Laser imageable polymeric film antec 2015 presentation 3-8-2015 (4)
- 1. Laser Imageable Polymeric Film “Inkless Printing” Pat Thomas PRThomas Technologies
- 2. INTRODUCTION Describe a method of producing laser-imageable polymeric film (U.S. Pat. 8871424) Where Technology Fits in with conventional printing methods Advantages of Laser-imageable Film Next Generation Laser-imageable Film Development
- 3. INTRODUCTION With FDA Regulatory Changes – Product labeling has become increasingly important Thermal Transfer Flexographic Inkjet Rotogravure Laser Imageable Film vs Conventional printing and labeling • Lot Data – Unit Traceability • Exp Date • Bar Codes
- 4. INTRODUCTION Currently the laser imaging systems: Incorporates a photochromatic pigment into ink Ammonium Octamolybdate (AOM) The ink is flood coated or spot coated on substrates
- 5. LASER IMAGEABLE FILM A Laser-Imageable coex film has been developed and patented with a thin marking layer formulated with: 1. Polyolefin or Non-polyolefin material 2. AOM MB AOM forms a grey/black marking when exposed to a CO2 laser light 3. Talc MB: Provides good thermal diffusivity and stiffness -prevents film deformation upon exposure to the energy source
- 6. AOM MB PREPARATION Twin screw compounding equipment used Compounding Challenges Include: Avoiding AOM degradation • AOM degrades at 200 C • Melt temp, shear rate, residence time • Color change AOM dispersion and distribution • Avoiding AOM agglomerates present in film AOM MB formulation: 64% HDPE 35% AOM pigment 1% amide wax
- 7. METHOD OF MAKING FILM Laser-imageable polymeric film can be manufactured by conventional processes: Film Manufacturing Challenges Include: Avoiding AOM degradation – film discoloration Avoiding AOM MB agglomerations on film surface Die-lip Build-up Film Deformation – Heat from laser
- 8. LASER IMAGING TECHNOLOGY Videojet VJ-3320 CO2 laser, 127 mm lens AOM undergoes an irreversible color change from white to black upon exposure to CO2 laser wavelengths near 10,000 nm AOM comprises an ionizable group, radiation creates a charge and causes the AOM to transform from unactivated to activated state
- 9. LASER IMAGING TECHNOLOGY Less Heat
- 10. IMAGING TECHNOLOGY X-Rite SpectroEye spectrophotometer used measure and record the black optical density values (ODB) Laser Parameters for Square Block images included: Filling Size 0.187 mm Power (%) 40% to 75% Marking Speed (mms-1) 2000
- 11. IMAGING TECHNOLOGY Label Element Text/Single Line 2D matrix EAN-13 Line Width (mm) N/A 0.2 0.187 Power (%) 72 55 67 Marking Speed (mms-1 ) 2000 2000 2000 Note: Laser is fully programmable
- 12. EXPERIMENTAL FILM: TRIALS All experimental films samples were fabricated on conventional coextruded blown film equipment 2 blown film trials were conducted: Pilot line trial Production trial Melt temperature, shear rates, and residence time were minimized in order: AOM degradation Die-lip build-up
- 13. EXPERIMENTAL DESIGN PILOT LINE TRIAL Objective: Determine feasibility of fabricating laser-imageable film • Legible markings • Minimal film distortion Marking Layer Variables Included: % AOM % Talc MB % HDPE Film Structure: Thickness: 3.5 mils Structure: 2 layer coex with 10% marking layer
