Transmission Efficiency Of Plastic Films Part 2

Advisor: 

Presented To: 

Presented By : 

Transmission efficiency 

Mr. Tariq Jamal 

of 

Plastic films 

.Ahsan Siddiqi 

Mr.Ahsan Ashraf 

Mr.Arshad Fauquier 

Mr.Tariq Jamal 

Mr.Zaheer Ahmad Chaughtai 

Mr.M.Arfan 

Aamir Naseem Satti (10-PE-02) 

Noman Sikander (10-PE-39) 

Sajid Mushtaq (10-PE-44) 

Syed Irfan Haidar Kazmi (10-PE-50) 

Syed Najmul Hassan (10-PE-52) 

PLASTICS TECHNOLOGY CENTRE KARACHI

This is certified that following group of students of semester-VIII final year B.E polymer, 

College of Polymer Engineering were examined on as per mandatory 

requirement of degree of B.E Polymer academic session Fall (2005-09) batch 10 prescribed 

by Hamdard University, Karachi. The report was studied and the following Project Design 

Thesis Assessment Board conducted the Presentation and Viva Examination. 

1. Aamir Naseem Satti 

2. Noman Sikander 

3. Sajid Mushtaq 

CERTIFICATE 

4. Syed Irfan Haidar Kazmi 

5. syed Najmul Hassan 

Each student has successfully performed about the specific segment of the project and overall 

concept of the project. 

Tesis Title: “ TRANSMISSION EFFICIENCY OF PLASTIC FILMS” 

Prof.Dr.Naeem Masood Hassan 

Head of Assessment board 

PROJECT DESIGN THESIS ASSESSMENT BOARD 

Engr.Sheikh Abdul Rahim (Member) 

Head’ Dept of Polymer Engineering 

Engr. Arshad Faruqui 

Associate Professor (Member) 

Engr. Zaheer Ahmed Chaughtai 




Engr. Muhammad Arfan 

Lecturer (Member) 

Dated:

TRANSMISSION EFFICIENCY OF PLASTIC FILMS 

C O N T E N T S 

S. No. CHAPTERS Page NO. 

1 STRUCTURE ANALYSIS 1 

1.1 

1.2 

1.3 

1.4 

Polyethylene (PE) 

Polyethylene Terephthalate (PET) 

Nylon (PA) 

Aluminum foil (Al) 

2 TEST AND STANDARD 7 

2.1 

2.2. 

2.2.1 

2.2.2 

2.2.3 

Gas Transmission Rate Test (GTR) 

Water Vapor Transmission Rate Test (WVTR) 

Tensile Strength 

Trouser Tear Strength 

Compression Strength 

3 TEST RESULT 18 

3.1 

3.1.1 

3.1.2 

3.1.3 

3.1.4 

3.2 

3.2.1 

3.2.2 

3.2.3 

3.2.4 

3.3 

3.3.1 

3.3.2 

3.3.3 

3.3.4 

National Tomato Ketchup 





National Garlic 





National Pickle 





[ 

1 

3 

4 

5 

7 

10 

12 

14 

17 

19 

19 

20 

21 

22 

23 

23 

24 

25 

26 

27 

27 

28 

29 

30

3.3.5 

3.4 

3.4.1 

3.4.2 

3.4.3 

3.4.4 

3.4.5 

3.5 

3.5.1 

3.5.2 

3.5.3 

3.5.4 

3.5.5 

3.6 

3.6.1 

3.6.2 

3.6.3 

3.6.4 


National Biryani Masala 





National Tayar Masala 






National Chinese Salt 






4 COMPARISON AND DISCUSSION 45 

4.1 

4.2 

4.3 

4.4 

4.5 






5 REMEDIES 50 

5.1 

5.2 

5.3 

Sealing failure of pouches 

Weight distribution 

Leakage 

[ 

31 

32 

32 

33 

34 

35 

36 

36 

37 

38 

39 

40 

41 

41 

42 

43 

44 

45 

46 

47 

48 

49 

50 

50 

50


Acknowledgement 

We are personally thankful to Mr. Sheikh Abdul Rahim. 

We appreciate the encouragement and understanding given 

by 

Mr. Tariq Jamal during the completion of this thesis. We 

should like to acknowledge their value suggestions and 

comments. 

Many thanks are also extended to the following individuals 

who have contributed to complete our thesis. 

Mr. Ahsan Siddiqi 

Mr. Ahsan Ashraf 

Mr. Arshad Faruqui 


Mr. Zaheer Ahmad Chaughtai 

Mr. M.Arfan 

[

Chapter: 1 


Structure Analysis 

Polyethylene 

Structure and properties of oriented Polyethylene films: 

It is cold-drawn in the machine direction Cast films of a metallocene Linear Low 

Density Polyethylene (mLLDPE) in two sequential steps to form ultra-oriented films. 

The Initial films were cast under low shear conditions to form essentially isotropic films. 

The first draw yields moderately oriented films, which display block-shear type chevron 

morphology. Under controlled conditions, void formation occurs during the second 

draw and the ultradrawn films whiten (become opaque), and display a fine crystalline 

morphology. Surprisingly, the films do not become more permeable; rather, they 

become high barrier films. In their ultra-oriented state, the water vapor transmission of 

the films is equivalent to that of poly (vinylidene chloride) (PVDC). 

The transport behavior of the films to various gases was studied using transient 

permeation methods. The decrease in permeability with orientation is attributed to an 

increase in the degree of crystallinity and increase in tortuosity due to the blocky 

crystalline morphology. A decrease in the permeability of the amorphous phase due to 

an increase in the amorphous phase density is also suggested by the data. 

