Test of Packaging Material
Test of Packaging Material
Test of Packaging Material
1. Tensile Strength:
It is a measure of films resistance to being pulled apart at a constant rate of speed.
Maximum load that a material can support without fracture when being stretched, divided by the original
cross-sectional area of the material. Tensile strengths have dimensions of force per unit area and in the
English system of measurement are commonly expressed in units of pounds per square inch, often
abbreviated to psi. When stresses less than the tensile strength are removed, a material returns are either
completely or partially to its original shape and size. As the stress reaches the value of the tensile strength,
however, a material, if ductile, that has already begun to flow plasticity rapidly forms a constricted region
called a neck, where it then fractures.
Tensile properties are an important and common way to compare physical properties of diverse materials,
from steel to plastic. In the narrower realm of flexible films, these tests provide measurement of attributes
we can see and feel: strength, stiffness, and resistance to stretching. The tensile strength of polypropylene
increases significantly by the orientation process. Resin selection and orientation method are the primary
variables that influence tensile values. Therefore, tensile properties are almost entirely defined by product
design itself. Small variations in tensiles will inevitably result due to normal process variation, but the
performance effect is insignificant.
Test principles
Each end of a film specimen, of specific width and measured thickness, is held by a clamp or grip. One
grip is stationary, while the other is pulled away from the first at a pre-selected velocity. The machine
continuously measures the changing distance between the grips and the force exerted on them as they pull
the film apart. The test is completed when the sample breaks.
Today, most machines run automatically after the operator selects settings, loads the specimen, and
initiates the test. Most are also equipped with microprocessors that perform the calculations and
automatically display all the resulting values. But, the test concepts are best understood by studying loadextension curves like the ones shown in Graph 1. These are actual machine direction (MD) and transverse
direction (TD) load-extension curves for a typical, tender-oriented, 75 gauges OPP. In Graph 1, load is
plotted as a function of extension, and the tensile tester software calculates the following properties that
are noted in Table 4.
Sample
Description
Thickness (mil)
Ultimate
Strength (kspi)
Modulus (kpsi)
Elongation (%)
MD pull
.75
18.9
343
174
2
TC pull
.75
39.3
687
Table 4 values are software-generated results based on the following equations.
Max Load (lbf)
Initial cross-sectional area
45
Modulus (psi) = At any point on the elastic region tangent line (Stress Strain) =
Load (lbf)
Initial cross-sectional area
Elongation (%) =
Extension (in)
Initial grip separation
=
=
Load (lbf)
.00075 in2
Extension (in)
2 in
Test conditions like pull speed, initial grip separation, full-scale load, and sample width will affect the
results. Tensile properties can change with small changes in temperature; so it is important to conduct
tests in a controlled environment. Standard laboratory temperature is 72F (22C) 2F (1C).
Other factors affecting the tensile strength are the composition of material, method of processing, type of
packaging material, their physical properties and Machinability.
Tensile strength is a most important value for materials used in applications such as heavy-duty bags. A
large value for elongation is an index of toughness, since it indicates a material will absorb a large amount
of
energy
before
breaking.
An instrument called Good Brand Tensile Tester is used for this purpose. The specimen is clamped
between jaws and pulling force is applied. The force at which the specimen breaks is noted as kg/15mm.
Elongation is a strength property. It is measured by the same instrument on a calibrated scale (having a
pointer) and the result is expressed as:
% Elongation = (reading100) / (2 inch)
A schematic diagram of the instrument is given below:
2. Tear resistance
It is the force necessary to continue tearing a sample after a nick has been made. This test is very
important for all films as well as for paper. High tear values may be needed for machine operations or for
package strength. However, low tear values are necessary and useful for easy opening of some package
types. Tear strength is reported in grams.
A tear tester has a stationary clamp and a movable clamp on a pendulum, means for holding this
pendulum in a raised position, then quickly releasing it, and a scale that registers the arc through which
the released pendulum swings. Samples of paper or film are clamped into the tester and nicked to start the
tear; then the pendulum clamp is released. This tears the sample and the scale
registers the arc. As the arc is proportional to the tear strength of the sample,
calibration of the arc gives the tear strength.
Tear test is of two types edge tearing and internal tearing. Internal tearing is mostly frequently used for
measuring the tear resistance of papers and plastic films. The tear resistance depends on the type of
packaging material, physical properties, processing method and the condition of testing.
