Recyclable barrier label for pressurized container

Abstract

Disclosed are removable recyclable barrier labels for a container designed to contain a food product, such as a pressurized container for containing dough, containers, and methods of making the same.

Description

[0001] Docket No. 9099W001

[0002] RECYCLABLE BARRIER LABEL FOR PRESSURIZED CONTAINER This application claims benefit to U.S. Provisional Patent Application No. 63 / 751, 371, filed on lanuary 30, 2025, the entire contents of which are incorporated herein by reference.

[0003] TECHNICAL FIELD

[0004] The present disclosure generally relates to recyclable barrier labels for a container, such as a pressurized container for a food product such as dough, containers comprising the recyclable barrier labels and methods for making the same.

[0005] BACKGROUND

[0006] The background description provided herein is for the purpose of generally presenting the context of the disclosure.

[0007] A common package for containing food products is a wound-cardboard container and self-sealing cans often used for pressurized food products, such as refrigerated dough. These packages, in various forms, have been a consumer staple for decades because of their ability to offer safe and stable transport, storage, and marketing for sale of refrigerated dough products. Their general construction includes a wound cardboard tube and two end caps, usually metal, that close the ends of the tube but also include a vent to allow air to escape when a dough located inside of the package expands.

[0008] Upon opening a pressurized container, such as a dough can, the packaging is disassembled into its individual components, including the label, body, and other materials. Upon disassembly at the time of use, the recyclability of each resulting packaging component needs to be determined. Currently, the label is intended to be removed by the consumer, making it a standalone packaging component for recycling. However, the inclusion of foil in fiber / foil laminate labels poses significant challenges for recyclability. Existing recycling systems are not equipped to efficiently separate the composite materials, rendering such labels unsuitable for effective reuse. For example, residual foil fragments in the recycled fiber stream can interfere with paper mill operations by causing processing inefficiencies or contamination. Additionally, foil remnants in recycled fiber products can trigger metal detection systems in downstream manufacturing processes, leading to quality assurance concerns and operational disruptions. Therefore, there is a need for labels that offer the required strength and barrier properties while being easily removable and compatible with existing recycling processes,Docket No. 9099W001

[0009] particularly for pressurized food containers.

[0010] SUMMARY

[0011] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features. In various aspects, the present teachings provide a recyclable label for a container comprising a fiber paper layer, a metallized layer on the fiber paper layer, and a grease resistant layer on the fiber paper layer. The recyclable label of the present disclosure does not contain aluminum foil. The recyclable labels may have a tensile strength of > 30 or > 40 pounds per inch in a machine direction (MD) and > 10 or > 20 pounds per inch in a cross direction (CD). The labels may be a removable spiral label. In some examples, the fiber paper layer is a primed fiber paper layer. The presently disclosed recyclable labels have a repulping and fiber recovery capability of at least 80%. The recyclable label of the present disclosure may further comprise an adhesive on an inner surface for adhering to a container body. In some examples, the labels of the present disclosure may be removable by peeling.

[0012] In some examples, the metallized layer of the recyclable labels of the present disclosure may comprise an aluminum alloy. In other examples, the metallized layer of the recyclable labels may comprise an aluminum oxide coating. The recyclable labels of the present disclosure may further comprise a topcoat layer on the metallized layer.

[0013] In some examples of the present disclosure, the grease resistant layer is on an inner surface of the fiber paper layer. In other examples, the grease resistant layer may be combined with a topcoat layer to form a grease resistant topcoat layer on the metallized layer. In some examples, recyclable labels of the present disclosure may include one or more ink layers on the grease resistant layer. In other examples, recyclable labels of the present disclosure may include one or more ink layers on the topcoat layer. The recyclable labels of the present disclosure may further comprise one or more varnish layers on the one or more ink layers.

[0014] In another aspect, the present teachings provide recyclable labels for containers. The recyclable labels comprise a fiber paper layer, and a grease resistant layer on the fiber paper layer. The recyclable labels do not contain aluminum foil. The recyclable labels have a tensile strength of > 30 or > 40 pounds per inch in a machine direction (MD) and > 10 or > 20 pounds per inch in a cross direction (CD). The recyclable labels may be a removable spiral label. In some examples, the fiber paper layer is a primed fiber paper layer. The presently disclosedDocket No. 9099W001

[0015] recyclable labels have a repulping and fiber recovery capability of at least 80%. The recyclable label of the present disclosure may further comprise an adhesive on an inner surface for adhering to a container body. In some examples, the labels of the present disclosure may be removable by peeling.