Conclusion 

Films of metallocene LLDPE with high orientations have been prepared in a 

two-step cold-drawing process. The drawing process was found to increase the 

orientation (measured by birefringence), melting temperature and degree of 

crystallinity of the samples. Such changes resulted in an increase in density of some of 

the samples. A comparison of the degree of crystallinity calculated from DSC and 

density measurements, suggested that increased orientation also resulted in an 

increase in the density of the amorphous phase. 

The second draw process was successful in producing voids in some of the 

films as evidenced by whitening of the films. In spite of the voiding, the permeability of 

the films to water-vapor (WVTR) did not increase. On the contrary, the doubly 

stretched films were found to possess barrier properties superior to oriented 

polypropylene films (OPP), and equivalent to PVDC, a commercially used barrier film. 

Time-lag permeability measurements showed decreases in the permeability, diffusion 

[ 

1


and solubility coefficients with orientation. The increased barrier properly in these films 

has been shown to be due to an increase in the degree of crystallinity and increase in 

tortuosity due to destruction of the original lamellar structure into more block-like 

crystal morphology. An increase in the amorphous phase density is also speculated to 

contribute to the decrease in permeability. 

The oriented films exhibited interesting anisotropic mechanical properties. 

Deserving special mention is the high elongation to break observed when deforming 

along TD, which is almost three times higher than that observed in isotropic films. The 

break strain along TI) was found to increase with increasing MD orientation of the 

initial film, and the cold-draw stress was found to decrease as well. This could be a 

very important feature in any biaxial orientation of mLLDPE films, where it might be 

desirable to produce a higher orientation along MD prior to stretching in the TD 

direction in a tenter operation, in order to attain higher draw states at lower stresses. 

[ 

2


Polyethylene Ethylene Terephthalate 

Barrier Properties of polyesters based on Ethylene Terephthalate: 

The effect of crystallization from the glassy state (cold crystallization) on the 

oxygen-barrier properties of copolyesters based on ethylene terephthalate with up to 

10 mol % isophthalate phthalate or naphthalate was examined. Generally 

crystallization affected diffusivity D more than solubility S; thus the reduction in 

permeability P reflected primarily a reduction in D. Systematic changes in crystallinity 

made it possible to test free-volume concepts in which permeation of a small gas 

molecule through a semicrystalline polymer is viewed as proceeding through the 

amorphous regions with an increased pathway (tortuosity) imposed by plateletlike 

crystallites Of the copolymers studied, those with the highest isophthalate or phthalate 

content 10 mol %) conformed to the simple two-phase model with constant densities of 

an impermeable crystalline phase and a permeable amorphous phase. Within the twophase 

model, solubility S correlated linearly with the volume fraction of the amorphous 

phase, and diffusivity D depended on crystallinity in accordance with the Nielsen 

model for randomly dispersed platelets with an aspect ratio of 4. The reduction in 

permeability of the other examined copolyesters could not be described only by the 

filler effect of crystallites. Data on solubility demonstrated a decrease in amorphousphase 

density upon cold crystallization (de-densification) like that previously reported 

for polyethylene terephthalate. Increasing the isophthalate or phthalate content 

reduced the dedensification effect, and 10 mol % of these comonomers was sufficient 

to eliminate the effect altogether. In contrast, 10 mol % naphthalate did not prevent dedensification. 

This was attributed to different effects of kinked and linear comonomers on 

chain packing in the amorphous phase. 

It is well known that the presence of a crystalline phase improves the barrier 

properties of polymers. Qualitatively this is understood in terms of free-volume 

concepts because sorption and diffusion processes depend on the availability of 

unoccupied volume in the polymer. The efficiency of chain packing in the crystallites 

reduces the free volume available for transport to such an extent that the crystalline 

phase is regarded as impermeable relative to the amorphous phase. 

The experiment for oxygen flux through films of amorphous PET and cold 

crystallized PET with approximately 30% crystallinity by DSC. The initial increase in 

oxygen flux determined diffusivity D. When the permeant reached a constant 

concentration, the flux achieved the steady-state value. 

Close agreement with the experimental data indicate that there was no 

concentration dependence of oxygen diffusivity. Diffusivity D and permeability P were 

obtained from the fit to the solution of Fick’s second law. Solubility S was obtained 

from the relationship S 5 PD21. 

[ 

3

Strong, safe and easy to use: 


Nylon 

Nylon-MXD6’s properties give it advantages in many areas important in food 

packaging. Co-extruded, co-oriented films of Nylon-MXD6 have been proven to 

provide excellent gas barrier properties, pinhole resistance, heat resistance and 

environmental compatibility. It is tough and highly transparent. In addition, it is highly 

rated for aroma retention, and odor proofing. Given Nylon-MXD6’s excellent gas 

barrier properties compared to conventional nylons, and its other advanced properties, 

it has emerged as a highly regarded option for food packaging and other multifunction 

packaging. 

Advantage: 

Provides superior protection for foods. Nylon-MXD6 has excellent gas barrier 

and aroma preserving properties, keeping oxygen out and flavor and aroma in. It offers 

the best gas barrier property among nylon resins even under high humidity. Nylon- 

MXD6 is also excellent in preserving aroma as shown in Table 2. One of the key 

characteristics of barrier packaging is to protect food from oxygen, and Nylon-MXD6 

offers immediate recovery of oxygen barrier after retorting or boiling treatment. 