An instrument named Tear-ASTM-D-1922 is most widely used for measuring tear resistance.
2. Resistance to abrasion
This test is done to measure the ability of a packaging material to withstand surface wear during rubbing
and friction. The test consists of abrading the sample with a wheel of standard abrasion pad (abradant) for
a definite number of revolutions and finding its volume loss.
Volume loss = weight loss/specific gravity.
3. Drop test
Drop Test: The test simulates actual shocks by dropping the package and its content freely against a
rigid plane surface from a predetermined height. For example, a drop test can be conducted so that the
package hits the surface diagonally against one corner, as in the picture beside.
The test is carried out by stacking the packaged material above one
another or by placing a fixed weight above the unit pack for a certain time.
It can also be done by compressing a pack from two opposite sides and
measuring the pressure applied to break/deform the container.
Fig: compression testing of a wooden box.
This
test
is
generally applicable in case of wooden box, paper box, paperboards, cans and
other secondary packaging material. This property is also important for finding the stacking height in a
warehouse.
5. Vibration test
The Vibration Test: Various forms of transportation vibrations can be simulated in a laboratory through
a vibration test. The test-bench can be made to swing and vibrate in almost any direction with a number of
frequencies and amplitudes to emulate the transportation being used.
Vibration refers to mechanical oscillations about an equilibrium point. The oscillations may be periodic
such as the motion of a pendulum or random such as the movement of a tire on a gravel road.
Vibration testing is accomplished by introducing a forcing function into a structure, usually with some
type of shaker. Alternately, a DUT (device under test) is attached to the "table" of a shaker. For relatively
low frequency forcing, servo-hydraulic (electro-hydraulic) shakers are used. For higher frequencies,
electro-dynamics shakers are used. Generally, one or more "input" or "control" points on the DUT are
kept at a specified vibration level. Other "response" points experience maximum vibration level
(resonance) or minimum vibration level (anti-resonance).
Two typical types of vibration tests performed are random- and sine test. Sine (one-frequency-at-a-time)
tests are performed to survey the structural response of the device under test (DUT). A random (all
frequencies at once) test is generally considered to more closely replicate a real world environment, such
as road inputs to a moving automobile.
Most vibration testing is conducted in a single DUT axis at a time, even though most real-world vibration
occurs in various axes simultaneously. MIL-STD-810G, released in late 2008, Test Method 527, calls for
multiple exciter testing.
standardized to 100F (37.8C) and 90% RH, which is the most common set of conditions reported in
North America.
Relevance to package performance
A critical function of flexible packaging is to keep dry products dry (potato chips, pretzels, fortune
cookies...) and moist products moist (cheese, muffins, chewing gum...). Without protective packaging,
products will quickly gain or lose moisture until they are at equilibrium with the environmental relative
humidity. At this point, crispy products are soggy, and chewy products are hard and dry.
WVTR is the standard measurement by which films are compared for their ability to resist moisture
transmission. Lower values indicate better moisture protection. Only values reported at the same
temperature and humidity can be compared, because transmission rates are affected by both of these
parameters.
The order of water vapor resistivity in films of 1 mm is as follows, BOPP > HDPE > cast PP >BPET
>LDPE>EVOH at 100F (38C), 90% RH for 1 mil film
What affects the WVTR of OPP films ?
The most obvious factor that impacts WVTR is thickness: if an OPP of the same product design is twice
as thick as another, its WVTR will be half the value. This is so because WVTR is an inherent, bulk film
property of OPP.
It is common to find variation in the reported WVTR values for same-gauge OPP films produced or
measured by different manufacturers. The primary factors causing these differences are:
1. Raw material: Homopolymer PP resin differences in average molecular chain length, range of
chain lengths, and degree of crystallinity can account for up to a 10% difference in WVTR.
Additives and copolymer resin layers can account for differences of up to 30%.
2. Process: Normal differences in process conditions between one orienter and another account for
about 5% variation in WVTR values. (WVTR is reduced through orientation, because the
crystalline regions of the polymer matrix are aligned. In other words, orientation efficiently
"packs" polymer chains, so that larger spaces are minimized. Process conditions affect this
"packing," and therefore, WVTR values.)