[0016] In yet another aspect, the present teachings provide a container comprising a tubular body having an interior space and comprising at least one paperboard body stock spirally wrapped around an axis such that a butt joint is formed between adjacent edges of successive spiral turns of the at least one paperboard body stock; an adhesive; and a removable, recyclable label attached to an outer surface of the tubular body. The recyclable label attached to the outer surface of the tubular body of the container comprises a fiber paper layer, a metallized layer on the fiber paper layer, and a grease resistant layer on the fiber paper layer. The recyclable labels do not contain aluminum foil. The recyclable labels have a tensile strength of > 30 or > 40 pounds per inch in a machine direction (MD) and > 10 or > 20 pounds per inch in a cross direction (CD). The recyclable labels may be a removable spiral label. In some examples, the fiber paper layer is a primed fiber paper layer. The presently disclosed recyclable labels have a repulping and fiber recovery capability of at least 80%. The recyclable label of the present disclosure may further comprise an adhesive on an inner surface for adhering to a container body. In some examples, the labels of the present disclosure may be removable by peeling.

[0017] In some examples, the metallized layer of the recyclable labels attached to the outer surface of the tubular body of the container may comprise an aluminum alloy. In other examples, the metallized layer of the recyclable labels attached to the outer surface of the tubular body of the container may comprise an aluminum oxide coating. The recyclable labels of the present disclosure attached to the outer surface of the tubular body of the container may further comprise a topcoat layer on the metallized layer.

[0018] In some examples of the recyclable labels attached to the outer surface of the tubular body of the container of the present disclosure, the grease resistant layer is on an inner surface of the fiber paper layer. In other examples, the grease resistant layer may be combined with a topcoat layer to form a grease resistant topcoat layer on the metallized layer. In some examples, recyclable labels of the present disclosure may include one or more ink layers on the grease resistant layer. In other examples, recyclable labels of the present disclosure may include one or more ink layers on the topcoat layer. The recyclable labels attached to the outer surface of the present disclosure may further comprise one or more varnish layers on the one or more ink layers.Docket No. 9099W001

[0019] In some examples, the container of the present disclosure is a pressurized container. In other examples the container is a dough can.

[0020] Further areas of applicability and various methods of enhancing the above technology will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present teachings will become more fully understood from the detailed description and the accompanying drawings wherein:

[0023] FIG. 1 is a perspective view of a recyclable barrier label.

[0024] FIG. 2 is an illustration of a container and a recyclable barrier label attached to the container body.

[0025] FIG. 3 is a perspective view of an exemplary recyclable barrier label.

[0026] FIG. 4A is a perspective view of an exemplary recyclable barrier label including a metallized layer.

[0027] FIG. 4B is a perspective view of an exemplary recyclable barrier label including a metallized layer.

[0028] FIG. 5 is a diagram illustrating an exemplary method for forming a recyclable barrier label.

[0029] FIG. 6A is a top view of an example of the container.

[0030] FIG. 6B is a perspective view of an example of the container.

[0031] It should be noted that the figures set forth herein are intended to exemplify the general characteristics of the methods, algorithms, and devices among those of the present technology, for the purpose of the description of certain aspects. These figures may not precisely reflect the characteristics of any given aspect and are not necessarily intended to define or limit specific embodiments within the scope of this technology. Further, certain aspects may incorporate features from a combination of figures.

[0032] DETAILED DESCRIPTION

[0033] The present teachings provide recyclable barrier labels for a container that are designed to provide strength, high barrier properties, and ease of use as a recyclable and removable label from a container for a food product, such as a pressurized container for dough. The labels of the present disclosure provide an opening feature based on tear properties, intra-layer adhesionDocket No. 9099W001

[0034] and inter-layer bond strength while also holding the container together until it is opened by the consumer. The recyclable barrier labels of the present disclosure are further designed to provide grease resistance and mask oil, grease, and other liquids absorbed by paper. Additionally, the labels provide an appealing decorated surface for shelf presence, and communication and allow for consumer recycling via curb-side handling. In another aspect, the recyclable labels of the present disclosure also include at least one metallized layer as the main component for the recyclable label. The terms “metallized”, “metallization”, and “metallic” may be used interchangeably in the present disclosure.

