Post-Formation Inkjet Printing for Customizable Fillable Pouches
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Solution Overview
Problem
Existing flexible packaging films for food and pet food sectors face issues with inkjet-printed surfaces being susceptible to damage during pouch production, requiring varnishing or lamination, and are not suitable for small lot sizes with customized print designs, while also risking print transfer to the inside of the pouch.
Innovation Solution
An unprinted inkjet-printable film with a multilayer structure comprising a base layer, sealing layer, and ink-receiving layer, coated with specific inorganic and organic particles, allowing for high-quality inkjet printing after pouch formation, which includes a method for producing and printing on commercial machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the film is printed before pouch production, then the print design is customized, but the printed surface is susceptible to scratches and damages during pouch production
Solution Approach 1:
The film is prepared with an unprinted inkjet-printable surface structure before pouch production. The ink-receiving layer with specific particle composition is applied in advance, but the actual printing is deferred until after pouch formation, allowing the surface to be protected during handling while still enabling customization.
Solution Approach 2:
Instead of printing the film before pouch production (conventional approach), the invention reverses the sequence by producing the pouch first and then printing it. This inversion protects the printed surface from damage during pouch handling and production processes.
2Adaptability or versatility
If the film is printed before pouch production, then the print design is customized, but varnishing or lamination is required before pouch production
Solution Approach 1:
The ink-receiving layer with specific particle composition is applied in advance as a preliminary preparation. This layer is designed to be directly compatible with inkjet printing after pouch formation, eliminating the need for additional varnishing or lamination steps while still enabling customization.
Solution Approach 2:
The surface properties are modified by applying an ink-receiving layer with specific particle size distribution (fine particles 50-300 nm and coarse particles 5-14 μm) and controlled surface roughness (Rz 3.0-12.0 μm). These parameter changes enable direct inkjet printing after pouch production without requiring additional protective coatings.
3Adaptability or versatility
If the film is printed before pouch production, then the print design is customized, but print transfer may occur to the backside of the film
Solution Approach 1:
The ink-receiving layer is applied in advance as a protective and functional preparation. This layer prevents direct contact between the inkjet ink and the base film during pouch production, eliminating the risk of print transfer to the backside while still enabling customization after pouch formation.
Solution Approach 2:
The ink-receiving layer acts as an intermediary between the inkjet printing system and the base film. It provides a controlled surface for ink deposition while preventing ink penetration through to the backside, thus avoiding contamination of the food-contact surface.
4Reliability
If a covering layer is applied to protect the printed surface, then the printed surface is protected from damage, but the risk of print transfer to the inside of the pouch remains
Solution Approach 1:
The ink-receiving layer is formulated with specific particle size distribution (fine particles 50-300 nm and coarse particles 5-14 μm) and controlled surface roughness (Rz 3.0-12.0 μm). These parameter changes create a surface that is both protective and ink-receptive, preventing print transfer while enabling quality printing.
Solution Approach 2:
The ink-receiving layer is a composite material combining polymeric binder with fine inorganic particles (silica, alumina, boehmite) and coarse inorganic/organic particles. This composite structure provides both protection against damage and prevention of print transfer to the food-contact surface.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides durable, customizable, and efficient inkjet-printable pouches with reduced waste and no print transfer, suitable for small lot sizes, maintaining food compliance and customer satisfaction.
Implementation Method 1
at least one ink-receiving layer as the outer layer deposited on the multilayer polymer film (a) from an aqueous coating composition
Implementation Method 2
coarse inorganic and/or organic particles having a median particle size (Dv50) of from 5 to 14 μm, wherein the coarse inorganic and/or organic particles have a specific pore volume of from 1.3 to 2.5 ml/g
Data Source
AI summary
The present invention is directed to an unprinted inkjet-printable fillable pouch made of an unprinted inkjet-printable film including (a) a multilayer polymer film including a base layer (a1) and a sealing layer (a2) which is the inner layer of the pouch and (b) at least one ink-receiving layer as the outer layer deposited on the multilayer polymer film (a) from an aqueous coating composition including (b1) a polymeric binder, (b2) fine inorganic particles, and (b3) coarse inorganic and/or organic particles. Also provided is a method for producing the unprinted pouches on a pouch making machine as well as a method for printing the pouches, preferably in a single pass inkjet printing process. The printed pouch is ideal to be filled with food, pet food, beverages, pharmaceuticals and/or personal care products.