Easy to work with. 

The moderate crystallization speed means that Nylon-MXD6 provides good 

processability. It is easy to be stretched and/or thermoformed. The processing 

temperature range of Nylon-MXD6 overlaps with that of other packaging materials 

which makes it possible to co-extrude with not only polyolefins but nylon 6, nylon 66, 

PET, polycarbonate and other materials with a relatively high processing temperature 

range. This processing temperature range allows for diverse combination with other 

resins and various combinations with other polymers. It is easy to manufacture 

multilayered containers by co-extrusion or co-injection combination with other 

polymers and it improves properties and/or processing window for the other 

polyamides. Nylon-MXD6 has excellent thermal stability in the melting condition in 

comparison with other gas barrier resins, which enables stable processing. 

Easy on the environment. 

Nylon-MXD6’s superior recyclability occurs because it recycles without any gel 

formation and decomposition, and it does not contain any halogens that could give rise 

to acid rain or dioxin upon incineration. Its thermal stability also enables users to 

recycle the trimming scraps resulting from film and sheet production. Nylon-MXD6, 

compared to other available packaging options, is an environmentally friendly material. 

Nylon-MXD6: 260°C, PVDC (Polyvinyldiene chloride): 180°C, EVOH (Ethylene 32%): 

210°C, PAN (Polyacrylonitrile): 210°C 

[ 

4

Characteristics and Properties: 


Aluminum Foil: 

Aluminum foil is a solid sheet of aluminum, or of an appropriate aluminum alloy, 

rolled very thin, varying from a minimum thickness of about 0.00017 in. to a maximum 

of about 0.0059 in. (aluminum 0.006 in. is sheet). From the standpoint of packaging 

and other principal applications one of the most important characteristics of aluminum 

foil is its impermeability to water vapor and gases. Bare foil one mil and thicker is 

completely impermeable; much thinner gauges laminated to an appropriate film form 

impervious composite materials, making them ideal for packaging and general 

insulation/barrier applications which, with solid foil semi-rigid containers, account for 

most foil consumption. 

While most aluminum foil is employed in packaging, its many unique properties 

also account for its use in literally hundreds of other applications. 

Chemical Characteristics of Aluminum Foil: 

Resistance of aluminum foil to chemical attacks depends upon the specific 

compound or agent, but it has excellent and good compatibility with most products. 

Even some of the compounds classified as only fair in this respect are frequently 

packaged in coated or film-laminated foils. 

Aluminum has high resistance to most fats, petroleum greases, and organic 

solvents. Intermittent contact with water generally has no visible effect on aluminum 

otherwise exposed to clean air. However, standing water in the presence of certain 

salts and caustics can be corrosive. For example, some hygroscopic products 

packaged in aluminum foil may cause some reaction, particularly if the product 

contains salt, or salt and some mild organic acid. In these or any other applications 

which may subject the aluminum to mild attack, coating or lamination protection is 

employed on the foil surface next to the product. 

In general, such food products as candies, milk, unsalted meats, butter and 

margarine are compatible with bare aluminum. They also greatly benefit from its 

opacity, which retards deterioration from exposure to light. Similarly, many drug and 

cosmetic products are compatible with aluminum foil and also must be protected from 

light. 

Aluminum resists mildly acidic products better than it does mild alkaline 

compounds, such as soaps and detergents. While use with the stronger 

concentrations of mineral acids is not recommended without proper protection 

because of possible severe corrosion, weak organic acids, such as those found in 

[ 

5


foods generally, have little or no effect on aluminum. Reliable information and suitable 

tests are always recommended. 

Plastic Films: 

Many plastic films are laminated to foil, including polyethylene, polypropylene, 

cellophane, cellulose acetate, rubber hydrochloride, vinyl’s, polyvinyldiene chloride, 

polyesters. All of the foregoing is used in packaging, but any of the modern plastic 

films can be laminated to aluminum foil for a variety of present and potential 

applications. 

The choice of these laminates is governed by the following product 

requirements: 

1. Water vapor and gas permeability 

2. Strength, flexibility and toughness 

3. Resistance to grease, oils, chemicals, etc. 

4. Heat salability 

5. End-use temperature range 

6. Cost 

Properties of Aluminum Foil Laminations: 

In many laminations, light gauge foil is the primary barrier against water vapor 

transfer and creasing can create pinholes or breaks in this barrier. The effects of 

creasing of the foil can be minimized in lamination by proper choice of paper or film, 

lamination adhesives, and laminating conditions. 

Additional barrier properties against water vapor transmission are built into 

laminated structures by the use of waxes, polyethylene, asphalt, and other appropriate 

compounds as the laminating adhesive, and/or through the use of heavier foils or 

films. 

The water vapor transmission rate of the film employed in a foil/film structure 

may or may not be of prime importance, but the film is often relied upon for toughness. 

In proper gauge, the foil remains impermeable under many end use conditions. 

Application requirements will dictate whether the laminate must have high resistance 

to moisture and to folding. Laminated foil materials offer a number of options. Material 

provides good machining and sealing characteristics and contributes to the ease of removal of 

the cover from the container. 

[ 

6

Chapter: 2 

ASTM 1434: 


Test and Standard: 


This method covers the estimation of the steady state rate of the transmission 

of a gas through plastic in the form of film, sheeting, laminates and plastic coated 

paper or fabrics. This method provide for the determination of 

Method: 

(1) Gas transmission rate (GTR). 