[0035] The recyclable labels of the present disclosure are designed to meet the performance characteristics required for product protection and consumer use, while additionally providing advantages over current constructs for attractiveness to recyclers desiring reusable fiber. The recyclable labels of the present disclosure are further characterized by a repulping and fiber recovery capability of at least 80%, ensuring compatibility with established recycling processes. Recycling performance is evaluated according to the Fibre Box Association (FBA) Voluntary Standard for Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor (August 16, 2013). This ensures that the materials meet industry standards for sustainability, allowing efficient fiber recovery while maintaining high water vapor barrier performance.

[0036] In some examples of the present disclosure the barrier layer is a metallized layer, while in other examples, an alternative barrier coating is employed. Metallized paper, or metallized fiber, is less detrimental (i.e., more acceptable) than a paper / foil lamination to the fiber recovery process and maintains high quality recycled fiber. In some examples, the construct of the recyclable labels of the present disclosure is a fiber paper, metallized on the outside surface with a grease-resistant topcoat printed for decoration and including a scuff-resistant varnish. At the time of conversion into a can, the inner surface of the recyclable label is further coated with a releasable type of adhesive imparting peelability of the label off of a container such as a fiberboard or paperboard can body to which it will adhere.

[0037] Examples of paper for the fiber paper layer or substrate include, but are not limited to bleached paper, bleached recycled, bleached Kraft paper, clay coated sulphate, natural Kraft paper (including coated), machine glazed (MG), machine finished (MF), and glassine papers. The paper substrate may vary in weight so long as other strength properties are met. In some examples, a 40 pound paper, (approximately 80 g / m2) may be used. In other examples, a 35 pound (approximately 70 g / m2) or 30 pound paper (approximately 60 g / m2) can be used. The thickness will depend on the density of the paper which also can vary. In some examples, theDocket No. 9099W001

[0038] fiber paper layer may be a primed fiber paper layer. Primed paper enhances chemical bonding, the topography for coatings, and the porosity of the paper (filling in holes in the paper). Primer coatings may include an aqueous polymeric suspension containing various inorganic fillers such as clays, calcium carbonate, titanium dioxide, methyl cellulose, silicon dioxide, epoxies, acrylics, methacrylates, and acrylics with epoxy components.

[0039] The metallized layer may comprise a metallized paper having a thin (~ 30-90 nm) metallic coating on a paper substrate. Alternatively, the metallized layer may be a metal-coated paper which involves applying the metallic layer to the paper post-production through methods such as lamination with a metallized film, spraying, or vacuum deposition. In further embodiments, the metallized layer is in contact with the fiber paper layer. These types of metallized layers enhance the paper’s barrier properties against moisture, oxygen, and light while providing an attractive appearance, making them suitable for packaging, labeling, and decorative applications. However, metallized paper is typically more recyclable and environmentally friendly due to its minimal metal content, while metal-coated paper may offer greater durability and barrier performance for demanding applications. Examples of suitable vapor deposition materials to form the thin metallic coatings of the metallized layer may include aluminum alloys specifically engineered for barrier applications and metal oxides. Suitable aluminum alloys may include high-purity aluminum, aluminum-magnesium alloys, or aluminum-silicon alloys, which provide excellent barrier properties to gases and moisture, strong adhesion to substrates, and compatibility with recycling processes. These alloys may be selected to optimize properties such as thermal stability, flexibility, and corrosion resistance, ensuring durability and sustainability in food container labels. Suitable metal oxides include aluminum oxide (AlOx), silicon oxide (SiOx), and Zinc Oxide (ZnO), magnesium oxide (MgOx), titanium oxides (TiOx), tin oxide (SnOx), yttrium oxide (Y2OX), zirconium oxides (ZrOx), calcium oxide (CaOx), boron oxide EEOx), and other oxides of metalloids. In these formulas, "x" represents the stoichiometric ratio of oxygen atoms bonded to the metal or metalloid in the compound, which may vary depending on the specific oxide and deposition conditions. In some examples, the metallized layer comprises an aluminum alloy or an aluminum oxide coating.

[0040] The metallic coating of the metallized layer may have an optical density (OD) of 2.0 -4.5, or 2.5 - 3.0. Optical density (OD) is a measure of the degree to which a material reduces the transmission of light through it. In the context of metallized layers as in the present disclosure, OD is used to assess the light-blocking properties of the material. The thickness and uniformity of the metal layer can be correlated to the OD, as is known to a person skilled in theDocket No. 9099W001

[0041] art. The relationship between OD and thickness is well established for many materials, including aluminum alloys, and serves as a reliable metric for quality control. Consistent OD values across the metallized layer indicate uniform deposition, minimizing defects such as pinholes that could compromise barrier integrity. Deviations outside the proscribed OD range may result in insufficient barrier performance (OD < 2.0) or unnecessary material use and costs (OD >4.5).