3. Measurement: The instrument manufacturer, MOCON,states a test precision of :t3% with their
PERMATRON-W product line. Therefore, trained operators using this type of instrumentation
will generate values from .34 to .36 when testing a 1 mil OPP with a nominal WVTR of .35 g/100
in2/24 hr.
Test principles
ExxonMobil test cell looks like Figure below. Dry nitrogen gas is swept through a chamber where the
test film acts as the membrane separating this dry gas stream from a "wet" nitrogen stream on the other
side. The partial pressure difference creates a driving force for the water vapor to permeate through the
film to the low pressure side. The barrier of the film determines how much water vapor can transfer, and
this is continuously measured by an infrared detector in the outgoing stream of the dry side.
potato chips, dried fruits, nuts, and shredded cheese are commonly extended by this packaging
method.
2. Vacuum packaging is where the atmosphere is drawn out and eliminated, rather than being
replaced by another gas. This vacuum forces the flexible material to conform to the product
shape. Meats (fresh and processed) and cheeses are commonly packaged this way.
Once air has been replaced or eliminated from the package, there must be an adequate oxygen barrier and
seal integrity to keep a low oxygen concentration inside the pack. Otherwise, the driving force created by
the oxygen partial pressure differences (21% outside the bag and 0-2% inside the bag) will cause an
ingress of oxygen and destroy the benefit of removing it in the first place. OTR values are used to
compare the relative oxygen barrier capabilities of packaging films. An industry rule-of-thumb is that a
material is considered a "high oxygen barrier" if its OTR is less than 1 cc/100 in 2/24 hr (15.5 cc/m2/24 hr).
Table 10 shows OTR values for common polymer packaging films. Note that the table is divided into two
sections. The first contains normalized (1 mil) values for common materials. The second section displays
the OTRs for coated or metallized films where the total film thickness is unimportant, because the barrier
is primarily coming from the additional layer.
Generally asked question: Many customers ask about the carbon dioxide (CO 2) and nitrogen (N2)
transmission rates through film. ExxonMobil does not perform transmission testing with these gases, but
a value range can be estimated from OTR values by using the following relationships.
CO2 TR will be 3 to 5 times the OTR value at 73F (23C), 0% RH
N2 TR will be .2 to .4 times the OTR value at 73F (23C), 0% RH
For example, the OTR of 110 AXT is .40 cc/100 in 2/24 hr @ 73F (23C), 0% RH. Therefore, at the same
conditions, the CO2 TR is approximately 1.2 - 2.0 cc/100 in2/24 hr and the N2 TR is approximately .08 to .
16 cc/100 in2/24 hr.
What affects the OTR of films
Good oxygen barrier is achieved by combining functional layers to create a film with the required barrier,
as well as those other properties necessary to produce a serviceable package. For example, EVOH has
exceptional OTR properties, but needs moisture barrier and mechanical properties provided by layers that
are coextruded or laminated around it.
OTR is most affected by the following factors.
1. Thickness of barrier layer: Generally, the thicker the oxygen barrier-providing layer, the better the
barrier. But there are process and cost limitations that restrict the thicknesses that can be realistically
produced or successfully utilized.
2. Copolymer ratio, plasticizer content, and polymerization process: All PVdCs (or EVOHs or
PVOHs) are not created equal. Properties are compromised during polymer and product
development, so that total performance in target applications is optimized. There can be substantial
differences in OTR values depending on the selections made. For example, both ASB-X and AXT
are PVdC-coated and sealable, but their OTRs are 4.5 cc/100 in 2/24 hr and .40 cc/1 00 in 2/24 hr,
respectively. ASB-X has the poorer OTR, but a broader seal range than AXT.
3. Base film surface compatibility: The physical and chemical characteristics of the base film surface
have a major effect on the OTR after metallization, and to a lesser degree, after coating. This is
evidenced by Met PET's exceptional barrier, as well as the difference in OTRs between various
metallized OPP products
Test Principle
Conceptually, a test cell looks like Figure 4. Dry nitrogen gas is swept through a chamber, where the test
film acts as the membrane separating this stream from an oxygen stream on the other side. The partial
pressure difference creates a driving force for oxygen molecules to diffuse through the film to the low
pressure side. The film barrier determines the rate of oxygen permeation, and this is continuously
measured by a MOCON patented coulometric sensor in the outgoing ,stream of the nitrogen side. The
standard test conditions are; 73F (23C) and 0% RH.