(2) Permeance and in the case of homogeneous materials. 

(3) Permeability. 

The sample is mounted in a gas transmission cell so as inform a sealed semi 

barrier between two chambers. One chamber contains the test gas at a specific high 

pressure, and the other chamber, at a lower pressure, receives the permeating gas. 

Either of the following procedure is used. 

Procedure M: 

In procedure M the lower pressure chamber is initially evacuated and the 

transmission of the gas through the test specimen is indicated by increase in pressure. 

Procedure v: 

In procedure V the lower pressure chamber is maintained near at atmospheric 

pressure and the transmission if the gas through the test specimen is indicate by a 

change in volume. 

Significance and use: 

These measurements give semi quantitative estimates for the gas transmission 

of single pure gases through the film and sheeting. Correlation of measured values 

with any given use, such as packaged 

Contents protection must be determine by experience. The gas transmission 

rate is affected by the condition not specifically provided for in these tests, such as 

[ 

7


moisture content (Test or run using gas with 0% moisture changes), plasticizers 

contents and non homogeneities; these tests do not include any provision for testing 

seals that may be involved in packaging applications. 

Use of the permeability coefficient (involving conversion of the gas transmission 

rate to a unit thickness bases) is not recommended unless the thickness-totransmission 

rate relationship is known from previous study to stop even in essentially 

homogenous structure, variation in morphology (as indicated, for example by density) 

and thermal history may influence permeability. 

Description of terms specific to this standard: 

1. Gas transmission rate. (GTR): 

The quantity of a given gas passing through a unit of parallel surfaces of plastic 

film in unit time under the condition of test. The SI unit of GTR is 1mol/ (m²). The test 

conditions, including temperature and partial pressure of the gas on both sides of the 

films must be stated. Other factor, such a relative humidity and hydrostatic pressure 

that influence the transport of the gas must also be stated. The inch pound unit of 

GTR, a commonly used unit of GTR is 1 ml (STP)/ (m².d) at a pressure difference of 

one atmosphere. 

2. Permeance, P-: 

The ratio of gas transmission rate to the difference in partial pressure of the gas 

on the two sides of the film. The SI unit of permeance is 1 mol / (m².pa). The test 

condition must be stated. 

3. Permeability, P-: 

The product of the permeance and the thickness of a film. The permeability is 

meaningful only for homogeneous materials, in which it is properly characteristic of the 

bulk material. 

[ 

8

Test Specimens: 


The test specimen shell be representative of the material, free of wrinkle, 

creases, pinholes, other imperfection and shell be off uniform thickness. The test 

specimen shall be cut to an appropriate size. 

Conditioning: 

Standard Values: 

Condition all test specimens at 23 ± 2ºC (73.4 ± 3.6ºF). 

[ 

9

ASTM E-9 


Water Vapor Permeability 

The time rate of water vapor transmission through the unit area of flat material 

of unit thickness induced by unit vapor pressure difference between two specific 

surfaces, under specified temperature and humidity condition. 

Note: 

Permeability is a property of material, but the permeability if a body that perform 

like a material may be used. Permeability is the arithmetic of permeance and 

thickness. 

Water vapor Permeance: 

The time rate of water vapor transmission through unit area of flat 

material or construction induces by unit vapor pressure difference between two 

specific surfaces, under specified temperature and humidity condition. 

Permeance: 

Permeance is a performance evaluation and not a property of a material. 

Water Vapor transmission rate: 

The steady water vapor flow in unit time through unit area of a body, normal to 

specific parallel surfaces, under specific conditions of temperature and humidity at 

each surface. 

Note: 

The time required for testing a thick specimen of low permeability is long, in 

many cases increasing as the square if the thickness. When testing a low permeance 

material that may be expected to lose or gain weigh through out the test (because of 

evaporation or oxidation), it may be advisable to provide an additional specimen or 

dummy tested exactly like the other except that no desiccant or water is put in the 

[ 

10


dish. For thick hygroscopic specimens of low permeability, the time required to reach 

the steady state may be as long as 60 days. Other material may reach it quickly. 


[ 

11

ASTM D-882 


Tensile strength of plastic films and sheets 

Test standard covers the determination of tensile properties of plastics in the 

form of thin sheeting including film (less than 1.00 mm) in thickness. 

Two types of tension test are available in standard book. These test method 

classify on the manner of load application 

METHOD A Static weighing -constant rate of grip separation test 

METHOD B B Pendulum Weighing -constant-rate of -power-grip motion test. 

As we follow the method A constant rate of grip separation. This method 

employs a constant rate of separation of grips holding the end of the specimen. 

We had performed this test on universal testing machine (UTM) 

Significance and Use 

Tensile properties determined by the method are of value for identification and 

characterization of material control and specification of material for control and 

specification purposes. Tensile properties may be varying with the material used. The 

nylon film and aluminum foil was high tensile strength then other film. 

Definition: 

The tensile energy to break (TEB) is the total energy absorbed per unit volume 

of specimen up to the point of rapture. It is also name as toughness. 

Apparatus: 

We use three types of apparatus to perform this test. 

1. Thickness gauge 

2. Making sample 

3. Universal testing machine (UTM) 

[ 

12

Test specimen: 


1. The test specimens consist of strips of uniform width and thickness, longer 

than grip separation used. 

2. The nominal width of the specimens shall not be less 5mm, 20inchor greater 

then 25.4mm 

3. A width thickness ratio of at least eight shall be used 

4. The utmost care should be exercised in cutting specimens to prevent nicks 

and tears which are likely to cause premature failure .The edges shall be parallel to 

with in 5% of the width over the length of specimen between the grips. 