[0042] The grease resistant layer may be formed by water-based coatings or additives. The grease resistant coatings or additives are selected for desirable properties of grease and oil resistance, particularly oil migration, and oxygen barrier properties as well as recyclability, flexibility, ease of applying as an overcoat, and / or adhesive properties. Since the grease resistant coatings used to form the grease resistant layer may be applied either onto a surface of a porous paper substrate (or a fiber paper layer), or onto a metallized layer, it is desirable to have a smooth, pinhole-free surface. Further, in some embodiments, a smooth, pinhole-free fiber paper layer ensures a high affinity towards the deposition or coating of metal onto the paper. In some cases in may be desirable to prime the paper surface to create a pinhole free and create a chemically attractive bonding surface for the deposition coating. The grease resistant coatings layer may be applied on the inner (lower or bottom) surface of the fiber paper layer or on the outer (upper or top) surface of the fiber paper layer. Grease resistant can be evaluated using KIT Testing, TAPPI (Technical Association of the Pulp and Paper Industry) Test Method T559, which measures how well paper and board resist grease, oil, and waxes. Examples of coatings for the grease resistant layer may include, but are not limited to, aqueous dispersions comprising a polymer or copolymer selected from an acrylic- or aciylate-based polymer or copolymer, such as styrene-acrylic copolymer and styrene-acrylic-acrylonitrile copolymer; a polyester such as polyethylene terephthalate (PET), a plant oil-based polyester resin; polyvinyl alcohol (PVOH); polylactic acid (PLA); ethylene-vinyl alcohol (EVOH), polyurethane, polyvinylidene chloride (PVDC); ethylene copolymer resin dispersion; paraffinic wax; styrene-butadiene copolymer, starch; dextrin; low-density polyethylene (LDPE); high-density polyethylene (HOPE); PLA; nylon, polypropylene; and mixtures thereof. Aqueous dispersion can also comprise minerals, such as calcium carbonate (CaCCh), clay, mica, talc, titanium dioxide and / or carbon black. A commercially available example of a suitable grease resistant layer material is Michem® Flex B1002. In other examples, grease resistant coating materials or additives can be added to the pulp in the paper making process to form the grease resistant layer.Docket No. 9099W001

[0043] In some examples, the recyclable barrier labels of the present disclosure may include at least one topcoat coating or layer. Examples of topcoat materials for forming the topcoat layer may include, but are not limited to latex, polyvinyl alcohol (PVOH), hyperpl atey nano talc (a high aspect ratio nano pigment), soy polymer proteins, polymer or copolymer dispersions, polymers selected from acrylic polymers, acrylic copolymers, styrene-butadiene copolymers or polyvinylidene chloride, MFC Microfibrillated cellulose (MFC), and polyesters such as polyethylene terephthalate (PET).

[0044] In some examples, the recyclable labels may include a topcoat layer that includes grease resistant coating materials or additives forming a combined grease resistant topcoat layer. The grease resistant topcoat layer may be applied on the fiber paper layer or on the metallized layer. The grease resistant topcoat layer may be applied by vapor deposition in a chamber right after metallization or as a wet coating applied off line after the metallization process followed by drying in a rapid oven drier or cured using an electron beam (E - Beam).

[0045] In some embodiments the grease resistant topcoat is provided on the fiber paper layer without a metallized layer, to provide the grease barrier. In other embodiments, the grease resistant topcoat is provided on a metallized layer and provides mechanical protection for the metallized layer as well as an added grease barrier. In some examples, a polyester polymer coating and / or an acrylic polymer coating may be used for the grease resistant topcoat to provide grease barrier properties. The polyester polymer coating and / or an acrylic polymer coating may have a thickness in the range of 0.8 - 1.5 g / m2

[0046] Additional coatings / treatment could enhance oxygen barrier characteristics. Topcoat chemistries can be modified to provide oxygen barrier characteristics as needed. For example, a thermoplastic polymer polyvinyl alcohol (PVOH) can be a candidate for an oxygen barrier.

[0047] The recyclable labels may also include one or more ink layers formed of conventional ink. Preferably the ink has low odor, low migration, and is non-toxic. The one or more ink layers may be applied to the grease resistant layer, topcoat layer or a combined grease resistant and topcoat layer. Suitable ink for the ink layers includes but is not limited to nitrocellulose resin, a solvent, a polyurethane resin.

