Flexible packaging material, recyclable and compostable package, and method of formation of same

Abstract

A flexible packaging material is disclosed for use in storing items, such as coated ice cream products, within a freezer. The flexible packaging material includes a first layer and a second layer positioned directly adjacent the first layer. The first layer has an exterior surface and an interior surface. The first layer is a paper substrate having a grammage in a range of about 30 gsm to 120 gsm. The second layer is a coating layer including a compostable resin having a thickness comprising a grammage in a range of about 5 gsm to about 30 gsm. The flexible packaging material has a permeability of about between 10 to 1500 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% relative humidity. The flexible packaging material includes 80% by weight of the paper substrate and is both recyclable and compostable.

Description

[0001] FLEXIBLE PACKAGING MATERIAL, RECYCLABLE AND COMPOSTABLE PACKAGE, AND METHOD OF FORMATION OF SAME

[0002] CROSS-REFERENCE TO RELATED APPLICATION

[0003]

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 571,166, filed March 28, 2024 which is incorporated herein by reference.

[0004] TECHNICAL FIELD

[0005]

[0002] The present application relates generally to a flexible packaging material, a recyclable and compostable package, and a method for the formation of the same. More particularly, the present application relates to a flexible packaging material with particular use for packages containing coated ice cream-based items stored within freezing conditions.

[0006] BACKGROUND

[0007]

[0003] Shelf life of ice cream products is usually one to three months when kept in freezing conditions in a freezer. The freezing conditions slow the growth of bacteria and maintain a structure of the ice cream products. Many ice cream products have a chocolate coating. Such chocolate coatings are generally thin layers containing high fat content to meet a short crystallization time, and provide benefits during manufacturing, structuration, and to ensure that the ice cream products do not lose too much water. The chocolate coating also provides an enhanced pleasurable and varied experience for consumers, both in terms of mouth feel and flavor. An ice cream product whose chocolate coating cracks too easily while being eaten, is already cracked before the wrapper is removed, or even worse, soft and chewie, might be considered to have a serious effect on consumer judgement of a particular brand’s quality. Further, after a period of time, ice crystals can appear on the chocolate coating indicating the chocolate covered ice cream product has approached an expiration date.

[0008]

[0004] During manufacturing, moisture of the chocolate coating is almost fully removed.

[0009]

[0005] During and after filling, the chocolate coating is exposed to an ice cream having a high-water content. Therefore, moisture from the ice cream may migrate to the chocolate coating. According to literature, for chocolate or cocoa containing products, it is recommended to have a water activity level below 0.9, and preferably below 0.6, to avoid microorganism growth.

[0010]

[0006] Therefore, in order to maintain these water activity levels, current ice cream packaging materials have a high moisture resistance (i.e., a low Water Vapor Transmission Rate (WVTR)) to prevent moisture from transferring to the chocolate coating.

[0011]

[0007] Currently, oriented polypropylene (OPP) packaging is used for packaging the ice cream products (e.g., the ice cream products having the chocolate coating). This is because the OPP packaging has a WVTR around 6- 10 g / m2 / day at 38 degrees Celsius (°C), 90% relative humidity (rH) and typically provides an estimated shelf life of one to four months in the freezing conditions.

[0012] SUMMARY

[0013]

[0008] A flexible packaging material has been developed to generally provide an improved structure specifically selected for the storage of ice cream items within freezing conditions. The flexible packaging material includes a first layer and a second layer. The first layer may be a paper substrate functioning as a buffer / moisture absorbing layer. The second layer may be a coating layer of a compostable resin positioned directly adjacent the first layer. The flexible packaging material includes 80% by weight of the paper substrate and is both recyclable and compostable. Further, the flexible packaging material is used for enclosing coated ice cream-based items stored in freezer conditions to retain the shelf life and audible characteristics of the coated component of the items after storage.

[0014]

[0009] One embodiment of the present disclosure is a flexible packaging material. The flexible packaging material includes a first layer having a first side defining an exterior surface and a second side defining an interior surface. The first layer is a paper substrate having a grammage in a range of about 30 grams per square meter (gsm) to 120 gsm. The flexible packaging material further includes a second layer positioned directly adjacent the first layer. The second layer is a coating layer including a compostable resin having a grammage in a range of about 5 gsm to 30 gsm resulting in a thickness of the second layer. The flexible packaging material has a permeability of about between 10 to 1500 g / m2 / day when a moisture vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38 degrees Celsius (°C), and 90% relative humidity (rH). Further, the flexible packaging material includes 80% by weight of the paper substrate and is both recyclable and compostable. Furthermore, the flexible packaging material is used for enclosing coated ice cream-based items stored in freezer conditions to retain the shelf life and audible characteristics of the coated component of the items after storage.

[0015]

[0010] The flexible packaging material may help to maintain or enhance the shelf life and cracking of the coated component of the coated ice cream-based items, stored in cool and humid conditions. The flexible packaging material having the high permeability may function as a buffer / absorbing moisture layer between the coated component and an external freezer environment. By absorbing excess water, the flexible packaging material may also regulate water activity of the coated component, thereby maintaining its texture and quality. As a result, the flexible packaging material may improve the shelf life in comparison to a standard oriented polypropylene (OPP) packaging.

[0016]

[0011] In some embodiments, the paper substrate is selected from the group of refined paper, recyclable paper, uncoated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper.

[0017]

[0012] In some embodiments, the paper substrate exterior surface includes a print layer.

[0018]

[0013] In some embodiments, the paper substrate exterior surface includes a lacquer.

[0019]

[0014] In some embodiments, the paper substrate exterior surface includes a print layer and a lacquer, which may commonly be referred to as an over lacquer. In some embodiments, the print layer is positioned between the lacquer and the paper substrate.

[0020]

[0015] In some embodiments, the compostable resin includes at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4-hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), or poly(vinyl alcohol) (PVOH), and combinations thereof.

[0016] In some embodiments, the permeability is of about between 100 to about

[0021] 1500 g / m2 / day, preferably of about 400 to about 800 g / m2 / day when a WVTR is measured according to ASTM F1249 at 38°C and 90% rH.

[0022]

[0017] In some embodiments, the grammage of the paper substrate is in a range of about 40 gsm to about 90 gsm.

[0023]

[0018] In some embodiments, the coated component is chocolate that surrounds an ice cream, such as a chocolate coated ice cream bar.

