IIP-HYDERABAD POLYVINYLIDENE CHLORIDE

Project Report On

“POLYVINYLIDENE CHLORIDE”

Guided by

Mr. MADAN MOHAN

HYDERABAD

BY

SHAIK DADA KHALANDAR

PG/H/17025

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IIP-HYDERABAD POLYVINYLIDENE CHLORIDE

ACKNOWLEDGEMENT

An endeavor of a long period can be successful only with the advice of many well wishers.
We take this opportunity to express our deep gratitude and appreciation to all those who
encouraged us for successful completion of the project work.

I would like to have special thanks to Mr. MADHAB CHAKRABORTY, Joint director for
his valuable guidance during the progress of project work, for his timely suggestions and help
in spite of his busy schedule

I would like to thank our Guide Mr. MADAN MOHAN, Asst. Director for his valuable
guidance and suggestions till the end of project work completion.

I thank all my seniors and friends for guiding me throughout this project work.

SHAIK DADA KHALANDAR

(PG/H/17025)

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Contents
ABSTRACT............................................................................................................................................ 5
1. INTRODUCTION TO PACKAGING: ................................................................................... 6
1.1 PACKAGING: ........................................................................................................................ 6
1.2 HISTORY OF PACKAGING:................................................................................................ 6
1.3 PACKAGING CRITERIA:..................................................................................................... 8
1.4 NEED OF PACKAGING: ...................................................................................................... 8
1.5 PACKAGE COMPONENTS:................................................................................................. 9
1.6 PACKAGING MATERIALS: ................................................................................................ 9
1.6.1 PAPER BOARD:.............................................................................................................. 10
1.6.2 Glass: ............................................................................................................................. 11
1.6.3 Metals: .......................................................................................................................... 12
1.6.4 Wood: ........................................................................................................................... 13
1.6.5 Bamboo: ........................................................................................................................ 13
2. PLASTICS: .................................................................................................................................. 13
2.1 SYNTHESIS OF PLASTICS: .............................................................................................. 14
2.2 COMMON PLASTIC POLYMERS USED IN PACKAGING: .......................................... 14
2.2.1 Polyethylene (PE): ....................................................................................................... 15
2.2.2 Polypropylene (PP): ....................................................................................................... 15
2.2.3 Polyethylene terephthalate (PET): ............................................................................ 16
2.2.4 Polyvinyl chloride (PVC): .......................................................................................... 16
2.2.5 Polystyrene (PS) .......................................................................................................... 16
2.2.6 Laminates and Co-extrusions: ................................................................................... 17
2.2.7 Tetrapaks: .................................................................................................................... 17
2.2.8 POLYVINYLIDENE CHLORIDE: .......................................................................... 17
3. POLYVINYLIDENE CHLORIDE: ............................................................................................. 18
3.1 INTRODUCTION: ............................................................................................................. 18
3.2 HISTORY OF PVDC:................................................................................................................ 18
3.3 PHYSICAL PROPERTIES OF PVDC: ......................................................................................... 20
3.4 PVDC description: ................................................................................................................. 20
3.5 PROPERTIES: ......................................................................................................................... 21
3.6 PROCESSING OF PVDC: ......................................................................................................... 22
3.7 PVDC COATINGS: .................................................................................................................. 23
3.8 APPLICATIONS: ..................................................................................................................... 24
3.8.1 FILM COATING:.............................................................................................................. 24
3.8.2 PAPER COATING: ........................................................................................................... 24

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IIP-HYDERABAD POLYVINYLIDENE CHLORIDE

3.8.3 IMPREGNATION IN/COATING ON POLYURETHANE FOAM: .......................................... 24

3.8.4 BINDER FOR PVDC or PVC FIBER: .................................................................................. 24
3.8.5 FLAME RETARDENT BINDERS AND BACK SIZING: ......................................................... 25
3.9 USES: ................................................................................................................................... 25
3.10 Role of PVDC in Pharma: ...................................................................................................... 25
3.11 Disadvantages: ...................................................................................................................... 26
3.12 HEALTH INFORMATION:................................................................................................. 27
3.13 ENVIRONMENTAL INFORMAION: ................................................................................ 28
3.14 IDENTIFICATION TEST FOR PVDC: ........................................................................................ 28
3.15 NEW PVDC DEVELOPMENTS: ............................................................................................... 28
3.16 PVDC Latex for Pharmaceutical Blister Packaging: ............................................................. 29
3.17 IMPROVED PVDC EXTRUSION RESINS: ................................................................................ 29
3.18 Recycling of Multilayer Structures containing PVDC: ......................................................... 29
REFERENCES:......................................................................................................................................... 30

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ABSTRACT

Polyvinylidene chloride is the resin produced by the polymerization of the Vinylidene chloride. Ralph

Wiley accidentally discovered polyvinylidene chloride in 1933.