For sample making we used 

(a)Width measuring device 

(b)Width measuring device 

No of test specimen: 

We make five test specimens for each of national foods test samples. 

Speed of testing: 

5 mm/min 

50 mm/min 

500 mm/min 

Procedure: 

1. Select a load range such that specimen failure occurs within upper two third. 

A few trial runs may run necessary to select a proper combination of load range and 

specimen width. 

2. Measure of the cross-sectional area of the specimen at several point along it 

lengths. 

Calculation: 

1. Breaking force Factor (nominal) shall be calculated by dividing the maximum 

load by the original minimum width of the specimen. The in force per unit p width, 

usually Newton per meter or pounds per inch of width, and reported of three significant 

figures. 

2. Tensile Strength shall be calculated by dividing maximum load by the original 

minimum cross sectional area of the specimen .the result shall be expressed in force 

per unit area, using mega Pascal (or pounds per square inch). 

3. Tensile Strength at break nominal shall be calculated in the same way as the 

tensile strength except the load at break shall be used in place of maximum load 

4. Percentage Elongation at break shall be calculated by dividing the elongation 

movement of rapture of the specimen of the specimen by the initial gauge length of 

specimen and multiplying by 100. 

5. Yield Strength where applicable, shall be calculated by dividing the load at 

[ 

13


yield point by the original minimum cross section area the specimen. The results shall 

be expressed force per unit area, usually mega Pascal’s (pounds force per square 

inch). 

6. Percentage Elongation at yield were applicable shall be calculated by 

dividing elongation at yield point by initial gauge length of specimen and multiplying by 

100. 


[ 

14

ASTM D1938 


Trouser tear Strength 

This test method covers determination of the force necessary to propagated 

tear in plastic film and the thing sheeting thickness of one mm or point zero four inch 

or less by a single tear method the value stated in is unit are to be recorded as the 

standard. 

Method: 

The force to propagated across a film or sheeting specimen is measured using 

a constant rate of grip separation machine as describe in the D 882 the force 

necessary to propagated the tear is interpreted from the load time chart. 

Apparatus: 

Test specimen: 

UTM Machine 

The specimen shell be of single tear type shall be of best single tear the single 

tear type and shell consist of strips 75 mm 3 inch long by 25 mm 1 inch wide and shell 

have clean longitudinal slit 50 mm 2 inch ± 2 percent long cut with a sharp razor blade 

or the equivalent . 

Procedure: 

1. Secure tongue A in one grip and tongue B in other grip of the constant rate of 

grip UTM testing machine. 

2. Using a grip separation speed of 250 mm per minute start the machine and 

record the load necessary to propagate the tear throw the entire un slit 25 mm portion. 

3. Test not less than 5 specimens in each of the principle film are sheeting 

directions. 

[ 

15

Calculation: 


For each series of test the median of all values obtain shall be selected 

to 3 significant figures and reported as the median value of the particular properties. 


[ 

16

ASTM E-6: 


Compression Strength Test 

Breaking Load [F]: A compressive load on an interface. 

Breaking Load [F]: The load at which the fracture occur. 

Compressive Strength [FL -2 ]: 

The maximum compressive stress which a material is capable of 

sustaining. Compression tress is calculated from the maximum load 

during a compression test and original cross section area of the 

specimen. 

Apparatus: 


[ 

17

Chapter: 3 


Tests 

Result 

[ 

18


[


Sheet Specification 

Separation Results of National Ketchup: 

4 Layers. 

PET (67µm) (Dissolved In: Nitro benzene/ Di methyl formamide) 

1. PE (23µm) (Dissolved In: Toluene) 

2. Aluminum foil (5µm) (Dissolved In: HCL) 

3. Nylon (54µm) (Dissolved In: Formic Acid) 

Original Thickness: (149µm) 

The thicknesses of different layers are evaluated @ 46 % average 

swelling. 

Sample Name 


Test Gas O2 

Thickness 148 

Set Pressure 100 

Set Temperature 32.7 

[ 

National Ketchup 

Transmission Rate (GTR) 136[fm/Pa.s] 

19


[



Test Specification: 

Test: Water vapor transmission rate. 

Standard: ASTM E96 

Chamber Type: L80 

Upper Limit: 100 

Lower Limit: 80 

Relative Humidity Range: 35% 

Rep in Tol for Equil: 5 

Thickness: 148µm or 0.148mm 

Sample Width: 210 mm 

Sample Length: 120 mm 

[ 

Rep Count Deg (ºc) g/m² day 

1 69 23.2 19.27 

2 83 23.1 16.89 

3 91 23.1 15.74 

4 97 23.1 14.50 

5 112 23.0 13.43 

30 

25 

20 

15 

10 

5 

0 

Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 

g/m² day 

The decreasing trend is due to the reduction of water in the foam. The cause of 

reduction is the extraction of vapor while operating to measure the water permeability. 

20


[


Tensile Strength Test 

Test Specification: 

Test: Tensile strength 

Standard: D 638 

Width: 15mm 

Area: 1 

Speed: 50 mm / min 


[ 

Load Extension 

Peak Break Peak Break 

5.724 4.627 29.09 364.3 

5.525 4.346 27.36 357.9 

5.638 4.436 26.68 348.5 

5.305 3.439 28.35 337.3 

5.296 5.630 29.66 337.3 

Calculation: 

Mean Value = 5.497 Kg f 

Area = Width x Thickness 

= 15 x .148 

= 2.22mm² 

Unit Value = 5.497/2.22 

= 2.476 Kg f / mm² 

6 

5.9 

5.8 

5.7 

5.6 

5.5 

5.4 

5.3 

5.2 

5.1 

5 

Sample 

1 

Sample 

2 

Sample 

3 

Sample 

4 

Sample 

5 

Mean 

Value 

The non uniform reading in this test is due to the thickness variation of film sample. 