[0024]

[0019] Another embodiment of the present disclosure is a recyclable and compostable package with a predetermined permeability for containing chocolate covered ice cream-based items within freezer storage conditions. The package includes a paper substrate having a first side defining a first surface and a second side defining a second surface opposed to the first surface. The first surface is an exterior surface of the package. The second surface is in alignment with an interior of the package. A distance between the first side and the second side defines a thickness of the paper substrate. The thickness of the paper substrate includes a grammage selected to be within a range of about 30 gsm to 120 gsm. Further, the paper substrate is selected from the group comprising refined paper, recyclable paper, uncoated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper. The package further includes a compostable resin. The compostable resin is an extrusion coating applied directly adjacent the second surface of the paper substrate. The compostable resin has a grammage in a range of about 5 gsm to 30 gsm resulting in a layer that has a thickness. The compostable resin includes at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4-hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), or poly(vinyl alcohol) (PVOH), and combinations thereof. The predetermined permeability of the package is of about between 10 to about 1500 g / m2 / day when a WVTR is measured according to ASTM F1249 at 38 °C and 90 % rH. The combination of materials including the package has at least 80% by total package weight of the paper substrate. The package retains the shelf life and measured audible characteristics of a chocolate component of the chocolate covered ice creambased items after removal from storage.

[0025]

[0020] The package may enhance the shelf life and cracking of the chocolate component of the chocolate covered ice cream-based items, stored in cool and humid conditions. The package having the high predetermined permeability may function as a buffer / absorbing moisture layer between the chocolate component and an external freezer environment. By absorbing the excess of water, the package may also regulate water activity of the chocolate component, thereby maintaining its texture and quality. As a result, the package may improve the shelf life in comparison to a standard oriented polypropylene (OPP) packaging.

[0026]

[0021] In some embodiments, the first surface of the paper substrate includes a print layer.

[0027]

[0022] In some embodiments, the first surface of the paper substrate includes a lacquer.

[0028]

[0023] In some embodiments, the first surface of the paper substrate includes a print layer and a lacquer. The print layer is positioned between the first surface and the lacquer.

[0029]

[0024] In some embodiments, the predetermined permeability is of about between 100 to about 1500 g / m2 / day, preferably about 400 to about 800 g / m2 / day when a WVTR is measured according to ASTM F1249 at 38°C and 90% rH.

[0030]

[0025] In some embodiments, the grammage of the paper substrate is in a range of about 40 gsm to about 90 gsm.

[0031]

[0026] Another embodiment of the present disclosure is a method for the formation of a recyclable and compostable package configured to contain chocolate coated ice cream-based articles within a freezer environment. The package is specifically selected with a predetermined permeability to retain the shelf life and audible properties of the chocolate coated ice cream-based article when consumed and after removal from the freezer environment. The method includes providing a paper substrate. The paper substrate has a grammage between of about 30 gsm to about 120 gsm and has an exterior surface and an interior surface. The method further includes coating via extrusion a compostable resin onto the interior surface at a grammage in a range of about 5 gsm to about 30 gsm resulting in a layer that has a measurable thickness.

[0032]

[0027] The method further includes optionally applying a print layer directly adjacent the exterior surface of the paper substrate. The method further includes optionally applying a lacquer directly adjacent to the exterior surface of the paper substrate or directly adjacent the optional print layer, if present. The method includes forming the coated paper substrate with optional print layer and optional lacquer into the package by sealing the coated paper substrate to itself to form an interior space and define an exterior of the package. The exterior surface is aligned with the exterior of the package. The interior surface is aligned with the interior space. The interior space is sized for receiving the chocolate coated ice cream-based article within. The method includes placing the chocolate coated ice cream-based article into the package and sealing the package.

[0033]

[0028] The method further includes storing the enclosed package containing the chocolate coated ice cream-based article in a freezer until desired for use. The package has a permeability of about between 10 to about 1500 g / m2 / day when a WVTR is measured according to ASTM F1249 at 38°C and 90% rH. The package includes 80% by weight of the paper substrate.

[0034]

[0029] In some embodiments, the compostable resin includes at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4-hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), or poly(vinyl alcohol) (PVOH), and combinations thereof.

[0035]

[0030] In some embodiments, the permeability is of about 100 to about 1500 g / m2 / day, preferably between about 400 to about 800 g / m2 / day when a WVTR is measured according to ASTM F1249 at 38°C and 90% rH.

[0036]

[0031] In some embodiments, the grammage of the paper substrate is in a range of about 40 gsm to 90 gsm.

[0037]

[0032] In some embodiments, the paper substrate is selected from the group comprising refined paper, recyclable paper, uncoated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper.

[0033] There are several aspects of the present subject matter which may be embodied separately or together. These aspects may be employed alone or in combination with other aspects of the subject matter described herein, and the description of these aspects together is not intended to preclude the use of these aspects separately or the claiming of such aspects separately or in different combinations.

[0038] BRIEF DESCRIPTION OF THE DRAWINGS

[0039]

[0034] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying drawings, in which:

[0040]

[0035] FIG. 1 is a schematic cross-sectional view of a flexible packaging material in accordance with an embodiment of the present disclosure;

[0041]

[0036] FIG. 2 is a schematic view of a recyclable and compostable package in accordance with an embodiment of the present disclosure;

[0042]

[0037] FIG. 3 is a flowchart depicting steps of a method for formation of the recyclable and compostable package in accordance with an embodiment of the present disclosure;

[0043]

[0038] FIG. 4 is an exemplary graph depicting an appearance over life analysis of various samples;

[0044]

[0039] FIG. 5 is an exemplary graph depicting organoleptic attributes of the samples;

[0045]

[0040] FIG. 6 is an exemplary graph depicting a force needed to crack a chocolate coating over a shelf life of the samples;

[0046]

[0041] FIG. 7 is an exemplary graph depicting a texture analysis of the samples; and

[0047]

[0042] FIG. 8 is an exemplary graph depicting a water activity in the samples.

[0048]

[0043] The figures are not necessarily to scale. Like numbers used in the figures refer to like components. It will be understood, however, that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0049] DETAILED DESCRIPTION

[0044] Before the present disclosure is further described, it is to be understood that the disclosure is not limited to the particular embodiments set forth herein, and it is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be. limiting.

[0050]

[0045] Various changes may be made to the invention described and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s), to the objective(s), spirit or scope of the present invention. All such modifications are intended to be within the scope of the disclosure made herein.

