Recyclable materials, additives, or coatings for monolayer barriers | Materials

Recyclable materials, additives, or coatings for monolayer barriers

Background
What we're looking for
What we can offer you
Who we are
Q&A

Have questions about this request?

Get them answered by the team at Altium Packaging.

Background

Altium Packaging has a long history in manufacturing blow-molded rigid packaging for a variety of markets, including food and chemical products. Extrusion blow molding (EBM) is a process in which plastic is melted and extruded into a hollow tube to form a plastic object from the mold cavity. Multi-layer packaging presents difficulties to recycling. Our goal is to increase the sustainability of our packaging by making everything we produce 100% recyclable, including barrier packaging.

What is reciprocating screw blow molding? https://knowledge.halo.science/what-is-reciprocating-screw-blow-molding

A video explaining the reciprocating screw blow molding process and comparing it to a continuous screw process can be found here: https://youtu.be/YWzaZYHXS9s

What we're looking for

We are thus seeking a monolayer barrier solution that is compatible with our manufacturing assets (specifically the reciprocating screw blow molding machines used for EBM). While a solution that can process on a reciprocating screw blow molding machine (such as those made by Uniloy and other machine suppliers) is highly preferred, a monolayer solution that can process on a continuous extrusion shuttle or wheel blow molding machine will also be considered.

Solutions of interest include:

Highly functional materials, additives, or coatings that improve packaging barrier properties
Primarily for H20, O2, hydrocarbons, and other household and industrial product chemistries

Our must-have requirements are:

A barrier solution that’s an additive to, or applied as a coating to high-density polyethylene (HDPE)
The solution is capable of being heated to an average temperature of 350F in the extrusion process, maximum 500F

Our nice-to-have's are:

Cost parity with incumbent barrier packaging
Does not impact organoleptic or sensory attributes of contents
Capable of FDA food contact approval
Color: natural white or transparent, and can be colored with pigments
Materials, additives, or coatings should fall in the “Preferred” or “Needs Testing” recyclability category not “Detrimental” as determined by the Association of Plastic Recyclers (APR). See: https://plasticsrecycling.org/apr-design-guide
Technology Readiness Level 3-5. A wider range may be considered

What's out of scope:

Multi-layer or co-extruded constructions
Any non-recyclable materials

Acceptable technology readiness levels (TRL):

Levels 3-5

What we can offer you

Eligible partnership models:

Sponsored researchCo-developmentLicensingSupply/purchase

Benefits:

Sponsored Research

A range of $25,000 - $100,000 USD is available for a proof-of-concept and development in 2024, with a potential for follow-on funding.

Expertise

Work directly with our team at Altium who can support with bringing new products to market at massive scale. Altium experts may consider providing support for the project up to 6 hours per week.

Facilities and Services

Altium will consider using various extrusion blow-molding machines for sampling purposes at an Altium facility or trusted 3rd party vendor. Number of trials and locations TBD based on the proposal

Who we are

Altium provides stock and custom design, development and manufacturing of plastic containers, closures and packaging materials. With over 500 stock molds and our state-of-the-art Studio PKG design studio, we elevate our customers’ brands through innovative packaging solutions. Our customer portfolio ranges from 1 ounce to 5 gallons and serves a variety of industries.

We are staffed with professional scientists, engineers, and technicians who are experts in solving packaging challenges. Our state-of-the-art laboratory performs hundreds of on-site analytical and performance tests with cutting edge equipment to ensure our customers’ bottles are Always Made Right®.

Learn more

Reviewers

Joe Palmer

Technical Fellow

Khosrow Hallaji

Senior Director of Technology and Innovations

John Manderfield

Innovation and Design Fellow

Q&A with Altium Packaging

The Q&A is now closed.

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Hi Altium Team- I have a few questions 1)Are there specific target requirements for OTR or WVTR values? 2)Is it permissible to introduce process modifications in production? 3) Are you targeting a specific price point?

Omid N.N, Researcher, Era PolyCare llc

September 8, 2023

Sorry for the delay Omid. We are still learning to use Halo. 1) Are there specific target requirements for OTR or WVTR values? - Focus is on OTR - We may consider WVTR improvement if your solution warrants that. - Virgin HDPE OTR typical = (cm3) (mil) / (24 hrs) (100 in2) (ATM) - We would like HDPE with additives or costings to approach glass-like OTR, but as little at 10x reduction can be commercially useful. 2) Is it permissible to introduce process modifications in production? - Yes 3) Are you targeting a specific price point? - Price target has not been identified. Similar to market rates for EVOH would be in the range.