PVDC is a remarkable barrier against water, oxygen and aromas (smells). PVDC has less water vapor

transmission rate as well as oxygen transmission rate.

PVDC grades are available in 2 types of polymer: (I) the historic grades offering medium to high

barrier properties and (II) a super barrier coating grade offering the highest barrier. The super

barrier coating grade has over two times the barrier to moisture and oxygen per gram coating

weight compared to the historic grades.

PVDC resins and coatings have been a part of the flexible packaging world for more than 50 years,

with a unique combination of functional characteristics that has found numerous applications. It is

available in a variety forms:

 Aqueous dispersions, or latex, for coating on a number of different films and paper

substrates

 Extrudable powders, for monolayer or multilayer films and sheet

 Soluble powders, for solvent-based coatings on films.

This project includes about the polyvinylidene chloride history, properties, coatings process,

advantages of PVDC, disadvantages of PVDC, identification of PVDC, processing of PVDC etc.

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1. INTRODUCTION TO PACKAGING:

1.1 PACKAGING:

Packaging is the combination of arts, science and technology which ensures safe delivery of

the product to the customer in a factory fresh condition at a minimum overall cost.

Packaging is described as a coordinated system of preparing goods for transport,

distribution, storage, retailing and use.

Packaging serves various functions like Containing, Protecting, Preserving, Dispensing, and

Display.

1.2 HISTORY OF PACKAGING:

Packaging as we know today is the result of a long development process. The very first

people to roam the earth, back in depths of prehistory, sought to conserve the surplus food

collected during hunting, fishing and food gathering for the longest possible time, to be

prepared for any future food shortages. In the middle age wooden barrels became the most

frequently used way of preserving goods. They were used for storing all kinds of solids and

liquids, protecting them from light, heat and dampness.

The development of packaging techniques involving the discovering of new packaging

materials and implementation of packaging process has progressed so much and improved

highly. There are lot of changes took place from Ancient era to the Modern era.

 In ancient days itself the people used the naturally available materials for the packing

and transport of the products.

 The ancient people used the natural materials originating from the plant and the animal

origin viz., leaves, fibers, metal containers, clay etc. by converting them into the shapes

suitable for the particular products and for their safety.

 Then people started using woven materials which are flexible and stronger.

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 Later people started making the containers with clay.

 Paper is also an older material which is obtained from Mulberry tree barks were used in

China in the 1st and 2nd centuries.

 Glass and wood are the very important materials which are used approximately around

5000 years.

 In 1500 BC Glass packaging first begun to used in Egypt as a pot, was being mixed with

melted limestone, soda, sand, silicate and shaped into glass packaging.

 Around 1200 AC the production of tin sheet was invented in Bohemia.

 In the beginning o 14th century tinned food can have started to be used.

 In 1817 first commercial cardboard box was produced in England.

 In 1823 Englishman Peter Durand obtained the patent for the first metal packaging

made from sheet metal “Canister”.

 In 1900s Paper and Cardboard have become important packaging materials.

 The General use of Plastics in Packaging applications has started after the World War II.

 Polyethylene was produced in abundance during the war years and became an easily

found materials in the market right after the war.

 Nowadays with today’s available technology and conditions, these previous materials

have been updated and replaced by more suitable and economic materials such as

glass, metal, plastic, paper and cardboard.

 In olden days only the packaging is used for only for transport and storage.

 Recent days by these new materials it has also begun to advertise the product.

 The newest form of packaging is using Plastic.

 In 1920, the invention of transparent cellophane marked the beginning o the era of

plastic. Polyethylene, the first plastic used for packaging, was discovered in 1933.

 Aluminium foil made it possible to effectively seal medications and other sensitive

products.