[0051]

[0046] Unless otherwise indicated, the words and phrases presented in this document have their ordinary meanings to one of skill in the art. Such ordinary meanings can be obtained by reference to their use in the art and by reference to general and scientific dictionaries.

[0052]

[0047] Definitions:

[0053]

[0048] The following terms are used throughout as defined below.

[0054]

[0049] As used herein and in the appended claims, singular articles such as “a” and “an" and “the” and similar referents in the context of describing the elements (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

[0055]

[0050] As used herein, “about” will be understood by persons of ordinary skill in the art and will vary to some extent depending upon the context in which it is used. If there are uses of the term which are not clear to persons of ordinary skill in the art, given the context in which it is used, “about” will mean up to plus or minus 10% of the particular term - for example, “about 10 wt.%" would be understood to mean “9 wt.% to 11 wt.%.” It is to be understood that when “about” precedes a term, the term is to be construed as disclosing “about" the term as well as the term without modification by “about” - for example, "about 10 wt.%" discloses “9 wt.% to 11 wt.%" as well as disclosing “10 wt.%."

[0056]

[0051] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. As will also be understood by one skilled in the art all language such as “up to," “at least," “greater than," “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above.

[0057]

[0052] The phrase “and / or" as used in the present disclosure will be understood to mean any one of the recited members individually or a combination of any two or more thereof - for example, “A, B, and / or C” would mean “A, B, C, A and B, Aand C, B and C, or the combination of A, B, and C.”

[0058]

[0053] As used herein, the term “adjacent” means that the items, such as layers of a film, are near each other, with or without intervening material, such as adhesive. As used herein, the term “directly adjacent" or “in direct contact with” means that the items are in contact with each other, without intervening material.

[0059]

[0054] As used herein the term “paper" and / or “paper component" and / or “paper substrate” may be any type of paper that can be processed in a paper recycling (repulpability) process. As used herein, the term “paper” and / or "paper component" and / or “paper substrate” may be described with respect to an amount of cellulose fibers in the paper. For example, the paper substrate comprises or may consist essentially of cellulose fibers. As used in this context, "consisting essentially of means that the total composition of the paper substrate includes greater than or equal to 95%, greater than or equal to 98%, greater than or equal to 99%, greater than or equal to 99.9% or 100% cellulose fibers. In some cases, the paper substrate may contain up to 20% mineral filler by weight and correspondingly an amount greater than or equal to 80% cellulose fibers.

[0060]

[0055] As used herein, the terms “fiberfs)” and / or “fiber-based” may include, but not be limited to, cellulose and / or cellulose-based fibers including virgin cellulose-based fibers, recycled fibers including materials like paper fibers and craft papers, textiles, non-wovens, wood-based fibers, cotton, linen, hemp, sugar cane or sorghum commonly known as bagasse fibers, or grains. These fibers may be untreated and / or treated to provide enhancements or improvements to their inherent properties.

[0061]

[0056] As used herein, the term “compostable” refers to materials such as polymers, layers, films or packages that are able to disintegrate and biodegrade at industrial and / or home composting conditions (12 weeks at 58°C or 26 weeks at 21 °C, respectively) and fulfill industrial compostable standards such as EN 13432-2000, ASTM D6400 “Standard Specification for Labeling of Plastics Designed to be Aerobically Composted in Municipal or Industrial Facilities" or ASTM D6868 “Standard Specification for Labeling of End Items that Incorporate Plastics and Polymers as Coatings or Additives with Paper and Other Substrates Designed to be Aerobically Composted in Municipal or Industrial Facilities,” and home compostable standards such as AS-5810-2010 NF T51800, among others.

[0062]

[0057] The term “recyclability” or “repulpability" or “repulpable” of the coated paper or fiber based packaging generally relates to the individual suitability of a fiber based package formed from the coated paper for its factual reprocessing in the post-use phase into new paper and board; factual means that separate collection (where relevant and followed by sorting) into grades according to EN 643 “European list of standard grades of paper and board for recycling” and final recycling takes place on an industrial scale. Standard paper recycling mills typically have equipment and processes to produce high quality end-products based on EN643 groups 1 to 4 with a classic low consistency pulper (5% fiber concentration). Often such processes operate deflakers to separate fiber bundles into individual fibers, as well as coarse and fine screening cleaners. The aim is to separate the fiber from the other material. The final result is fibrous material suspended in water ready for papermaking (= recycled pulp). Specialized recycling mills can treat a mix of special grades (group 5 of EN 643) and grades from other groups (1-4 from EN 643). The recovered paper stock preparation process for the packaging stream (Cat. 2) typically does not include a deinking step for the removal of printing inks. As opposed to a standard recycling mill, a specialized recycling mill determines the optimal mix and adds one or more piece of dedicated equipment, such as a horizontal high-density drum pulper, a separate batch pulper with longer pulping time, deinking, fine cleaners, hot dispersion, special process, and wastewater systems. As in standard mills, the final result of the process is also fibrous material suspended in water ready for papermaking.

[0063]

[0058] As used herein, the terms “standard paper recycling process” are intended to refer to a waste-paper recycling process that may include one and typically more or all common steps selected from repulping, screening, flotation, roughing, concentration, defibrinating, deinking, washing, purification, and bleaching, as is known in the art.

[0064]

[0059] The coated paper described herein as well as packages, including fiberbased packages, prepared therefrom are suitable for recycling in a standard recycling paper process (i.e., they can be processed in a standard paper mill). For the purposes of the present invention recyclability (i.e., the suitability of a paper-based packaging film or package obtained therefrom to be processed in a standard paper recycling process) can be established using standard laboratory testing simulating the industrial standard waste paper process on a laboratory scale, based on characteristics including repulpability and sheet formation. The testing procedure comprises a disintegrating step (pulping step) which is typically performed using a standard disintegrator (according to ISO 5263-1 ). Testing procedures may comprise one or more of the following phases: disintegration, filtrate analysis; determination of the coarse reject (for example 5 mm hole residue), determination of the consistency after the coarse screening (AC); sheet adhesion test and visual appearance test of the accept of the coarse screening; determination of the fine reject (for example, 150 μm slot residue); sheet adhesion test and visual appearance test of the accept of the fine screening, determination of the content of adhesive particles (macro stickles); The testing procedure may optionally include a sheet forming step (total stock), which may include sheet adhesion testing and a visual appearance test, both typically optional. Specific testing may include one or more of the following: measurement of coarse rejects, measuring the flake content (fine reject, according to TAPPI T275 sp18), calculation of the content of soluble and colloidal solids below 10 microns (measured according to ISO 4119), measurement of the area of adhesive particle (macro stickles, according to ISO 15360-2, optionally), indication of the ash content (measured according to ISO 1762, optionally). Standard testing protocols suitable to establish recyclability of a coated paper or fiber-based packaging film or package made therefrom in a standard paper recycling process include one or more of PTS-RH 021 - Cat 2, Aticelca 501 (2019) and the CEPI “Harmonized European laboratory test method to produce parameters enabling the assessment of the recyclability of paper and board products in standard paper and board recycling mills - Version 2,” referred to herein as “CEPI 2.0." For the purpose of the present invention, recyclability of the coated paper or a product made therefrom in the form of a package means that the coated paper or package achieves at least good ratings in accordance with at least one, two or all of these standards, such as at least level B when rated according to Aticelca 501 (2019).