[0048] The recyclable labels may also include one or more varnish or lacquer layers. The one or more varnish layers may be applied on the one or more ink layers to protect the ink layer(s). Suitable varnishes are selected for desirable properties such as scratch resistance, a low coefficient of friction, to produce a smooth finish that resists sticking and promotes easy handling and providing a matte overprint for transparency with a less white appearance. An exemplary varnish is a cold seal release lacquer which is generally a polyamide orDocket No. 9099W001

[0049] nitrocellulose / polyamide blend system designed to act as a protective coating for the printed side of a paper / film material. A commercially available example of a suitable varnish is Michem®Flex Ml 479. C More details of cold seal release lacquers are found in US Patent No. 5,466,734, incorporated herein by reference.

[0050] The recyclable labels of the present disclosure may include graphics identifying the product and providing relevant product information and have a printable outer surface that maintains print quality through package handling.

[0051] The recyclable labels of the present disclosure are designed to be removable and include a releasable adhesive applied to the inner surface of the label. The releasable adhesive is selected and engineered for temporary bonding and controlled separation to allow the bonded materials to be separated without causing significant damage to either surface or leaving residue. Suitable releasable adhesives may include but are not limited to peelable adhesives, delaminating adhesives, and self-sealing adhesives. Some examples of suitable peelable adhesives include rubber-based adhesives, acrylic-based peelable adhesives, and pressuresensitive peelable adhesives. Examples of delaminating adhesives include dual-layer adhesive systems, controlled delamination adhesives, and tamper-evident adhesives designed to delaminate and leave an indication of prior removal, peeling, or another type of break in the seal. Cold seal adhesives may also be employed for their peelable or delaminating functionality, with the added advantage of enabling removal of the entire label in one piece. The technology used to create cold seal adhesives is varied, some of the adhesives contain natural rubber latex of various percentages. Some cold seal adhesives are latex free. Other components are added, such as synthetic polymers to improve adhesion and antifoam to ensure the adhesive meets performance specifications. The packaging speed of cold-seal packaging can be much faster than that of heat-seal packaging. Self-sealing adhesives, such as latex -based or pressuresensitive formulations, may also be used, particularly when designed to provide clean removability while maintaining a firm bond during storage and transport. Additionally, starch-based adhesives, such as dextrin adhesives, can be used when moisture-sensitive or biodegradable solutions are desirable. In some examples, the adhesive is removable by peeling. In some examples a cold seal adhesive is employed which is particularly advantageous for enabling removal of the entire label in one piece.

[0052] The recyclable labels of the present disclosure are constructed to have a tensile strength to hold a container, such as a pressurized container, together until a consumer opens the container. The labels of the present disclosure have a tensile strength of > 30 or > 40 poundsDocket No. 9099W001

[0053] per inch in a machine direction (MD) and > 10 or > 20 pounds per inch in a cross direction (CD) adequate to withstand the forces generated in a typical pressurized dough package.

[0054] It is also desirable for the labels of the present disclosure to have a minimum Mullen burst strength of 25 psi in wet conditions and 40 psi in dry conditions (which can be determined using the ISO 2759 Standard) to ensure durability and integrity when applied to pressurized containers, such as dough cans, to ensure that the recyclable label remains functional, intact, and visually appealing under the expected mechanical and environmental stresses. The minimum burst pressure relates to the efficacy of the entire can construct to hold pressure. If the pressure exceeds a maximum desired level the can is designed to fail either by the metal end lifting off of the tube, or (even preferentially) of the multilayer can body to rupture along the spiral geometry of the paperboard “butt-joint”. Label materials under the desired burst pressure minimum are more likely to rupture at the butt joint at pressures suitable for the product contained within.

[0055] The recyclable labels of the present disclosure should have tear properties sufficient for consumers to remove the label effectively in one piece.

[0056] The recyclable labels described in this disclosure may possess moisture vapor barrier properties that effectively prevent water vapor from penetrating the container, thereby protecting the interior fibers from strength degradation. The performance of the recyclable labels of the present disclosure can be measured by the Water Vapor Transmission Rate (WVTR), also referred to as the Moisture Vapor Transmission Rate (MVTR). A lower WVTR / MVTR indicates that the metallized layer effectively inhibits water vapor transmission, which is critical for preventing moisture-related spoilage and microbial growth in humiditysensitive products. The metallized layer serves as a water vapor barrier, with its effectiveness evaluated based on the WVTR / MVTR.