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1.3 PACKAGING CRITERIA:

Package development is based on and influenced by many entities and could be broadly

classified into five criteria groups:

a) Appearance

b) Protection

c) Function

d) Cost

e) Disposability

These are the main considerations when developing a pack. The relative emphasis placed on

them depends on the product and on its marketing requirements.

1.4 NEED OF PACKAGING:

Packaging plays an essential role in protecting and containing the products we buy until they

reach our homes and consumed. It also provides us with important product information about

nutrition and storage for example.

Some of the products are stored in our homes for the longer time. In this case they may prone

to attack by the various microorganisms or reaction with various environmental conditions

which may lead to the spoilage of the product. So, for protecting the products from these

hazards the products needs to be packed with suitable packaging which saves them from

spoilage.

Since ancient days to present days the import and export of the products occurs in between

different places which involves the transport of products occurs for a longer distances also

exposing the different kinds of environment. For this transports also good packaging of the

product is compulsory.

The packaging plays very crucious role in the packing of the pharmaceutical products. The

special packing techniques are required for packing the pharmaceutical products which

protects them to withstand the various temperatures and light reactions etc.

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In this new generation after becoming the world digitalized and online shopping became more

famous in which the customers are shopping through internet and the manufacturer or seller

has to deliver the product to the customer at his home, It is the responsibility of the seller to

deliver the product in the safe conditions to the customer. In this case also the good packing

of the products with the proper packaging is plays a key role.

Nowadays after growing the super markets, the products are displayed in the racks which do

not have the sales persons who can explain the products to the customers. In this case the

products are packed with those designs which can act as a sales person itself.

1.5 PACKAGE COMPONENTS:

Package serves mainly as a protective device to avoid deterioration in the quality of contents

against external agencies. However, in many instances packages have also to be designed

taking into account marketing considerations such as sales appeal, easy open ability, handling

convenience and distribution factors etc. it will thus be desirable if important package

components are classified and studied to know what their functions and duties are. A broad

classification of package components is given below.

a) Unit pack

b) Intermediate pack

c) Outer or shipping container

d) Inner packaging components

e) Closures

f) External reinforcements

1.6 PACKAGING MATERIALS:

The main purpose of packaging is to hold its contents securely to prevent leakage and

breakage, to protect the foods from different hazards like germs, heat, moisture loss or

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moisture pick up, etc. To protect the contents while distribution, etc. For all types of

packaging, there are different types of packages.

Although paper was made in China as early as 200 BC, commercial production of paper started

only around 1300 AD in the west. Principal packaging materials until about 1200 AD was not

paper, but leather, cloth, wood, grass, earthenware, metal and glass. Paper and paper

products later became the principal packaging media. This is the age o plastics.

The different types of packaging can be classified as following types:

1.6.1 PAPER BOARD:

Paper is widely used because it’s low cost, holds its shape, and is easily decorated.

Commercially-available paper is predominantly made from cellulose fiber from pulped wood,

but can also be made from other sources such as cotton, straw, sisal and hemp. All are

recyclable.

Paper and board are usually measured by weight or caliper. Material weighing less than 250

grams per square meter (gsm) is referred to as paper, and material at about 250 gsm is

referred to as paperboard.

The fibers of machine-made paper run parallel to the length of the machine that produced it.

This machine or grain direction affects performance:

 Paper tears easiest along the fibers

 Folding is easiest along the fibers

 Fold endurance is greatest across the fibers

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IIP-HYDERABAD POLYVINYLIDENE CHLORIDE

 Stiffness is greatest when flexed across the fibers

Paper can also be laminated to increase strength or provide barrier properties. The materials

used can be gloss or matt finished or embossed. Other materials can be laminated onto

paperboard e.g. foil or plastics.

Packaging produced using paper and board includes cartons, labels, leaflets, tubes, corrugated

cases, rigid boxes and pulp packs.

1.6.2 Glass:

Commercially-available glass is made from silica, sodium carbonate and calcium carbonate.

Other compounds can be added to give colour, sparkle or heat shock resistance.

Glass is a popular and useful packaging material because it is:

 Inert

 Sterilisable

 Barrier to moisture and gas

 Pressure resistant to a degree

 Can be moulded into a variety of shapes

 Transparent making the product visible

 Glass is also highly recyclable

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The most obvious drawback is fragility and the danger of broken glass. The transparency of

glass can be a problem where the product is degraded by light. Glass can be directly decorated

but is most commonly labeled.