[0065]

[0060] The criteria used in the assessment of the recyclability PTS-RH 021 - Cat. 2 are repulpability (mass percentage of the constituents not usable in papermaking) and undisturbed sheet formation (purity of the furnish mass percentage usable in papermaking regarding stickies or optical inhomogeneities).

[0066]

[0061] The Aticelca 501 (2019) system is an evaluation based on a laboratory analysis, developed by Aticelca starting from 2011 and which became the UNI 11743:2019. The analysis simulates the main phases of the industrial process of manufacturing paper to be recycled up in a standard recycling process to producing a new sheet of paper. The technical standard Aticelca 501 (2019) reproduces at laboratory scale what happens at industrial scale when a paper mill recycles the paper for recycling. Pulping, fiber cleaning and sheet formation are performed. The following parameters are measured: coarse rejects, flake content, macrostickies area, sheet formation and adhesiveness, optical inhomogeneities, and ash content (optional). The result of the laboratory tests, which analyze the main elements that characterize the recyclability of paper and cardboard and of the products obtained with them, is summarized by an index scaled in four levels of recyclability: A+, A, B, C (and not recyclable), A+ being the highest recyclability level.

[0067]

[0062] The CEPI Recyclability Test Method - Version 2 “CEPI 2.0” describes a laboratory scale method for determining the key parameters for evaluating the level of recyclability of paper and board-based materials and other cellulose fiber-based products, emulating the relevant phases of standard paper and board recycling mills without deinking technology or other special features to recycle paper for producing new paper and board. This method enables analyzing both process parameters (coarse reject, fine reject, dissolved and colloidal substances and stickle particles with a diameter smaller than 2 mm) and quality parameters (sheet formation and interfering materials like adhesiveness and visual impurities) of products produced from recycled fibers. This document considers only the minimum characteristics of paper and board products that can be generally recycled. Therefore, it does not take into consideration additional specifications necessary to valorize the paper and board products using deinking technologies. It also does not include parameters of recyclability in mills with specialized processing technology.

[0068]

[0063] As used herein, the term “layer” refers to a thickness of material that may be homogeneous or heterogenous. Layers may be of any type of material including polymeric, cellulosic, and metallic, or a blend thereof. A layer may include a single polymer-type or a blend of polymers and may be accompanied by additives. A given layer may be combined or connected to other layers or substrates, such as a paper substrate, to form films. A layer may be either partially or fully continuous as compared to adjacent layers or the film. A given layer may be partially or fully coextensive with adjacent layers. A layer may also contain sub-layers. As used herein, layers or films that are “in direct contact with” or "are directly adjacent to” each other have no intervening layer or film between them.

[0069]

[0064] As used herein, water vapor transmission rate (WVTR) is a measurement of the barrier properties of a layer. The barrier may reduce the influx of moisture or water through the barrier layer during the shelf-life of a packaged product (i.e., while the package is hermetically sealed). The WVTR of the barrier of a material is an indication of the barrier provided and can be measured according to ASTM F1249 at 38°C and 90% RH. As used herein, the term “ASTM F1249” refers to a test method covering a procedure for determining the rate of water vapor transmission through flexible barrier materials.

[0070]

[0065] As used herein, the term “print layer” refers to a layer including a printed indicia. As used herein, the term "printed indicia” refers to a marking, image, text, and / or symbol located on the surface of a film, sheet, or web. The printed indicia can be placed on the surface by any suitable means (e.g., ink printing, laser printing, etc.). The printed indicia can include, e.g., a printed message or instructions, list of ingredients (active and inactive), weight of product, manufacturer name and address, manufacturer trademark, etc.

[0071]

[0066] As used herein, the term “extrusion process” refers to the process of forming continuous shapes by forcing a molten material through a die, followed by cooling and solidification.

[0072]

[0067] The present application describes a flexible packaging material with particular use for storing items within freezing conditions, such as within a freezer. The flexible packaging material includes a first layer having an exterior surface and an interior surface. The first layer is a paper substrate having a grammage in a range of about 30 grams per square meter (gsm) to about 120 gsm. The flexible packaging material further includes a second layer positioned directly adjacent the first layer. The second layer is a coating layer including a compostable resin having a grammage in a range of about 5 gsm to about 30 gsm resulting in a thickness. The flexible packaging material has a permeability of about between 10 to about 1500 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38 degrees Celsius (°C) and 90% relative humidity (rH). Further, the flexible packaging material includes 80% by weight of the paper substrate and is considered to both be recyclable and compostable. Furthermore, the flexible packaging material is used for enclosing coated ice cream-based items stored in freezer conditions to retain the shelf life and audible characteristics of the coated component of the items after storage.

[0073]

[0068] Referring now to FIG. 1, a schematic cross-sectional view of a flexible packaging material 100 in accordance with an embodiment of the present disclosure.

[0069] Flexible packaging material 100 includes a first layer 110. First layer 110 has a first side 111 and a second side 112. In some positions the first side 111 can be positioned as an exterior surface and the second side 112 can be positioned as an interior surface. First layer 110 is a paper-based substrate 10. In some embodiments, first layer 110 is a paper substrate 10. Accordingly, paper-based substrate 10 may be interchangeably referred to as paper substrate 10, paper, or paper layer herein.

[0074]

[0070] A distance between the first side 111 and the second side 112 defines a thickness “pt" of paper substrate 10. Thickness pt is related to what is commonly referred to as a weight, such as a paper weight including papers having a grammage selected to be within a range of about 30 grams per square meter (g / m2)(gsm) to about 120 gsm, wherein paper substrate 10 is a paper having a grammage in a range of about 30 gsm to about 120 gsm. In some embodiments, thickness pt of paper substrate 10 is in a range of about 40 gsm to about 90 gsm.