Peak 

21


[


Trouser Tear 

Specification: 

Test: Trouser Tear strength 

Standard: D 1938-85 


Sample Length: 75mm 

Sample Breadth: 25mm 

Speed: 250mm (10inch)/10min 

18 

Calculation: 

Mean Value = 0.4347 Kg force 

Thickness = 0.148 mm 

Unit Value = .4347/0.148 

= 2.937 Kg f / mm 

0.49 

0.47 

0.45 

0.43 

0.41 

0.39 

0.37 

0.35 

Load 

Peak (Kg force) 

.4644 

.4678 

.4107 

.4168 

.4141 


Non linear result is caused by non uniform thickness at the tear point. The thicker tear 

point will require more force to achieve tear, vice versa. 

[ 

Load 

22


[


[



Separation Result of National Garlic: 

4 Layers. 

[ 

1. PET (4µm) (Dissolved In: Nitro benzene/ Di methyl formamide) 


3. Aluminum (6µm) (Dissolved In: HCL) 




swelling. 


Sample Name National Garlic 

Test Gas O2 

Thickness 174 micron 




23


[

[[ 














Rep Count Deg ºc g/m² day 

1 70 22.7 20.00 

2 81 22.6 17.28 

3 95 22.7 14.74 

4 100 22.7 14.00 

5 110 22.7 12.73 

30 

25 

20 

15 

10 

5 

0 


[ 

g/m²day 



24


[






Width: 15mm 

Area: 1 

Speed: 50 mm/min 




5.442 4.298 29.04 354.3 

5.275 4.247 27.24 367.0 

5.238 4.078 26.95 358.1 

5.415 3.509 28.73 337.7 

5.493 5.450 29.33 347.5 

Calculation: 



= 15 x .174 

= 2.61mm² 

Unit Value = 5.372/2.61 

= 2.058 Kg f / mm² 

5.6 

5.5 

5.4 

5.3 

5.2 

5.1 

5 

Sample 

1 

Sample 

2 

Sample 

3 

[ 

Sample 

4 

Sample 

5 

Mean 

Value 


Peak 

25


[


Trouser Tear Strength Test 








Calculation: 

0.445 

0.44 

0.435 

0.43 

0.425 

0.42 

0.415 

0.41 

0.405 

0.4 

0.395 

Load 


.4301 

.4372 

.4409 

.4246 

.4131 


Thickness = 0.174mm 

Unit Value = 0.4291/0.174 

= 2.466 Kg f / mm 




[ 

Load 

26


[


[



Separation Result of National Pickle: 

2 Layers. 


2. PE (147.66µm) (Dissolved In: Toluene) 

Original Thickness: (164.66 µm) 


Sample Name National Pickle 

Test Gas O2 

Thickness 164.66 



Transmission Rate (GTR) 288 [fm/Pa.s] 

[ 

27


[















1 70 23.0 20.00 

2 80 23.1 19.44 

3 85 23.1 18.67 

4 91 23.1 17.72 

5 99 23.1 16.47 

20 

15 

10 

5 

0 


The decreasing trend is due to the reduction of water in the foam. The cause of reduction 

is the extraction of vapor while operating to measure the water permeability. 

[ 

28


[






Width: 15mm 

Area: 1 





6.765 6.295 29.96 30.09 

6.854 6.148 29.23 30.11 

6.462 5.313 24.65 25.74 

6.741 4.827 26.57 268.9 

6.542 4.840 14.28 225.2 

Calculation: 



= 15 x .164 

= 2.46mm² 

Unit Value = 6.672/2.46 

= 2.712 Kg f / mm² 

7 

6.9 

6.8 

6.7 

6.6 

6.5 

6.4 

6.3 

6.2 

6.1 

Sample 

1 

Sample 

2 

Sample 

3 

[ 

Sample 

4 

Sample 

5 


Peak 

29


[


Trouser Tear Test 




Thickness: 164µm or0.164mm 




Calculation: 



Unit Value = 0.6124/0.164 

= 3.374 Kg f / mm 

0.9 

0.8 

0.7 

0.6 

0.5 

0.4 

0.3 

0.2 

0.1 

0 

Load 


.4644 

.3463 

.8456 

.7087 

.6974 




[ 

Load 

30


[



Compression Test 

Test: Compression 

Standard: E-6 

Speed: 10mm/min 

Load 


98.4 

[ 

31


[



Separation Result of National Biryani Masala: 

4 Layers. 

[ 




4. Aluminum Foil (2.3µm) (Dissolved In: HCL) 

Original Thickness: (.0563 mm) 


swelling. 