1.6.3 Metals:

The metals used in packaging are predominantly tin-plate or aluminium and are used to make

food and drink cans, aerosol cans, tubes, drums and slip or hinged lid Drums Drum boxes for

gift sets and selections of confectionery or biscuits. All packs are recyclable.

Tin-plate is tin-plated steel and the most common material used in food cans. Steel can also

be used un-plated or with coatings.

Aluminium is used for drinks cans, closures, trays, tubs and tubes. As foil it can be used in

multi-laminate constructions or as a blister pack or container seal.

Metal can be exploited to produce the following packaging characteristics:

 Strong and rigid

 Barrier to gas and moisture

 Pressure resistant

 Temperature and pressure resistant / tolerant

 Corrosion resistance via coatings

 Sterilisable

 Directly decorated or labeled

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IIP-HYDERABAD POLYVINYLIDENE CHLORIDE

1.6.4 Wood:

Mostly used for pallets and crates (heavy duty products). Some lidded or hinged boxes are

produced e.g. cigars, gifts, tea, cheese. High value spirits use wood and a few caps incorporate

wood.

1.6.5 Bamboo:

Bamboo is emerging as a packaging material. The illustration shows bamboo cushions for

cradling Dell net books and laptops.

2. PLASTICS:

A plastic material is one which is a solid at ordinary temperatures and allows appreciable and

permanent change of form without losing its coherence on the application of pressure and

heat.

This is the most common packaging material and, at the same time, one of the most difficult

to dispose of. The factors common to all plastics are that they are light, strong cheap to

manufacture. It is for these reasons that they are used so much, as an alternative to cardboard

glass packaging materials. Plastics can be used as single materials or in combination.

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Their properties vary considerably but usually include:

 Lightweight

 Easily mouldable into almost limitless shapes

 Can produce rigid containers or flexible films

 Can be impact resistant

 Directly decorated or labeled

 Heat sealable

The relative disadvantages of plastics are typically polymer specific and the correct choice of

polymer can to a practical degree mitigate the weakness. Factors to consider are:

 No plastic provides absolute gas and moisture barrier

 Plastics melt at temperatures ranging from 650°C to 2,300°C

 Chemical resistance varies

 Additives in plastics can contaminate some products.

2.1 SYNTHESIS OF PLASTICS:

Plastics are generally made either by polymerization or poly condensation-the chemical union

of large numbers of small molecules, to form a macromolecule. With the possible exception of

cellophane, which is one form of regenerated cellulose, no naturally occurring polymer is a

commercially significant plastic as originally isolated. However, derive or chemically modifies,

natural polymers are important.

2.2 COMMON PLASTIC POLYMERS USED IN PACKAGING:

 Polyethylene

 Polypropylene

 Polystyrene

 Polyvinyl chloride

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 Polyvinylidene chloride(PVDC)

 Polyethylene terepthalate(PET) etc.,

2.2.1 Polyethylene (PE):

Low Density (LDPE): used for flexible tubes, film and some bottles. It has a low melting point

and as a film relatively poor oxygen and moisture barrier.

High Density (HDPE): widely used for bottles and tubs. Higher melting point but not ovenable.

Reasonably wide chemical resistance which can be enhanced by fluorination. Not a sufficient

gas barrier for carbonated drinks.

Linear Low Density (LLDPE) is Predominantly used as a film or as a sealing layer on multi-

laminate materials for bottle seals, sachets, pouches, bags. Available in expanded form for

wads.

2.2.2 Polypropylene (PP):

Widely used for closures for its ability to form a hinge which resists cracking and splitting. Also

used for dispensers, actuators, bottles, jars, cartons, trays and as film on its own or within

laminations e.g. crisp bags or pouches. Available in expanded form for tubs and trays.

Typically has higher melting point than PE so although still not “ovenable” it is better suited to

hot fill products. Resistant to a relatively wide range of chemicals.

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2.2.3 Polyethylene terephthalate (PET):

Widely used for stretch blown bottles containing drinks, toiletries and food, it has excellent

clarity. Also used for jars, tubes and trays. By far the best gas and moisture barrier of any

packaging plastic used for containers it is ideal for carbonated beverages. Its heat resistance

makes it suitable for ovenable trays for ready meals.