[0057] Metallized coatings as used in the present disclosure are particularly effective for packaging applications requiring moisture protection due to their low WVTR / MVTR. These coatings can help extend the shelflife of food products by maintaining optimal moisture levels within the container. The metallized film (i.e. layer) utilizing aluminum alloys or aluminum oxide coatings typically achieve WVTR values of less than 1 g / m2 / day under standard testing conditions, such as 38°C and 90% relative humidity. The performance of the metallized barrier layer depends on factors such as the metallization process, coating thickness, and uniformity. The WVTR can be assessed under conditions of 37.8°C and approximately 90% relative humidity (reported as 100°F / 90%RH) following ASTM F1249 standards.Docket No. 9099W001

[0058] In examples of the present disclosure incorporating the metallized barrier layer, suitable barrier levels may exhibit WVTR values less than 0.15 g / 100 in2 / 24 hours, as determined using the following ASTM F1249 standards. For grease resistance as determined using KIT Level test methods, suitable barrier levels range from a minimum of 8 to as high as 14. Other examples, without the metallized layer, typically exhibit WVTR values greater than 10.0 g / 100 in2 / 24 hours.

[0059] Inner surface interface capable of bonding to a peelable / delaminating adhesive. Factors affecting the inner surface interface capability to bond to an adhesive may include topography, density, surface energy, and paper COBB levels (i.e., measure of water absorbency of paper or cardboard). The peel bond strength of the recyclable labels of the present disclosure may be in the range of 0.11 to 0.25 pounds per inch-width (as can be determined by ASTM F88).

[0060] In some examples, the recyclable barrier label of the present disclosure is a removable spiral label for wrapping around a tubular container.

[0061] The recyclable labels of the present disclosure do not contain aluminum foil. FIGs 1 and 2 illustrate an example of a label 100 of the present disclosure which has an inner surface 101 configured to face the product inside of the container 200 and an outer surface 102. The outer surface may be configured for printing and maintain print quality through package handling when printed. In at least one example, as shown in FIG. 3, a recyclable label 110 of the present disclosure comprises a fiber paper layer 111, and a grease resistant layer (approximately 1-2 g / m2dried) 112 on the fiber paper layer 111, wherein the fiber paper layer is configured to provide an inner surface interface 113 capable of bonding to a peelable / delaminating adhesive. Labels of the present disclosure may also include an ink layer 114 on the grease resistant layer 112 and a varnish or lacquer, layer 115 on the ink layer (each approximately 1-2 g / m2dried). In at least one example, the ink and varnish layers combined may have a total thickness of 0.00024 to 0.00048 inches (6-12 microns). The thickness of the entire label in at least one example is about 0.0022 inches (54 microns).

[0062] In another example the recyclable barrier labels of the present disclosure include a metallized layer which facilitates recyclability as compared to traditional foil laminates. The metallized layer contains a very thin metal layer which does not compromise the recyclability of the label, while providing protection from moisture, grease, and oxygen. As shown in FIG.

[0063] 4A, a recyclable label 120 comprises a fiber paper layer 121, a metallized layer 122 on the fiber paper layer 121, a grease resistant topcoat 123 on the metallized layer 122, an ink layer 124 on the grease resistant topcoat and a varnish layer 125 on the ink layer 124. The fiber paper layer 121 is configured to provide an inner surface interface 126 capable of bonding to aDocket No. 9099W001

[0064] peelable / delaminating adhesive. The metallized layer 122 comprises a thin metal coating deposited directly onto the fiber paper layer 121. The metal coating may be formed by vacuum metallization, sputtering, or other suitable metallization techniques. In some embodiments, the metallized layer 122 may be formed on one or both major surfaces of the fiber paper layer 121. Each layer is approximately 1-2 g / m2dried). In at least one example, the ink and varnish layers combined may have a total thickness of 0.00024 to 0.00048 inches (6-12 microns). The thickness of the entire label in at least one example is about 0.0022 inches (54 microns). Other alternative arrangements could employ a machine glazed paper for in place of metallized paper, in order to provide for reduced water and oxygen transfer rates.