[0075]

[0071] In some embodiments, paper substrate 10 is selected from a group comprising refined paper, recyclable paper, uncoated paper, clay coated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper.

[0076]

[0072] In some embodiments, paper substrate 10 first side 111 includes a print layer 12 on the surface. In some embodiments, the paper substrate 10 first side 111 further includes a lacquer 11 on the surface. Furthermore, in some embodiments, print layer 12 is positioned between lacquer 11 and paper substrate 10, wherein print layer 12 is positioned between the first side 111 surface and lacquer 11. Print layer 12 and lacquer 11 are optional.

[0077]

[0073] Flexible packaging material 100 further includes a second layer 120. Second layer 120 is positioned directly adjacent first layer 110. Second layer 120 is a coating layer including a compostable resin 20. In some embodiments, compostable resin 20 is an extrusion coating applied directly adjacent the second surface of the paper substrate. Compostable resin 20 has a thickness ct and a grammage in a range of about 5 gsm to about 30 gsm.

[0078]

[0074] In some embodiments, compostable resin 20 includes at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4-hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), or poly(vinyl alcohol) (PVOH), and combinations thereof.

[0079]

[0075] Flexible packaging material 100 includes 80% by weight of paper substrate 10 and may be considered to be both recyclable, repulpable, and / or compostable.

[0080]

[0076] Further, flexible packaging material 100 has a permeability of about between 10 to 1500 g / m2 / day (gsm) when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% rH. In some embodiments, the permeability is of about between 100 to 1500 g / m2 / day, preferably of about 400 to about 800 g / m2 / day when the WVTR is measured according to ASTM F1249 at 38°C and 90% rH.

[0081]

[0077] Flexible packaging material 100 has been shown to be particularly useful for enclosing coated ice cream-based items (e.g., a coated ice cream-based item 205 shown in FIG. 2) stored in freezer conditions to retain a shelf life and audible characteristics of the coated component (e.g., a coated component 210 shown in FIG. 2) of the items after storage. In some embodiments, coated component 210 is chocolate. In such embodiments, coated ice cream-based item 205 may be referred to as "chocolate covered ice cream-based items 205” or “chocolate coated ice cream-based articles 205” herein.

[0082]

[0078] Referring now to FIG. 2, a schematic diagram of a recyclable and compostable package 200 with a predetermined permeability for containing chocolate covered ice cream-based items 205 within freezer storage conditions and comprising the flexible packaging material in accordance with the embodiments of the present disclosure. Recyclable and compostable package 200 may be interchangeably referred to as “package 200” herein.

[0083]

[0079] Package 200 is comprised of the flexible packaging material including paper substrate 10 and compostable resin 20 as described herein in reference to FIG 1. The first side surface is an exterior surface 220 of package 200. In some embodiments, paper substrate first side 111 (shown in FIG. 1) is the exterior surface 220 of package 200. In other embodiments, the exterior surface 220 is the print layer 12 and / or lacquer 11 (shown in FIG. 1) of the paper substrate exterior. Further, the second side 112 (shown in FIG. 1) surface is in alignment with an interior 215 of package 200. In some embodiments, interior 215 of package 200 may be interchangeably referred to as “interior space 215”.

[0084]

[0080] Package 200 is preferably used for enclosing coated ice cream-based items 205 stored in freezer conditions to retain the shelf life and the audible characteristics of any coated components 210 of items 205 after storage.

[0085]

[0081] The predetermined permeability of package 200 is of about between 10 to 1500 g / m2 / day when the WVTR is measured according to ASTM F1249 at38°C and 90% rH. In some embodiments, the predetermined permeability is of about between 100 to 1500 g / m2 / day, preferably of about 400 to about 800 g / m2 / day when the WVTR is measured according to ASTM F1249 at 38°C and 90% rH.

[0086]

[0082] Furthermore, the combination of materials including package 200 has at least 80% by total package weight of paper substrate 10. In some embodiments, package 200 includes 80% by weight of fiber of the paper substrate 10. Based upon current recycling guidelines as provided in CEPI 2.0 and compostable standards, package 200 may be considered to be both recyclable and compostable.

[0087]

[0083] FIG. 3 is a flowchart depicting steps of a method 300 for formation of recyclable and compostable package 200 shown in FIG. 2 in accordance with an embodiment of the present disclosure. Package 200 is configured to contain chocolate coated ice cream-based articles 205 (shown in FIG. 2) within the freezer environment. Package 200 is specifically selected with the predetermined permeability to retain the shelf life and the audible properties of chocolate coated ice cream-based article 205 when consumed and after removal from the freezer environment. Method 300 will be described with further reference to FIGS. 1 and 2.

[0088]

[0084] At step 302, method 300 includes providing paper substrate 10.

[0089]

[0085] At step 304, method 300 includes coating, via extrusion, compostable resin 20 onto the interior surface of the second side 112 at thickness ct having a grammage in a range of about 5 gsm to about 30 gsm.

[0090]

[0086] At step 306, method 300 includes optionally applying print layer 12 directly adjacent the exterior surface of the first side 111 of paper substrate 10.

[0087] At step 308, method 300 includes optionally applying lacquer 11 directly adjacent to the exterior surface of the first side 111 of paper substrate 10 or directly adjacent optional print layer 12, if present.

[0091]

[0088] At step 310, method 300 includes forming the coated paper substrate (e.g., flexible packaging material 100) with optional print layer 12 and optional lacquer 11 into package 200 by sealing the coated paper substrate to itself to form interior space 215 and define an exterior 225 of package 200. The first side 111 exterior surface is aligned with exterior 225 of package 200 and the second side 112 interior surface is aligned with interior space 215. In other words, the first surface is aligned with exterior 225 of package 200 and the second surface is aligned with interior space 215. Interior space 215 is sized for receiving chocolate coated ice cream-based article 205 within.

[0092]

[0089] At step 312, method 300 includes placing chocolate coated ice creambased article 205 into package 200 and sealing the package 200.

[0093]

[0090] At step 314, method 300 includes storing enclosed package 200 containing chocolate coated ice cream-based article 205 in a freezer (not shown) until desired for use.