2.2.4 Polyvinyl chloride (PVC):

Not widely used even though only has a third of its content is derived from oil. It still has a

strong presence in vacuum formings used for inserts, clam packs and blister packs, due to its

good production line performance. PVC films have excellent stretch and cling properties for

hand wrapping fresh produce.

2.2.5 Polystyrene (PS)

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Mainly seen in its expanded form as protective moldings for fragile products. Also available as

molded toiletries/cosmetics containers (compacts), some bottles, jars and cups. It has good

chemical resistance and excellent clarity although it can be colored.

2.2.6 Laminates and Co-extrusions:

Laminates and co-extrusions are designed to benefit from the properties of two or more

materials. Technically laminates are two materials bonded together and co-extrusions are

multiple polymers extruded together from molten to form a single piece material.

The following laminates are used widely from sachets through to form-fill-seal cartons such as

2.2.7 Tetrapaks:

 Paper (or board) / Polythene (PE)

Typically the paper or board gives rigidity and an easily decorated surface while the polythene

gives heat-seal ability and liquid containment. (But not a barrier in the true sense because

water vapour can pass through PE.)

 Paper or PET / Aluminium foil / Polythene

Again the polythene provides heat-sealability while the aluminium foil provides barrier

properties, with the paper or PET on the outer surface allowing for decoration. PET in

particular gives a high gloss finish.

 PET/PE-EVOH (ethyl vinyl alcohol)-PE

As above but for a clear high barrier laminate EVOH is used in place of foil.

2.2.8 POLYVINYLIDENE CHLORIDE:

While normally only used in multi-layer films, PVDC has exceptional moisture and gas barrier

properties. Many pharmaceutical products could not be packed in blister strips without using

PVDC as a layer in the blister film.

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3. POLYVINYLIDENE CHLORIDE:

3.1 INTRODUCTION:

Polyvinylidene chloride (PVDC) is a synthetic resin produced by the polymerization of

Vinylidene chloride. It is a homopolymer of vinylidene chloride.

Vinylidene chloride (CH2=CCl2), a clear, colorless, toxic liquid, is obtained from tri chloro

ethane (CH2=CHCl3) through the de hydro chlorination (removal of Hydrogen chloride) of that

compound by alkali treatment.

PVDC grades are available in 2 types of polymer: (I) the historic grades offering medium to

high barrier properties and (II) a super barrier coating grade offering the highest barrier.

The super barrier coating grade has over two times the barrier to moisture and oxygen per

gram coating weight compared to the historic grades.

PVDC resins and coatings have been a part of the flexible packaging world for more than 50

years, with a unique combination of functional characteristics that has found numerous

applications. It is available in a variety forms:

 Aqueous dispersions, or latex, for coating on a number of different films and paper

substrates,

 Extrudable powders, for monolayer or multilayer films and sheet, and

 Soluble powders, for solvent-based coatings on films.

3.2 HISTORY OF PVDC:

Ralph Wiley accidentally discovered polyvinylidene chloride in 1933. He, then, was a college

student who worked part-time at Dow Chemical lab as a dishwasher. While cleaning

laboratory glassware, he came across a vial he could not scrub clean. Dow researchers made

this material into a greasy, dark green film, first called "Eonite" and then "Saran”.

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Ralph Wiley went on to become one of Dow Chemical's research scientists and invent and

develop many plastics, chemicals and production machines.

The military sprayed Saran on fighter planes to guard against salty sea spray, and carmakers

used it for upholstery. Dow later devised a formulation of polyvinylidene chloride free of

unpleasant odour and green colour and named the product Saran.

The most well known use of polyvinylidene chloride came in 1953, when Saran Wrap, a plastic

food wrap, was introduced.

In 1942, fused layers of original-specification PVDC were used to make woven mesh

ventilating insoles for newly developed jungle or tropical combat boots made of rubber and

canvas.

These insoles were tested by experimental Army units in jungle exercises in Panama,

Venezuela, and other countries, where they were found to increase the flow of dry outside air

to the insole and base of the foot, reducing blisters and tropical ulcers.

The PVDC ventilating mesh insole was later adopted by the United States Army for standard

issue in its M-1945 and M-1966 Jungle Boots.

In 1943, John Reilly (Ralph Wiley's boss) and Ralph Wiley of The Dow Chemical Co. completed

the final work needed for introduction of PVDC, which had been invented in 1939. PVDC

monofilaments were also extruded for the first time. The word "Saran" was coined by a

combination of John Reilly's cat's and dog's names, Sarah and Ann Reilly.