- 14. EXPERIMENTAL DESIGN MARKING LAYER FILM FORMULATIONS RUNS HDPE (%) AOM MB (%) Process Aid (%) Talc MB (%) 1 88 10 2 0 2 78 20 2 0 3 68 30 2 0 4 58 40 2 0 5 48 50 2 0 6 38 20 2 40 7 28 30 2 40 8 18 40 2 40
- 15. SUBJECTIVE IMAGE RATING Rating Film Distortion Darkness/Legibility Best Minimal Very Dark Good Slight-Minimal Dark Fair Slight-Minimal Light Poor Significant Very Faint
- 16. IMAGING RESULTS RUN AOM MB, Talc Poor Fair Good Best 1 10% AOM MB, No Talc X 2 20% AOM MB, No Talc X 3 30% AOM MB, No Talc X 4 40% AOM MB, No Talc X 5 50% AOM MB, No Talc X 6 20% AOM MB, with 40% Talc X 7 30% AOM MB, with 40% Talc X 8 40% AOM MB, with 40% Talc X • A small amount of smoke was observed during the laser imaging process
- 17. CONCLUSIONS PILOT LINE TRIAL The marking layer formulated with 40% AOM MB; 40% Talc MB provided the “BEST” images: Darkest, most legible images Least amount of film distortion Least amount of AOM MB The addition of Talc MB to the marking layer formulation reduced: Film distortion % AOM MB required for acceptable legibility
- 18. EXPERIMENTAL DESIGN PRODUCTION TRIAL Objective: Identify the optimal film structure and formulation Marking Layer Variables: % AOM 35%; 40% % Talc MB 0; 40%; 45%; 50% % HDPE % Nucleating Agent 0; 3% Film Structure: Thickness: 3.5 mils Structure: A/B/C/10% Marking Layer
- 19. EXPERIMENTAL DESIGN MARKING LAYER FILM FORMULATIONS RUN HDPE (%) AOM MB (%) Talc MB (%) Nucleating Agent (%) Slip MB (%) Process Aid (%) 9 19.5 35 40 3 1.5 1 10 14.5 35 45 3 1.5 1 11 9.5 35 50 3 1.5 1 12 14.5 40 40 3 1.5 1 13 9.5 40 45 3 1.5 1 14 4.5 40 50 3 1.5 1 15 54.5 40 0 3 1.5 1 16 17.5 40 40 0 1.5 1 17 57.5 40 0 0 1.5 1
- 20. IMAGING RESULTS 0.65 0.79 0.78 0.83 0.88 0.85 0.85 0.88 0.81 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 9 35% AOM 40% Talc 10 35% AOM 45% Talc 11 35% AOM 50% Talc 12 40% AOM 40% Talc 13 40% AOM 45% Talc 14 40% AOM 50% Talc 15 40% AOM 0% Talc 16 40% AOM 40% Talc 17 40% AOM 0 % Talc ODB ODB Measurements Formulations • #13 exhibited least amount of film deformation • Small amount of smoke was observed during laser imaging
- 21. CONCLUSIONS PRODUCTION TRIAL Optimal marking layer formulation comprised: 40% AOM MB 45% Talc MB 9.5% HDPE 3.0% Slip 1.5% Process Aid Addition of a nucleating agent does not reduce film deformation Although die-lip build-up was evident after 8 hours of run time at 900 lbs/hr, it wasn’t affecting film quality
- 22. What is “inkless printing”? Laser Vac nozzle Seal head Marking field Laser-imageable Film LASER IMAGING FILM TECHNOLOGY
- 23. LASER IMAGEABLE POLYMERIC FILM INNOVISION AWARD DEMO
- 24. OVERALL CONCLUSIONS A method of producing Laser-imageable film has been developed in which AOM, typically used in ink formulations, is directly incorporated into film A laser-imageable polymeric film offers substantial advantages over traditional methods of printing and laser imaging film
- 25. ADVANTAGES OF LASER-IMAGEABLE FILM PROCESS Improves efficiency Reduces scrap Eliminates registration set-up waste Reduces material changeover time No clean-up, No ink formulating
- 26. ADVANTAGES OF LASER-IMAGEABLE FILM PROCESS Reduces material inventory costs: Reduces the number of pre-printed material (SKU’s) No ink No printing plates No toners No primers No solvents No ribbons No Consumables??