[0094]

[0091] Flexible packaging material 100, package 200, and method 300 may enhance the shelf life and cracking of coated component 210 of coated ice cream-based article 205, stored in cool and humid conditions. Flexible packaging material 100 and package 200 having high permeability may function as a buffer / absorbing moisture layer between coated component 210 and an external freezer environment. By absorbing the excess of water, flexible packaging material 100 and package 200 may also regulate water activity of coated component 210, thereby maintaining its texture and quality. As a result, flexible packaging material 100 and package 200 may improve the shelf life in comparison to a standard oriented polypropylene (OPP) packaging.

[0095] Examples

[0096]

[0092] The following illustrative examples are merely meant to exemplify the present invention and are not intended to limit or otherwise define the scope of the present disclosure.

[0097]

[0093] Table 1 provided below summarizes different trials and respective packaging configurations used for a study on the shelf life of a chocolate component (e.g., component 210 shown in FIG. 2) of chocolate covered ice cream-based items (e.g., chocolate covered ice cream-based item 205 shown in FIG. 2).

[0098]

[0094] A resin (e.g., compostable resin 20 shown in FIG. 1) was melted via an extrusion process and was laid at its molted state on a substrate (e.g., paper substrate 10 shown in FIG. 1).

[0099]

[0095] Table 1

[0100]

[0096] "Control” refers to a trial using a comparative packaging for the chocolate covered ice cream-based items. The comparative packaging included horizontal form fill seal (HFFS) Printed oriented polypropylene (OPP) / cold seal packaging.

[0101]

[0097] “Trial 1” refers to a trial using a packaging having an experimental designation of AF-1, which provides a dual end of life (DEOL) solution (recyclable and compostable) with a predetermined oxygen transmission rate (OTR).

[0102]

[0098] “Trial 2” refers to a trial using the AF-1 material as in Trial 1 with the addition of an ink layer (e.g., print layer 12 shown in FIG. 1).

[0103]

[0099] “Trial 3” refers to a negative control, i.e., a trial without any packaging.

[0104]

[0100] AF-1 is defined here as an experimental structure comprising a flexible packaging material constructed from a 60 gsm kraft paper that is extrusion coated with compostable resin (PBAT at a grammage of 15 gsm with the addition of an overprint varnish at a grammage of 3 gsm on an exterior side of the kraft paper opposite the compostable resin. The structure can be defined from exterior to interior with the following layer structure: OPV (3gsm) / Kraft paper (60 gsm) / compostable resin (15 gsm).

[0105]

[0101] Inks and overprint varnish (OPV) were hand coated in the laboratory.

[0102] Storage condition was -20°C in a freezer where a relative humidity inside the freezer was an average of about 63%.

[0106]

[0103] Duration of the trials was 3 months.

[0107]

[0104] Some of samples of Control, Trial 1, and Trial 2 were stored in a cardboard box inside the freezer and are referred to as control box CB, Trial 1 box T1B, and Trial 2 box T2B. Other samples of Control, Trial 1, and Trial 2 were stored loose inside the freezer and are referred to as control loose CL, Trial 1 loose T1L, and Trial 2 Loose T2L.

[0108]

[0105] Furthermore, samples of Trial 3 were stored in the cardboard box (without any packaging) inside the freezer and are referred to as Trial 3 box T3B.

[0109]

[0106] Various parameters were tested for the samples at “P+0” indicating the parameters of the samples before storing the samples in the freezer, “P+1” indicating the parameters of the samples after the samples were stored for 1 day in the freezer, “P+7” indicating the parameters of the samples after the samples were stored for 7 days in the freezer, “P+56” indicating the parameters of the samples after the samples were stored for 56 days in the freezer, and “P+84” indicating the parameters of the samples after the samples were stored for 84 days in the freezer.

[0110]

[0107] Experimental Results

[0111]

[0108] Appearance of the ice cream:

[0112]

[0109] The external appearance of the ice-creams of all the samples was excellent until the last assessment at P+84 apart from Trial 3 which as expected, failed from P+7, showing ice crystals at P+1. Further, at P+84, Control sample was showing a deposit on the outside of the chocolate coating which was not visible on Trials 1 and 2.

[0113]

[0110] FIG. 4 shows a graph 400 depicting an appearance over life analysis of the samples. Graph 400 includes a score (0 to 5) in the ordinate, depicting an appearance quality level of the samples during the appearance over life analysis. In graph 400, the score of 1 depicts a very poor appearance quality level, 2 depicts a poor appearance quality level, 3 depicts an average appearance quality level, 4 depicts a good appearance quality level, and 5 depicts an excellent appearance quality level. Furthermore, graph 400 includes a horizontal dash line depicting an acceptable quality level for the samples. In other words, the average appearance quality level may be the acceptable quality level for the samples.

[0114]

[0111] Organoleptic Analysis:

[0115]

[0112] Overall, all the samples remained acceptable at P+84.

[0116]

[0113] FIG. 5 shows a graph 500 depicting organoleptic attributes (i.e., taste, texture, and aroma) of the samples at P+84.

[0117]

[0114] In graph 500, the score of 1 depicts “very poor”, 2 depicts “poor”, 3 depicts “average”, 4 depicts “good”, and 5 depicts “excellent”. Furthermore, graph 500 includes a horizontal dash line depicting an acceptable quality level for the organoleptic analysis of the samples.

[0118]

[0115] At P+7, it was felt that a strength of vanilla in T rials 2 and 3 samples had decreased very slightly. At this point, the texture of the ice-cream itself of Trial 3 samples was not so smooth as the other samples. The organoleptic properties were very similar when assessed at P+56. Specifically:

[0119]

[0116] Taste: there was a slight loss on vanilla strength for Trials 2 and 3 samples but still scored as “good” at P+84.

[0120]

[0117] Aroma: there was no change to the aroma of any samples apart from Trial 3 over the shelf-life trial. The aroma of Trial 3 samples was not as strong as the other samples but there were no off notes present, so it was still scored as “good”.

[0121]

[0118] Texture: organoleptic properties at P+84 showed some changes between samples in terms of the texture.

[0122]

[0119] Ice-cream - There was no difference to the texture of the ice-cream of Control samples at this stage. Trial 3 samples, although having the same performance on the chocolate coating, the ice-cream itself was not as smooth in the mouth as the other samples.

[0123]

[0120] Chocolate coating - Control samples showed a ‘softer’ crack to the chocolate coating which could be ‘heard’ as well as felt in the mouth.