In 1949, Dow introduced Saran Wrap, a thin, clingy plastic wrap that was sold in rolls and used

primarily for wrapping food.

It quickly became popular for preserving food items stored in the refrigerator. Saran

Wrap was later acquired by S. C. Johnson & Son. However, today's Saran Wrap is no longer

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composed of PVDC, due to cost, processing difficulties and environmental concerns with

halogenated materials, and is now made from ordinary polyethylene.

However, polyethylene has a higher oxygen permeability, which in turn affects food spoilage

prevention.

After the end of the Vietnam War, the U.S. military phased out PVDC insoles in favor of Poron,

a microcellular urethane, for its jungle and combat boots. However, the British Army

continues to use PVDC insoles in its combat boots, primarily because of its insulating

properties.

3.3 PHYSICAL PROPERTIES OF PVDC:

 Density - 1.63 g.cm-3

 Flammability - self extinguishing

 Limiting oxygen index - 60%

 Resistance to ultra-violet - fair

 Water absorption-over 24 hours - 0.1%

3.4 PVDC description:

 The resins are white colored

 Odorless granules

 Soluble in polar solvents

 Insoluble in non polar solvents

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3.5 PROPERTIES:

o It is a remarkable barrier against water, oxygen and aromas(smells)

o It has a superior chemical resistance to alkalis and acids.

o Protection against oxidation of ingredients

o Prevention of oil and grease permeation

o Good seal integrity, using heat seals, high-frequency seals or ultrasonic seals

o Good anti fog properties

o Excellent printing characteristics

o Good scratch and abrasion resistance

o PVDC film provides hermetic seals

o PVDC film is transparent and glossy

o It is insoluble in oil and organic solvents

o it is soluble in polar solvents.

o It has a very low moisture regain

o It is impervious to mold, bacteria, and insects

o Cost effective high barrier film

o 2 layer films and 3 layer films

o Superior dimensional stability

o It has good thermal stability, but above 125 °C decomposes to produce HCl

o The outstanding property of PVDC is its low permeability to water vapour and gases-making

it ideal for food packaging

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3.6 PROCESSING OF PVDC:

For processing into PVDC, the liquid is suspended in water as fine droplets or treated with

soap like surfactants and dispersed in water as an emulsion of small particles. Under the

action of free-radicals initiators, the vinylidene-chloride monomers (small, single-unit

molecules) are linked together to form large, multiple-unit polymers. The polymer is

obtained from the water phase as dry powder or beads, which can be melted for extrusion

into plastic film.

PVDC resins are produced by reacting vinylidene chloride monomer with co monomers

such as vinyl chloride alkyl acrylates in closed systems under controlled conditions as shown

in the process schematic below. An initiator is added to start the polymerization reaction.

The location of co monomer units along the polymer chain depend on the quantity and

reaction of the co monomer that is polymerized with vinylidene chloride.

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3.7 PVDC COATINGS:

o PVDC can be coated onto a PVC film to obtain very high moisture and oxygen barrier

properties depending on the coating weight. PVDC coated blister films are the most

common and prevailing barrier films used for pharmaceutical blister packs.

o Since the PVDC is applied by a coating process, the coating weight is expressed in grams per

square meter (gsm).

o PVDC is used as coating for various polymers like LDPE, HDPE, OPP, R-PVC, PA 6-6, PET, PAN

EVOH, CELLOPHANE, PVOH (PVAL) for controlling permeability of oxygen and water vapor.

o PVDC blister films are available in 2 or 3 layer specifications referred to as duplex or triplex.

o Duplex structures are typically PVC/PVDC films, ranging from 250µPVC/40gsmPVDC to

250µPVC/120gsmPVDC with WVTR from 0,65 to 0,25 g/m2/d and OTR from 1 to 0,1

cc/m2/d.

o The triplex specifications are used PVC/PE/PVDC, where the PE layer assists when forming

deeper cavities. Triplex specifications exists in similar coating weights as duplex

specifications: 250µPVC/25µPE/40gsmPVDC up to 250µPVC/25µPE/120gsmPVDC.

o The PE (polyethylene) forms a soft intermediate layer between the rigid PVC and PVDC

layers.

o In order to obtain high barrier properties, PVDC is always applied using an emulsion coating

process using a PVDC resin dispersed in water. The film producer applies the coating in

several steps, drying-off the water between each coating station.