Gas Transmission Rate test (GTR) 

Sample Name National Biryani Masala 

Test Gas O2 

Thickness 61 



Transmission Rate (GTR) 478 [fm/Pa.s] 

32


[


Water Vapor Transmission rate Test (WVTR) 









Thickness: 56.3µm or 0.0563mm 




1 59 23.0 21.03 

2 68 23.1 20.76 

3 75 23.1 20.37 

4 83 23.0 19.21 

5 84 23.0 18.69 

30 

25 

20 

15 

10 

5 

0 


[ 

g/m²day 



33


[






Width: 15mm 

Area: 1 





5.247 8.472 44.45 44.45 

5.518 5.718 47.20 47.20 

5.272 5.238 44.28 44.53 

5.428 5.482 50.22 50.22 

5.447 5.393 50.53 49.28 

Calculation: 



= 15 x 0.0563 

= 0.84mm² 

Unit Value = 5.393/0.84 

= 6.420 Kg f / mm² 

5.8 

5.7 

5.6 

5.5 

5.4 

5.3 

5.2 

5.1 

5 

Sample 

1 

Sample 

2 

Sample 

3 

Sample 

4 

[ 

Sample 

5 


Peak 

34


[










Load 


1.565 

1.659 

1.489 

1.683 

1.635 

Calculation: 



Unit Value = 1.606/.0563 

= 28.52 Kg f / mm 

2 

1.8 

1.6 

1.4 

1.2 

1 

0.8 

0.6 

0.4 

0.2 

0 

Sample 

1 

Sample 

2 

Sample 

3 

[ 

Sample 

4 

Sample 

5 



Peak 

35


[


[



Separation Result of National Tayar Masala: 

3 layers. 

[ 


2. Nylon (24µm)( Dissolved In: Formic Acid) 

Original Thickness: (57µm 

Gas Transmission Rate Test 

Sample Name National Tayar Masala 

Test Gas O2 

Thickness 57 




36


[















1 61 23.4 22.95 

2 70 23.3 22.22 

3 78 23.4 21.21 

4 85 23.5 19.72 

5 84 23.6 18.42 

30 

25 

20 

15 

10 

5 

0 


[ 

g/m²day 



37


[






Width: 15mm 

Area: 1 





8.317 7.217 18.14 18.14 

8.405 8.405 20.46 20.46 

8.236 8.236 18.76 18.76 

8.542 8.742 19.45 19.45 

8.474 7.674 18.86 18.86 

Calculation: 



= 15 x 0.057 

= 0.855mm² 

Unit Value = 8.395/ Kg f 0.855 

= 9.819 / mm² 

8.6 

8.5 

8.4 

8.3 

8.2 

8.1 

8 

Sample 

1 

Sample 

2 

Sample 

3 

[ 

Sample 

4 

Sample 

5 

Load 


38


[

1.6 

1.4 

1.2 

1 

0.8 

0.6 

0.4 

0.2 

0 


Tear Strength 


Test: Tear strength 






Load 


1.418 

1.245 

1.498 

1.289 

1.306 

Calculation: 

Mean Value = 1.351Kg f 


Unit Value = 1.351/.057 

= 23.7 Kg f / mm 


[ 

Load 

Non linear result is caused by non uniform thickness at the tear point. The 

thicker tear point will require more force to achieve tear, vice versa. 

39


[



Compression 

Test: Compression 

Standard: E-6 

Speed: 10mm/min 

Load 


97.5 

[ 

40


[


Separation Result of National Chinese Salt: 

2 Layers 


1. PE (44µm) (120 o C) (Dissolved In: Toluene)(0.044 mm) 

2. PP (20.6µm) (168 o c)( Dissolved In: Toluene)(0.02066 mm) 


Gas Transmission Test (GTR) 

Sample Name Chinese Salt 

Test Gas O2 

Thickness 61.66 




[ 

41


[











Thickness: 61.66µm or 0.0616 



[ 


1 71 22.9 19.72 

2 78 22.9 17.44 

3 81 22.8 18.92 

4 90 22.8 16.87 

5 94 22.8 15.91 

30 

25 

20 

15 

10 

5 

0 


g/m²day 



42


[






Width: 15mm 

Area: 1 





8.137 6.137 11.20 11.20 

8.609 8.609 21.04 21.04 

8.309 8.309 19.15 19.15 

8.880 8.880 19.29 19.29 

8.282 8.282 17.90 17.90 

8.9 

8.7 

8.5 

8.3 

8.1 

7.9 

7.7 

7.5 

Calculation: 



= 15 x 0.0616 

= .924mm² 

Unit Value = 8.504/0.924 

= 9.203 Kg f / mm² 

Sample 

1 

Sample 

2 

Sample 

3 

[ 

Sample 

4 

Sample 

5 

Load 


43


[


Trouser Tear Strength Test 








= 7.417 Kg f / mm 

0.5 

0.48 

0.46 

0.44 

0.42 

0.4 

0.38 

Load 


.4416 

.4940 

.4819 

.4242 

.4429 


[ 

Calculation: 

Mean Value = 

0.4569 Kg force 

Thickness = 

0.0616mm 

Unit Value = 

0.4569/.0616 

Load 

Non linear result is caused by non uniform thickness at the tear point. The 

thicker tear point will require more force to achieve tear, vice versa. 

44


[

Chapter: 4 


Comparison and Discussion: 

All test charts will show variation among products. This variation is due to the 

thickness variation of respective material layer used in the sample. The sample with 

thicker layer of basic component material will show poor permeability and vice versa. 

The table of material thickness with respect to their product is provided after 

each test comparison chart. This table will give better understanding about the 

permeability in various products. 

The table will also provide a sufficient knowledge about the mechanical 

properties of the products. The conclusion about mechanical properties such as 

tensile, tear and compression is based on the thickness of rigid layer (PET, Nylon and 

aluminum Foil) present in the respective sample. The thicker the layer greater will be 

the rigidity and higher mechanical strength is shown and vise versa. 