[0124]

[0121] FIG. 6 shows a graph 600 depicting a force needed to crack the chocolate coating over shelf life. The force is depicted in kilogram (Kg) in the ordinate. This force generally is used as a measure of the audible characteristics of the chocolate coating, wherein a higher force indicates a louder “cracking sound" during consumption.

[0122] It can be seen in graph 600, the force needed to crack the chocolate coating at the start of the trial was closest to Trial 1 samples at P+84. Control samples needed less force to crack to the chocolate coating over the shelf life when compared to the other samples. This was also noted in both the texture in the mouth and the sound made during the organoleptic analysis.

[0125]

[0123] Packaging performance:

[0126]

[0124] No change was seen from P+0 until P+84. None of the samples had any seal failures, no staining visible, and no change to an inside of the packaging.

[0127]

[0125] Table 2 provided below summarizes color scores for the samples in different color gamut. The color gamut is based on an opponent color model of human vision, where red-green and blue-yellow forms an opponent pair.

[0128]

[0126] Table 2

[0129]

[0127] Where, “L*" refers to lightness value defining black at 0 and white at 100;

[0130]

[0128] “a*” refers to a green-magenta opponent colors, with negative values toward the green and positive values toward the magenta;

[0131]

[0129] “b*” refers to a blue-yellow opponent colors, with negative values toward the blue and positive toward the yellow;

[0132]

[0130] Table 3 provided below summarizes delta E values for the samples.

[0131] Table 3

[0133]

[0132] It was observed that there was no difference in color in Control samples at P+0 to any of the samples at P+84. This was demonstrated by the fact that the Delta E value was less than 2 which determines a level at which a color difference cannot be detected by a human eye.

[0134]

[0133] Overall, at P+84, it was seen that Trial 1 samples provided a beneficial result, especially in terms of the chocolate crack sound when compared to Control samples (i.e., ice-creams stored in the packaging made of OPP). Further, it was observed that removing packaging all together is not acceptable as the ice crystal formation on the chocolate was excessive.

[0135]

[0134] To further understand the shelf-life surprising results, and the increase of the chocolate coating texture quality, Control and Trial 1 ice-cream samples were sent to an external lab for a texture analysis. Table 4 provided below summarizes list of the samples and quantity of the samples sent to the external lab for the texture analysis.

[0136]

[0135] Table 4

[0137]

[0136] Using a Stable Microsystems Texture Analyzer (TA.XT), cracking force and sound were measured. Generally, the more force required to crack the coating results in a louder sound. This louder sound is considered more desirable to consumers as it is representative of a fresh product. In an effort to equate this force to sound the Stable Microsystems Texture Analyzer (TA.XT) was fitted with a three-point bend rig (3 cm gap), blade attachment, acoustic envelope detector (placed at 5 cm distance, Gain 0) and 5kg load cell. All the samples were stored frozen (-18 °C) upon arrival, one side of the chocolate coating was removed from the ice-cream and tested immediately when taken out of storage. Three replicates were performed per sample. All the samples were tested outside of the chocolate coating to inside of the chocolate coating.

[0138]

[0137] The following test parameters were used:

[0139]

[0138] Test mode: Compression

[0140]

[0139] Test speed: 1 mm / s

[0141]

[0140] Test distance: 10 mm

[0142]

[0141] Comer envelope frequency: 3.25 kHz

[0143]

[0142] Table 5 provided below summarizes results of the texture analysis.

[0144]

[0143] Table 5

[0145]

[0144] Where, “Peak force” is defined as a maximum compression force reached when deforming the sample.

[0146]

[0145] “Area” is defined by an area under a curve calculated up to the peak force. This refers to an amount of energy / work required to deform the sample.

[0147]

[0146] “Peak sound pressure level” is defined as a pressure deviation in an atmospheric pressure caused by a sound wave. When a crunchy / crispy material is fractured, the stored elastic energy is released as an acoustic energy and hence a noise is perceived.

[0148]

[0147] FIG. 7 depicts a graph 700 for the texture analysis. Time is depicted in the abscissa. Force is depicted in grams (g) in the ordinate.

[0149]

[0148] Graph 700 includes horizontal dash lines 702, 704, 706. Horizontal dash line 702 depicts group low max. Horizontal dash line 704 depicts group mean max. Horizontal dash line 706 depicts group high max. Graph 700 further includes curves 710, 720. Curve 710 depicts performance of Control samples and curve 720 depicts performance of Trial 1 samples.

[0150]

[0149] Referring to Table 5 and FIG. 7, the texture analysis showed that Trial 1 samples had a higher peak force and area, suggesting a harder texture that requires more energy to deform. As is apparent from curve 720, T rial 1 samples showed a clear drop in the force profile which is representative of a mechanical failure. This was also accompanied by an acoustic peak. As is apparent from Table 5 and visualized in FIG. 7, a peak acoustic sound pressure level was detectable for Trial 1 samples but not for Control samples. This suggests that Control samples have a softer texture when bitten into but also a ‘crack’ sound will most likely not be heard when consuming the Control samples.

[0151]

[0150] A water activity test was also conducted to determine a water activity (aW) of each of Control samples and Trial 1 samples.

[0152]

[0151] FIG. 8 shows a graph 800 depicting the water activity (aW) in Control samples and Trial 1 samples.

[0153]

[0152] The water activity (aW) was measured using a dew point water activity meter model Aqualab 4TE. A three-point calibration procedure was performed with calibration fluids of aW 0.50, 0.75, and 0.96. The water activity (aW) measurements for individual layers were measured in triplicate.

[0154]

[0153] As is apparent from FIG. 8, it was observed that both Control samples and Trial 1 samples demonstrated a large variation as shown by error bars 802, 804 of graph 800. Based on the water activity test, there was a difference between the water activity of Control samples and Trial 1 samples. Specifically, Trial 1 samples showed less water activity.

[0155]

[0154] Each and every document cited in this present application, including any cross referenced, is incorporated in this present application in its entirety by this reference, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed in this present application or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this present application conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this present application governs.

[0155] Spatially related terms, including, but not limited to, “lower,” “upper,"

[0156] “beneath,” "below,” “above,” “bottom,” and “top,” if used in the present application, are used for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation, in addition to the particular orientations depicted in the figures and described in the present application. For example, if an object depicted in the drawings is turned over or flipped over, elements previously described as below, or beneath other elements would then be above those other elements.

[0157]

[0156] The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings.