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3.8 APPLICATIONS:

The applications of PVDC are predominantly packaging and barrier films, often as the barrier

layer in multi-layer structures.

3.8.1 FILM COATING:

Gas barrier and moisture barrier properties of OPP, PET, PVC, and nylon films can be greatly

improved by coating with PVDC latex. The shelf life of foods and pharmaceuticals can be

extended significantly by packaging wit PVDC-coated fill.

PVDC latex coating is commonly used in pharmaceutical blister packs. Oil resistance, chemical

resistance, and heat seal ability can also be added to films by coating with PVDC latex.

3.8.2 PAPER COATING:

Gas barrier, moisture barrier water resistance, oil resistance, and heat seal ability can be

added to kraft paper, fine paper, and glassine paper by coating with PVDC latex.

PVDC latex coating can also give a smooth, glossy surface.

3.8.3 IMPREGNATION IN/COATING ON POLYURETHANE FOAM:

Microwave seal ability can be added to polyurethane foam by impregnating or coating with

PVDC latex. This is used in automotive interiors, footwear, seat cushioning, and many other

applications.

3.8.4 BINDER FOR PVDC or PVC FIBER:

Fibers of PVDC and pvc are often used in water filters, air filters, and household brushes

where resistance to water, oil, and chemicals is required. PVDC latex is the ideal binder for

these fibers.

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3.8.5 FLAME RETARDENT BINDERS AND BACK SIZING:

Self-extinguishing properties can be added to fabric, nonwoven, paper, and leather, by

impregnating or coating with PVDC latex. Greater flame-retardant effect can be obtained by

using PVDC latex in combination with other flame retardants.

3.9 USES:

Packaging: Polyvinylidene chloride is applied as a water-based coating to other plastic films

such as biaxially-oriented polypropylene (BOPP) and polyethylene terephthalate (PET). This

coating increases the barrier properties of the film, reducing the permeability of the film

to oxygen and flavours and thus extending the shelf life of the food inside the package. It can

also impart a high-gloss finish, which may be aesthetically pleasing and also provides a high

degree of scuff resistance to if applied over print.

Household: Cleaning cloths, filters, screens, tape, shower curtains, garden furniture.

Industry: Screens, artificial turf, waste-water treatment materials, underground materials.

Miscellaneous: Doll hair, stuffed animals, fabrics, fishnet, pyrotechnics, shoe insoles.

 Food packaging and wrap

 Pharmaceuticals packaging

 Unit packaging for hygiene and cosmetic products

 Sterilized medical packaging

 Other non-packaging applications

3.10 Role of PVDC in Pharma:

PVDC plays a critical role in blister packaging as laminations or coatings on PVC. PVDC can

reduce the gas and moisture permeability of PVC blister packages by a factor of 5–10. Coated

PVC films have a thickness of 8–10 mil; the thickness of the PVDC coat amounts to 1–2 mil.

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The coating is applied on one side and usually faces the product and the lidding material.

PVDC provide excellent barrier to both oxygen and water vapor while most other barrier

polymer offer just one or the other. The gas barrier properties are unaffected by relative

humidity, do the performance can be relied on through a wide range of packaging and

environmental conditions. All PVDC products on the market are actually copolymers of

vinylidene chloride (VDC) and other co-monomers. The relative amount of VDC in the

copolymer dictates some key properties. With more VDC, the barrier properties are generally

better, with less VDC, flexibility usually improves. However, the amount and type of co-

monomer as well as other additives and processing technology used, will influence other

properties such as sealing, surface properties, transparency, gloss coefficient or friction, etc.

PVDC coatings have been used with duplex (PVDC/PVC) and triplex (PVDC/PE/PVC) structure

being the most common ones used. Approximately, 67% of the barrier blister packaging

market uses these PVDC-coated films. Typical coating weights used include 40, 60, 90 and

120g/m2, with the WVTR for a typical 120 g/m2 PVDC-coated PVC film being around 0.16

g/m2 at 40oC and 75% RH.