4.
Figure 4: Cross-section of an OTR test cell
The test is complete when equilibrium, or steady state, is achieved; that is, it is complete when the sensor
detects a constant amount of oxygen in the nitrogen carrier stream. The rate of oxygen permeating
through the sample is not changing. This rate is the sample OTR and is recorded in units of cc/100 in 2/24
hr or cc/m2/24 hr at 73F (23C), 0% RH.
It is important to discuss the effects of relative humidity on OTR, even though the ASTM standard
procedure is at dry conditions. Relative humidity has a dramatic and negative effect on the OTRs of some
materials, most notably nylon, EVOH and PVOH. The effect is especially pronounced at RHs over about
70%.
Film Type
(cc/m2/24 hr)
The following OTRs are bulk material properties displayed at 1 mil. You may divide by the gauge (in
mil) in order to approximate OTR at a different thickness.
EVOH* (ethylene vinyl alcohol)
.005 - .12
.08 - 1.9
Biax Nylon-6
1.2 - 2.5
18.6 - 39
2-6
31 - 93
OPP
100 - 160
1550 - 2500
Cast PP
150 - 200
2300 - 3100
150 - 200
2300 - 3100
280 - 400
4350 - 6200
450 - 500
7000 - 8500
7. Optical test
-gloss
-opacity
-haze
-light transmission
-optical density
a. Gloss:
Gloss is a measurement of the relative luster or shininess of a film surface. ExxonMobil uses 45-degree
gloss, where the incident light beam strikes the film surface at a 45 degree angle from the perpendicular.
A sensor measures the amount of light reflected by the film at a mirror image angle. The gloss value is the
ratio of this reflected light to incident light and is reported in gloss units. Theoretically, the range of the
gloss scale is 0 to 100.
Shininess, brilliance, and sparkle are properties related to a film's gloss value. They can be valuable
appearance attributes for packages, labels, or graphic arts items.
Precise comparisons of gloss values can only be made when the measurements are performed on samples
of the same general type of material, using the same procedure and test angle. In particular, it is not valid
to compare the gloss values of transparent films and opaque films.
What affects film gloss
Gloss is primarily determined by material selection and surface smoothness, which are defined during
product and process development. Day-to-day process variations will have an insignificant effect on
gloss. Transparent films have two reflecting surfaces. Although rare, this can lead to gloss values that
exceed 100.
Test principles
ExxonMobil uses commercially available gloss meters to measure 45-deg gloss consistent with ASTM
procedure D 2457. The simplified diagram in Figure 2 graphically summarizes the test.
log10(
Incident light
Transmitted light
) = log10(
100
Light transmission (%)
As represented in Figure 1, a unidirectional light beam is directed onto the film specimen. After it enters
an integrating sphere, a photo detector measures the total light transmitted by the film and the amount of
transmitted light that is scattered more than 2.5. Haze is the percentage of total transmitted light that is
scattered by more than 2.5.
e. Light transmission
Definition
Light transmission is the percentage of incident light that passes through a film. ExxonMobil generally
evaluates this property for OPPalyte films.
Relevance to performance
This property is significant to the performance of opaque films like OPPalyte. Customers expect these
products to obstruct light transmission in a predictable way, which is important for the appearance of
printed graphics and protecting light-sensitive packaged products. OPPalyte film light transmission values
range from 15% to 50%, depending on the product design and film thickness.
NOTE:
Metallized films are very effective at blocking light transmission, but the preferred test for
100
The same test equipment with a different setup is also used to measure and display haze.
8. Machinability test
Machinability refers to the ease of which packaging material may be used in manufacturing and
packaging operations. Material with a lower machinability causes less tool wear, require less cutting
force and power, provide a better surface finish and better chip disposal.
It also includes the following;
- Handling properties
- Slip properties/frictional properties
- Printability
- Efficiency
- Convenience function
- Crimp test
- Sealibility etc
and potential energy of the pendulum after rupture of sample. This difference in energy is defined as
impact strength and is reported in units of kilogram-centimeters. It is useful in predicting resistance of a
material to breakage from dropping or other quick blows.
A test similar in scope, method and significance is the dart drop test. Weighted dart is dropped from
standard height onto taut sample. Significance and purpose are the same as in the pendulum test. Dart unit
is weight of dart in grams that breaks sample 50% of the time.