[0158]

[0157] The description, examples, embodiments, and drawings disclosed are illustrative only and should not be interpreted as limiting. The present invention includes the description, examples, embodiments, and drawings disclosed; but it is not limited to such description, examples, embodiments, or drawings. As briefly described above, the reader should assume that features of one disclosed embodiment can also be applied to all other disclosed embodiments, unless expressly indicated to the contrary. Modifications and other embodiments will be apparent to a person of ordinary skill in the packaging arts, and all such modifications and other embodiments are intended and deemed to be within the scope of the present invention.

Claims

CLAIMSWhat is claimed is:

1. A flexible packaging material comprising: a first layer, the first layer having an exterior surface and an interior surface, the first layer being a paper substrate having a grammage in a range of about 30 gsm to about 120 gsm; a second layer, the second layer positioned directly adjacent the first layer, the second layer being a coating layer comprising a compostable resin having a grammage in a range of about 5 gsm to about 30 gsm; wherein the flexible packaging material has a permeability of about between 10 to 1500 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% relative humidity; wherein the flexible packaging material comprises 80% by weight of the paper substrate and is both recyclable and compostable; and wherein the flexible packaging material is used for enclosing coated ice creambased items stored in freezer conditions to retain the shelf life and audible characteristics of the coated component of the items after storage.

2. The flexible packaging material as in claim 1 , wherein the flexible packaging material comprises at least 80% of the paper substrate being selected from the group of refined paper, recyclable paper, uncoated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper.

3. The flexible packaging material as in claim 1 to 2, wherein the paper substrate exterior surface includes a print layer.

4. The flexible packaging material as in claim 1 to 3, wherein the paper substrate exterior surface includes a lacquer.

5. The flexible packaging material as in claim 4, wherein the paper substrate exterior surface includes a print layer, the print layer positioned between the lacquer and the paper substrate.

6. The flexible packaging material in any one of claims 1 to 5, wherein the compostable resin comprises at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4- hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), poly(vinyl alcohol) (PVOH), and combinations thereof.

7. The flexible packaging material as any one of claims 1 to 6, wherein the permeability is of about between 100 to 1500 g / m2 / day, preferably of about 400 to 800 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C90% relative humidity.

8. The flexible packaging material as in any one of claims 1 to 7, wherein the grammage of the paper substrate is in a range of about 40 gsm to 90 gsm.

9. The flexible packaging material as in any one of claims 1 to 8, wherein the coated component is chocolate.

10. A recyclable and compostable package with a predetermined permeability for containing chocolate covered ice cream-based items within freezer storage conditions, the package comprising: a paper substrate, the paper substrate having a first side and a second side opposed to the first side, the first side being an exterior surface of the package, the second side being in alignment with an interior of the package, a distance between the first side and the second side defining a thickness of the paper substrate, the thickness comprising a grammage selected to be within a range of about 30 gsm to 120 gsm, the paper substrate selected from the group of refined paper, recyclable paper, uncoated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper; a compostable resin, the compostable resin being an extrusion coating applied directly adjacent the second side of the paper substrate, the compostable resin having a thickness comprising a grammage in a range of about 5 gsm to 30 gsm, the compostable resin comprising at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylenesuccinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4- hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), poly(vinyl alcohol) (PVOH), and combinations thereof; wherein the package predetermined permeability is of about between 10 to 1500 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% relative humidity; wherein the combination of materials comprising the package has at least 80% by total package weight of the paper substrate; and wherein the package retains the shelf life and measured audible characteristics of a chocolate component of the chocolate covered ice cream-based items after removal from storage.

11. The package as in claim 10, wherein the first side of the paper substrate includes a print layer.

12. The package as in claim 10 or 11 , wherein the first side of the paper substrate includes a lacquer.

13. The package as in claim 11 , wherein the first side of the paper substrate includes a print layer, the print layer positioned between the first side and the lacquer.

14. The package as in any one of claims 10 to 13, wherein the predetermined permeability is of about between 100 to 1500 g / m2 / day, preferably 400 to 800 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% relative humidity.

15. The package as in any one of claims 9 to 14, wherein the thickness of the paper substrate is in a range of about 40 gsm to 90 gsm.

16. A method for the formation of a recyclable and compostable package configured to contain chocolate coated ice cream-based articles within a freezer environment, the package specifically selected with a predetermined permeability to retain the shelf life and audible properties of the chocolate coated ice cream-basedarticle when consumed and after removal from the freezer environment, the method comprising the steps of: providing a paper-based substrate, the paper-based substrate having a grammage between 30 gsm to 120 gsm and having an exterior surface and an interior surface; coating via extrusion a compostable resin onto the interior surface at a grammage in a range of about 5 gsm to 30 gsm; optionally applying a print layer directly adjacent the exterior surface of the paper substrate; optionally applying a lacquer directly adjacent to the exterior surface of the paper substrate or directly adjacent the optional print layer, if present; forming the coated paper substrate with optional print layer and optional lacquer into the package by sealing the coated paper substrate to itself to form an interior space and define an exterior of the package, the exterior surface aligned with the exterior of the package, the interior surface aligned with the interior space, the interior space sized for receiving the chocolate coated ice cream-based article within; placing the chocolate coated ice cream-based article into the package; storing the enclosed package containing the chocolate coated ice cream-based article in a freezer until desired for use; wherein the package has a permeability of about between 10 to 1500 g / m2 / day when a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% relative humidity; and wherein the package comprises 80% by weight of the paper substrate.

17. The package formed from the method of claim 16, wherein the compostable resin comprises at least one of a polylactic acid (PLA), amorphous polylactic acid (aPLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB), 4-hydroxybenzoate hydroxylase (PHBH), polybutylene succinate-co-adipate (PBSA), cellulose acetate (CA), poly(vinyl alcohol) (PVOH), and combinations thereof.

18. The package formed from the method of claim 16 to claim 17, wherein the permeability is of about 100 to 1500 g / m2 / day, preferably between 400 to 800 g / m2 / daywhen a water vapor transmission rate (WVTR) is measured according to ASTM F1249 at 38°C and 90% relative humidity.

19. The package formed from the method of any of claims 16 to 18, wherein the grammage of the paper substrate is in a range of about 40 gsm to 90 gsm.

20. The package formed from the method of any of claims 16 to 19, wherein the paper substrate is selected from the group of refined paper, recyclable paper, uncoated paper, pigment coated paper, paper containing micro fibrillated and / or nano fibrillated fibers, and unsized paper at an amount of at least 80% of the package.

Images