- 27. WHERE DOES LASER-IMAGEABLE FILM FIT? Low Volume/high mix printing applications Language/country specific products (English, German, Chinese….) Vary sizes of same product (100mm, 105mm, 110mm) High frequency of artwork changes Individual packages requiring unique coding On Demand Printing
- 28. FUTURE DEVELOPMENT Next generation laser-imageable development: Significantly reduced costs Increase imaging speed Allow for coextruded film with internal marking layer capability • Eliminate die-lip build-up • Possibly eliminate the need for reverse printing and laminating • Eliminate smoke during imaging No film deformation issues • Different laser technology will eliminate film deformation issues • Down gauging capability for thinner films
- 29. NEXT GENERATION LASER-IMAGEABLE FILM DEMO
- 30. Questions
Editor's Notes
- #2: The title of my presentation is “Laser-imageable polymer film
- #3: The purpose of the presentation is to describe a method of producing a LIPF I’ll review the material used, the laser imaging technology, how the images were evaluated, and review the film trials and results After reviewing the development trials, I’ll where this technology may fit in with traditional printing methods and a few of the advantages of laser imageable film I’ll conclude with comments regarding the next generation LIPF development
- #4: With changes in FDA labeling requirements, product labeling is becoming increasing important Typically such information as: Lot data, exp dates, and bar codes are included on labels which provides the capability to trace products LIPF will need to compete with conventional methods of printing and labeling such as TT FLEX Inkjet and Rotogravure
- #5: Currently a photochromatic powder (AOM) is incorporated into ink The ink is then flood coated to spot coated on various substrates The AOM within the ink absorbs light from a laser Undergoes an irreversible white to black color change
- #6: The marking layer formulation of a coex film comprises: Polyolefin AOM MB – AOM forms a grey/black marking when exposed to a CO2 laser Talc MB -Provides good thermal diffusivity and stiffness which helps prevent film deformation
- #7: An AOM masterbatch was developed using conventional twin screw compounding equipment Compounding challenges include: Aom Degradation AOM degrades at 200 C Melt temp, shear rate, residence time AOM dispersion and distribution AOM agglomerates present in film AOM MB was developed comprising: 64% HDPE 35% AOM pigment 1% amide wax
- #8: LIPF can be manufactured by conventional processes: Blown Film Cast Film Extrusion Coating However, melt temp, shear rates and residence time must be minimized in order to avoid: AOM Degradation Die-lip Build-up
- #9: Videojet 3320 CO2 laser, 127 mm lens Laser parameters adjustable: Radiation time Energy output AOM changes color upon exposure to laser wavelengths near 10,000 nm Film samples imaged with: 2D matrix Text Single line graphics Bar codes
- #10: Videojet 3320 CO2 laser, 127 mm lens Laser parameters adjustable: Radiation time Energy output AOM changes color upon exposure to laser wavelengths near 10,000 nm Film samples imaged with: 2D matrix Text Single line graphics Bar codes
- #11: Videojet 3320 CO2 laser, 127 mm lens Laser parameters adjustable: Radiation time Energy output AOM changes color upon exposure to laser wavelengths near 10,000 nm Film samples imaged with: 2D matrix Text Single line graphics Bar codes
- #12: Videojet 3320 CO2 laser, 127 mm lens Laser parameters adjustable: Radiation time Energy output AOM changes color upon exposure to laser wavelengths near 10,000 nm Film samples imaged with: 2D matrix Text Single line graphics Bar codes
- #15: 8 runs AOM is increased from 10% to 50% with any Talc added Note: As AOM and Talc is increase the amount of HDPE is decreased AOM is again increased form 20 to 50% with 40% Talc added
- #16: A SUBJECTIVE Imaging Rating System was developed as follows: Best refers to film with minimal distortion and very dark imaging Good refers to film with Slight distortion and dark imaging And so on
- #17: Imaging results show that as the amount of AOM increased, image legibility improved Note: As the amount of AOM is increased with the presence of Talc, the image legibility improves even more
- #19: Based on the results of the pilot plant trials, a product trial was designed to: Identify the optimal film structure and formulation which provided the best film imaging With minimal film distortion
- #20: There were 9 runs AOM varied from 35 to 40% Talc varied form 40 to 50% A nucleating agent was added in order to possibly reduce film deformation
- #21: This is a graph of the imaging results: ODB values are on the Y axis Film formulations are on the x axis Run 13 provided the most legible images with least amount of film distortion
- #23: Photograph of the imaging process using a multivac
- #26: Advantages of LIPF include:
- #28: LIPF fits well with low volume and high mix printing applications
- #31: Rearrange to follow bill’s agenda FOOD + Protective + Other