[0065] Another example of a recyclable label of the present disclosure containing at least one metallized layer is illustrated in FIG. 4B, wherein recyclable label 130 includes a fiber paper layer 132, a metallized layer 133 on a top surface of the fiber paper layerl32, a grease resistant layer 131 on a bottom surface of the fiber paper layer 132, a topcoat layer 134 on the metallized layer 133, an ink layer 135 on the topcoat layer 134, and a varnish layer 136 on the ink layer 135. The metallized layer 133 comprises a thin metal coating deposited on the top surface of the fiber paper layer 132. In some embodiments, the metallized layer 133 may be formed on one or both major surfaces of the fiber paper layer 132. Other alternative arrangements could employ a machine glazed paper in place of metallized paper, in order to provide for reduced water and oxygen transfer rates.

[0066] The recyclable barrier layer may be formed by known techniques. In one example the layers are placed in order according the desired construction and laminated. The addition of non-barrier paper reduces water transfer by a least about 75% to less than about 0.021 g H2O / IOO in2 / day and reduces oxygen transfer by 90% or more to less than about 0.0463 cc O2 / IOO in2 / day. The adhesive employed is preferably a laminating adhesive that does not include any solvent since such adhesives are specifically designed to work with flexible film and for food handling. Non-solvent adhesives also do not interfere with recyclability of the barrier label. However, a solvent, a water based, or even a laminating film could be employed. The laminating adhesive is preferably suitable for use around food.

[0067] FIG. 5 schematically illustrates a method 500 of manufacturing a recyclable barrier label of the present disclosure. The process starts at step 510 providing a fiber paper sheet such as a bleached Kraft paper that has been treated with bleach and other chemicals to whiten and purify the natural Kraft pulp. At step 520, the paper is preferably metallized by adding an aluminum deposition layer. During production of the metallized paper, the fiber paper sheet is preferably precoated with a base varnish (not shown). The metal coating, which isDocket No. 9099W001

[0068] approximately 30-90 nanometers thick, is preferably formed by evaporating aluminum in a vacuum environment and then depositing the aluminum onto the fiber paper sheet. The metal coating may be further coated, or roll finished to have the metal coating be printable. Next, at 530, other coatings or layers may be added, such as an ink layer, a cold-seal adhesive, or an ink layer covered with a cold seal release lacquer. At 540, a releasable adhesive is applied to the inner surface of the label to produce the removable recyclable barrier label.

[0069] The present disclosure also provides a container for a food product comprising a removable recyclable barrier label of the present disclosure on the outer surface of a container body. Referring to FIGs. 6A and 6B, the container 600 comprises a wound tubular body 610 formed from at least one layer of paperboard body stock 630 spirally wound in a manner to form sidewalls of a hollow tubular container having an interior space 620 for the food product. The at least one layer of paperboard body stock 630 is spirally wound, or wrapped, around an axis such that a butt joint 640 is formed between adjacent edges of successive spiral turns of the at least one layer of paperboard body stock 630. The ends of the container may be sealed with metal end caps (not shown), to allow for initial venting during dough proofing.

[0070] The container further includes an outer removable recyclable barrier label 660 attached to an outer surface of the wound tubular body 610, via an adhesive 650. The removable recyclable barrier label 660 is designed for recyclability and does not contain aluminum foil making it compatible with recycling processes. Additionally, the removable recyclable barrier layer is designed to provide an amount of the required strength of the package to hold the wound sidewall together under pressure so that, when the outer layer is removed, the wound sidewall may be disrupted at the exposed seam to burst open.

[0071] The recyclable container of the present disclosure can be made by conventional means. In one example, the container can be produced by forming a cylindrical winding of the at least one paperboard body stock 630 to form the sidewalls of the container and placing a wound layer of the printed label layer about the wound paperboard body stock.

[0072] The wound package construct of the invention can be adapted for use as a cylindrical sidewall of a pressurized package for containing a raw dough which is intended to be refrigerated. The dough can be placed at the package interior, the ends of the package can be covered and closed, preferably while accommodating at least some initial venting as the dough proofs and expands within the interior of the package. The expanded dough then seals the package from within and produces a pressurized package interior.

[0073] The preceding description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. As used herein, the phrase at least one of A, B, andDocket No. 9099W001

[0074] C should be construed to mean a logical (A or B or C), using a non-exclusive logical “or.” It should be understood that the various steps within a method may be executed in different order without altering the principles of the present disclosure. Disclosure of ranges includes disclosure of all ranges and subdivided ranges within the entire range.

[0075] The headings (such as “Background” and “Summary”) and sub-headings used herein are intended only for general organization of topics within the present disclosure and are not intended to limit the disclosure of the technology or any aspect thereof. The recitation of multiple embodiments having stated features is not intended to exclude other embodiments having additional features, or other embodiments incorporating different combinations of the stated features.