600 

500 

400 

300 

200 

100 

0 

Gas Transmission Rate Test: 

Ketchup Garlic Pickle Bryani 

Masala 

[ 

Tyar 

Masala 

Chinese 

Salt 

45


The ketchup and garlic contains thicker layer of PET, Nylon and AL foil 

providing high barrier to gasses. 

The pickle shows intermediate behavior, though AL foil is not present in this 

sample but the layer of PE and Nylon provide sufficient barrier. The transmission rate 

of pickle is higher than garlic and ketchup because PET is not present in pickle. 

In baryani all PET, PE, Nylon and AL foil are present but transmission rate is 

higher because layer thickness are thin. 

Both tayar masala and chinese salt have highest transmission rate due to very 

thin layer and absence of AL foil. 

Water Vapor Transmission Rate Test: 

There is a small difference of water vapour transmission rate among the 

products because of slight variation in PE and Al foil layer thickness which determines 

WVTR in all samples. 

[ 

46


Tensile Strength: 

Both Tayar Masala and Chinese Salt have the highest Tensile Strength among 

other products, due to the absence of aluminum foil in them. The remaining plastic 

layers shows tremendous stretching enhance more forces required to achieve the 

break point. 

National Biryani Masala shows intermediate tensile strength. Though aluminum 

foil is present but its thickness is very thin and is not able to provide sufficient rigidity in 

combination with plastic layers. The sample shows sufficient stretching while testing. 

Pickle shows reduced tensile strength due to the presence of rigid PET and 

Nylon layer in it. The rigidity in Pickle is enhancing due to the presence of Nylon which 

comprises best mechanical properties. 

Ketchup and garlic shows lower tensile strength because all three layer (PET, 

Nylon and Aluminum Foil) are rigid and tough and break point is achieve very quickly. 

[ 

47

30 

25 

20 

15 

10 

5 

0 


Trouser Tear Strength: 

Ketchup Garlic Pickle Chinese 

Salt 

[ 

Tayar 

Masala 

Biryani 

Masala 

Ketchup, Garlic and Pickle shows lowest tear strength because they consist of 

rigid layers. Due to this rigidity the force is exerted linearly at the notch point and 

hence break point is achieved very soon. 

The Chinese Salt contains two plastic layers (PE and PP) which show 

intermediate stretching when force is applied. This results comparatively higher tear 

strength then Ketchup, Garlic and Pickle. 

Biryani Masala and Tayar Masala show prolong stretching and exhibits highest 

tear strength in our sample. The reason of prolong stretching is the presence of three 

plastic material (PET, Nylon and PE) which show flexible property. Though Aluminum 

Foil is present in Biryani Masala but its thickness is not sufficient enough to provide 

rigidity. 

48


Compression: 

In Pickle the nylon layer is present having thickness of 17µm along with PE up 

to 147.44. Nylon exhibits the best mechanical properties and the combination of PE 

makes it stronger. In combination of both these material the Pickle pouch is capable of 

bearing the compressive force of about 98.4Kg at the speed of 10 mm/min. 

The Tayar Masala consists of PET and Nylon providing sufficient compression 

strength according to its respective application. Allowing it to with stand the force of 

97.5 Kg at the rate of 10mm/min 

[

Chapter: 5 


REMEDIES 

In this project we were assigned a technical task about the problem faced by 

NATIONAL FOOD at their production line. The problems are as follow, 

Sealing failure of pouches. 

Weight distribution failure in Ketchup. 

Leakage 

Sealing failure of pouches: 

We were informed that sealing failure is faced during production. We sealed the 

sample of national pickle, biryani and tayar masala for compression test and found 

excellent test value. We suggest you following remedies to over come this problem. 

[ 

I. To check the sealer heater weather it is working properly. 

II. Closely examine that no substance should be present in between the two 

contact surface to be sealed. 

III. Appropriate temperature should be given according to the material. 

Weight distribution: 

For weight distribution we compared the NATIONAL ketchup with SHANGRILA 

ketchup and found that the lower end of the SHANGRILA pouch is wider than 

NATIONAL ketchup. This wide area gives more weight transfer to the base and 

provides pouch the out standing balance. 

Another reason for the balance is that the circumference of the point where the 

ketchup settles at the bottom is more rounding SHANGRILA ketchup. This type of 

geometry is help full in dividing the weight across entire base region. 

Leakage: 

The leakage problem occurs due to insufficient sealing. To overcome this 

problem sealing should be done properly with appropriate temperature and pressure. 

49 

50


Another reason of leakage is due to smaller fusion area between two sheets at 

the base area of pouch. To resolve this issue extended area of sheet should be fused 

to increase the joining area, which provide greater strength to the pouch and prevents 

the pouch from leak at the base area. 

[ 

51

1. Plastic Films 

3 rd Edition 

J.H Briston 

Dr. L.L Katan 

2. Plastic Materials 

7 th |Edition 

J.A. Bradson 


Bibliography: 

3. Polymer Materials and Processing 

A. Brent Strong 

4. Polymer Chemistry 

4 th Edition 

Charles E & Carrher. Jr. 

5. Polymer Physics 

ULF W.GEDDE 

6. Hand Book Of Adhesive 

D.M Charls 

7. Hand Book of Extrusion 

Rewandar 

8. Hand Book of Polymer Testing 

R.P. Brown 

9. Internet Source 

[ 

52


[

Transmission Efficiency Of Plastic Films Part 2

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