboratory efficiency of these perovskite solar cells already exceeds that of the well-known silicon solar cells. An international team led by Stefan Weber from the Max Planck Institute for Polymer Research (MPI-P) in Mainz has found microscopic structures in perovskite crystals that can guide the charge transport in the solar cell. Clever alignment of these "electron highways" could make perovskite solar cells even more powerful.
Solar cells convert sunlight into electricity. During this process, the electrons of the material inside the cell absorb the energy of the light....
Empa researchers have succeeded in applying aerogels to microelectronics: Aerogels based on cellulose nanofibers can effectively shield electromagnetic radiation over a wide frequency range – and they are unrivalled in terms of weight.
Electric motors and electronic devices generate electromagnetic fields that sometimes have to be shielded in order not to affect neighboring electronic...
A promising operating mode for the plasma of a future power plant has been developed at the ASDEX Upgrade fusion device at Max Planck Institute for Plasma...
07.07.2020 | Event News
02.07.2020 | Event News
19.05.2020 | Event News
09.07.2020 | Physics and Astronomy
09.07.2020 | Power and Electrical Engineering
09.07.2020 | Physics and Astronomy