[0076] As used herein, the terms “comprise” and “include” and their variants are intended to be non-limiting, such that recitation of items in succession or a list is not to the exclusion of other like items that may also be useful in the devices and methods of this technology. Similarly, the terms “can” and “may” and their variants are intended to be non-limiting, such that recitation that an embodiment can or may comprise certain elements or features does not exclude other embodiments of the present technology that do not contain those elements or features.

[0077] As used herein, the term “about”, in the context of concentrations of components of the formulations, typically means + / -5% of the stated value, more typically + / -4% of the stated value, more typically + / -3% of the stated value, more typically, + / -2% of the stated value, even more typically + / -1% of the stated value, and even more typically + / — 0.5% of the stated value.

[0078] The broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the specification and the following claims. Reference herein to one aspect, or various aspects means that a particular feature, structure, or characteristic described in connection with an embodiment or particular system is included in at least one embodiment or aspect. The appearances of the phrase “in one aspect” (or variations thereof) are not necessarily referring to the same aspect or embodiment. It should be also understood that the various method steps discussed herein do not have to be carried out in the same order as depicted, and not each method step is required in each aspect or embodiment.

[0079] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure.Docket No. 9099W001

[0080] Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations should not be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

Docket No. 9099W001WHAT IS CLAIMED IS:

1. A recyclable label for a container comprising:a fiber paper layer,a metallized layer on the fiber paper layer, anda grease resistant layer on the fiber paper layer;wherein the recyclable label does not contain aluminum foil,wherein the label is a removable spiral label, andwherein the recyclable label has a repulping and fiber recovery capability of at least 80%.

2. The recyclable label according to claim 1, wherein the metallized layer comprises an aluminum alloy or an aluminum oxide coating.

3. The recyclable label according to claim 1, further comprising one or more ink layers on the grease resistant layer.

4. The recyclable label according to claim 3, further comprising one or more varnish layers on the one or more ink layers.

5. The recyclable label according to claim 3, wherein the grease resistant layer is on an inner surface of the fiber paper layer.

6. The recyclable label according to claim 1, further comprising a topcoat layer on the metallized layer.

7. The recyclable label according to claim 1, wherein the grease resistant layer is combined with a topcoat layer to form a grease resistant topcoat layer on the metallized layer.

8. The recyclable label according to claim 1, further comprising an adhesive on an inner surface for adhering to a container body.

9. The recyclable label according to claim 1, wherein the recyclable label has a tensile strength of > 30 pounds per inch in a machine direction (MD) and > 10 pounds per inch in a cross direction (CD).Docket No. 9099W00110. The recyclable label according to claim 1, wherein the label is removable by peeling.

11. A recyclable label for a container comprisinga fiber paper layer, anda grease resistant layer on the fiber paper layer;wherein the recyclable label does not contain aluminum foil,wherein the label is a removable spiral label, andwherein the recyclable label has a repulping and fiber recovery capability of at least 80%.

12. A container comprisinga tubular body having an interior space and comprising at least one paperboard body stock spirally wrapped around an axis such that a butt joint is formed between adjacent edges of successive spiral turns of the at least one paperboard body stock;an adhesive; anda recyclable label attached to an outer surface of the tubular body, wherein the label comprises:a fiber paper layer,a metallized layer on the fiber paper layer, anda grease resistant layer on the fiber paper layer;wherein the recyclable label does not contain aluminum foil,wherein the label is a removable spiral label, andwherein the recyclable label has a repulping and fiber recovery capability of at least 80%.

13. The container according to claim 12, wherein the label further comprises one or more ink layers on the grease resistant layer.

14. The container according to claim 13, wherein the label further comprises one or more varnish layers on the one or more ink layers.

15. The container according to claim 12, wherein the grease resistant layer is on an inner surface of the fiber paper layer.Docket No. 9099W00116 The container according to claim 12, wherein the metallized layer comprises an aluminum alloy or an aluminum oxide coating.

17. The container according to claim 12, further comprising a topcoat layer on the metallized layer.

18. The container according to claim 12, wherein the grease resistant layer is combined with a topcoat layer to form a grease resistant topcoat layer on the metallized layer.

19. The container according to claim 12, wherein the recyclable label has a tensile strength of > 30 pounds per inch in a machine direction (MD) and > 10 pounds per inch in a cross direction (CD).

20. The container according to claim 12, wherein the container is a pressurized dough can.

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