3.11 Disadvantages:
While extremely useful as a food packaging agent, the major disadvantage of polyvinylidene

chloride is that it will undergo thermally induced de hydro chlorination at temperatures very

near to processing temperatures. This degradation easily propagates, leaving polyene

sequences long enough to absorb visible light, and change the color of the material from

colorless to an undesirable transparent brown (unacceptable for one of polyvinylidene

chloride chief applications: food packaging). Therefore, there is a significant amount of

product loss in the manufacturing process, which increases production and consumer costs.

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3.12 HEALTH INFORMATION:

Health information for PVDC resins is summarized on the relevant safety data sheets. It is

important to note that health risks associated with individual products may vary based on

their formulations or intended use. These materials may also contain minor components or

additives that have additional health risks. An overview of health information for PVDC resins

appears below but it must be noted that the relevant product safety data sheet is the

preferred source for specific health information.

EYE CONTACT:

Contact with solids or dusts may cause irritation or corneal injury due to mechanical action.

Thermal degradation of the resin may generate hydrogen chloride gas at concentrations that

may cause eye irritation.

SKIN CONTACT:

Brief contact is essentially nonirritating. Prolonged contact may cause slight irritation with

local redness. Contact with heated resin during processing can cause thermal burns.

INHALATION:

Dust may cause irritation to upper respiratory tract (nose and throat). Thermal degradation of

the resin may generate hydrogen chloride gas at concentrations that may cause respiratory

irritation.

INGESTION:

Material has very low toxicity if swallowed. Harmful effects are not anticipated from

swallowing small amounts.

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REPEATED EXPOSURE:

Repeated exposures to dusts are not anticipated to result in systemic toxicity or permanent

lung injury, however, excessive exposures may cause less severe respiratory effects.

3.13 ENVIRONMENTAL INFORMAION:

PVDC resins are inert polymers that are not soluble in water. The products will sink into

sedimentor float depending on product density. No appreciable bio degeradation is expected,

but surface photo degradation with exposure to sunlight and degradation due to mechanical

action would be expected.

PVDC resins are not expected to accumulate in the food chain due to their relatively high

molecular weight (bio concentration potential is low). They are practically nontoxic to fish and

aquatic organisms on an acute basis.

3.14 IDENTIFICATION TEST FOR PVDC:

This test can be made in a well-equipped lab or sourced through ink suppliers.

This test requires use a solution of potassium hydroxide, tetra hydrafuran and di methyl

sulfoxide.

When the above solution is applied to a PVDC coating, the film turns black in 30-60 seconds.

3.15 NEW PVDC DEVELOPMENTS:

Even though PVDC has been around for so many years, new grades of PVDC latex and resins

have been introduced in recent years that offer improved barrier vs. standard grades that

have been used traditionally. Reduction in both oxygen and water transmission rates are

allowing flexible packaging converters the ability to offer higher barrier, lighter-weight, and/or

less packaging solutions.

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3.16 PVDC Latex for Pharmaceutical Blister Packaging:

A new grade of PVDC latex was introduced this year for use in pharmaceutical blister

packaging. The target of this development was a PVDC latex that would provide twice the

water vapor barrier of the standard grades used for pharmaceutical blister packaging, while

maintaining the machining properties necessary for the end use.

3.17 IMPROVED PVDC EXTRUSION RESINS:

New IXAN PVDC resins for coextruded films have also been developed that offer significant

improvements over standard PVDC resins used in packaging for many years. These resins are

made using proprietary new polymerization and formulations technologies, cutting oxygen

transmission rates by more than half.

3.18 Recycling of Multilayer Structures containing PVDC:

Finally, a new technology has been developed and demonstrated that can allow the recycling

of film structures containing PVDC and other polymers. The process involves selective

dissolution of the materials involved, followed by separation and cleaning, allowing the PVDC

and other polymers to be separated into relatively pure recycle streams. The technology has

been shown to be feasible for several different mixed polymer structures, including

 PVC/PVDC

 PVC/PE/PVDC

 PE/EVA/PVDC/EVA/PE

 PET/PVDC

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This recycling technology overcomes an historical belief that materials that have been

combined with PVDC cannot be recycled. Since the process is based on the relative solubilities

of the materials used, it must be designed specifically for each application.

REFERENCES:

1. Packaging technologies, Educational volume-1

2. Wikipedia

3. Article by Kirck paisley

4. Product safety assessment by DOW CHEMICALS

5. Images from google

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