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Appropriate packaging to maintain the integrity of the packaging
The plastic in the microwave oven is polypropylene which has a relatively high heat tolerance so it is suitable for use as packaging for hot food as it has a relatively high melting point, between 146°C. The melting point exceeds the microwave temperature of 100°C and it is a type of plastic that is generally safe to reuse, or reheat many times. In general, there are three types of PP plastic that are often used every day, namely PP homopolymer, random copolymer PP, and block copolymer PP. Usually, PP homopolymer and block copolymer plastics are the two types most suitable for use at hot temperatures and are resistant to cold temperatures so they are suitable for use as frozen food packaging. However, the U.S. Food and Drug Administration (FDA) has deemed plastics labeled "microwave safe" suitable for microwave use. As far as
information that I can find no studies showing short or long term health effects from heating microwave safe plastics .https://www.youtube.com/watch?v=vVSEhRDu6rI&t=35s

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1.HDPE stands for High-Density Polyethylene is suitable packaging material to maintain freshness of fruits and vegetables and it's easy too environmentally friendly.

High-Density Polyethylene, which is a type of thermoplastic polymer. It is known for its high strength-to-density ratio and is commonly used for a variety of applications due to its durability, chemical resistance, and low moisture absorption properties.

Another advantage of HDPE is its low moisture absorption, which makes it resistant to moisture-related issues such as rotting, swelling, or warping. This property makes HDPE an excellent choice for products that require water or moisture resistance.

In addition to its physical properties, HDPE is also environmentally friendly. It can be recycled and reused multiple times, reducing its impact on the environment and promoting sustainability.

Overall, HDPE is a versatile and durable polymer that finds extensive use in various industries due to its excellent properties, such as strength, chemical resistance, low moisture absorption, and recyclability.

2. Mesh Bags

Mesh bags allow air circulation and are suitable for storing fruits like apples, oranges, and avocados. They help to reduce moisture accumulation and prevent

fruit from spoiling.

3. Paper-based packaging

Paper-based packaging can help maintain the freshness of fruits. Paper is a breathable material that allows some air circulation, which can prevent the buildup of moisture that can lead to mold and spoilage. Additionally, paper can also absorb excess moisture and help regulate the humidity around the fruit, which can extend its shelf life. However, it is important to note that the effectiveness of paper-based packaging in maintaining fruit freshness may vary depending on factors such as the type of fruit, packaging design, and storage conditions.

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How is HDPE manufactured?

HDPE is manufactured at low temperatures (70-300°C) and pressure (10-80 bar). It is derived from:

Either modifying natural gas (a methane, ethane, propane mix)

Or the catalytic cracking of crude oil into gasoline

Two major techniques to produce HDPE: Slurry Polymerization or Gas Phase Polymerization.

What are the properties of HDPE?

1.  HDPE Melting point: 120-140°C

2.  Density of HDPE: 0.93 to 0.97 g/cm³

3. Chemical resistance of HDPE:

Excellent resistance to most solvents

Very good resistance to alcohols, dilute acids and alkalis

Moderate resistance to oils and greases

Poor resistance to hydrocarbons (aliphatic, aromatic, halogenated)

4.  Continuous temperature: -50°C to +60°C, relatively stiff material with useful temperature capabilities

5.  Higher tensile strength compared to other forms of PE

6.  Low-cost polymer with good processability

7.  Good low-temperature resistance

8.  Excellent electrical insulating properties

9.  Very low water absorption

10.  FDA compliant

Some grades are designed for your specific requirements like environmental stress cracking resistance (ESCR), high stiffness, low shrinkage, UV stabilized, etc. Check out HDPE grades here »

TIP: In case you have specific requirements, try using the “key feature” facet to narrow down your search.

What are the disadvantages of HDPE?

Susceptible to stress cracking

Lower stiffness than polypropylene

High mold shrinkage

Poor UV- and low heat resistance

High-frequency welding and joining impossible

However, some grades have been smartly upgraded and offer some improved performance profiles.

What are the applications of HDPE?

Excellent combination of properties makes HDPE an ideal material in diverse applications across industries. Some of the major uses of HDPE include:

1.  Packaging Applications – HDPE is used in several packaging applications including crates, trays, bottles for milk and fruit juices, caps for food packaging, jerry cans, drums, industrial bulk containers etc. In such applications HDPE provides the end product a reasonable impact strength.

2.  Consumer Goods – Low cost and easy processability make HDPE a material of choice in several household/consumer goods like garbage containers, housewares, ice boxes, toys etc.

1.  Fibers and Textiles – Thanks to its high tensile strength, HDPE is widely used for agricultural applications, such as in ropes, fishing and sport nets, nets as well as industrial and decorative fabrics.

Other applications of HDPE include pipes and fittings (pipes for gas, water, sewage, drainage, sea outfalls, industrial application, cable protection, steel pipe coating, large inspection chambers and manholes for pipe sewage etc.) due to its excellent resistance to chemical and hydrolysis, automotive – fuel tanks, wiring & cables – sheeting of energy, telecommunication cables.

https://omnexus.specialchem.com/selection-guide/polyethylene-plastic

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What is PE?
Polyethylene or polythene is a type of polyolefin. It is often abbreviated as PE. The chemical formula of PE is (C ₂H ₄) n. It is lightweight, durable, and one of the most commonly produced plastic. Used for frozen food bags, bottles, cereal liners, yogurt containers, etc.

Look around you, all plastics with recycling codes 2 and 4 are made of PE. These plastics come with different crystalline structures.

Molecular Structure of PE

How is PE made?

How is PE made?
Polyethylene is made from the polymerization of ethylene (or ethene) monomer. The PE chains are produced by addition or radical polymerization. The possible synthesis methods are:

Ziegler-Natta Polymerization and

Metallocene catalysis

What are the common types of PE?

What are the common types of PE?
Depending on its density and branching, different PE grades can have very different performance from one another.

PE grades are therefore classified as follows.

Additionally, other types of PE are also available such as:

Medium-density polyethylene (MDPE)

Ultra low-density polyethylene (ULDPE)

High-molecular-weight polyethylene (HMWPE)

Metallocene polyethylene (mPE)

Chlorinated polyethylene (CPE)

Browse the largest online catalogue to select your PE grades

Also search directly for:

How to compare between the main PE types?

How to compare between the main PE types?

LDPE LLDPE HDPE

Polymer Full Name
Low Density Polyethylene

Linear Low Density Polyethylene

High Density Polyethylene

Structure
High degree of short chain branching + long chain branching

High degree of short chain branching

Linear (or Low degree of short chain branching)

Catalyst and process
Using radical polymerization using tubular method or autoclave method

Using Ziegler-Natta catalyst or metallocene catalyst

Ziegler-Natta catalyst in:
- Single-stage polymerization
- Multi-stage polymerization or a Cr or Phillips-type catalyst

Properties

See detailed property comparison: LDPE vs. LLDPE vs. HDPE

Density

0.910-0.925 g/cm ³

0.91-0.94 g/cm ³

0.941-0.965 g/cm ³

Crystallinity
Low crystalline and high amorphous (less than 50-60% crystalline)

Semi-crytalline, level between 35 to 60%

High crystalline and low amorphous (>90% crystalline)

Characteristics

Flexible and good transparency

Good moisture barrier properties

High impact strength at low temperature

Excellent resistance to acids, bases and vegetable oils

As compared to LDPE, it has:

higher tensile strength

higher impact and puncture resistance

Excellent chemical resistance

High tensile strength

Excellent moisture barrier properties

Hard to semi-flexible

Recycling Code

General Applications
Shrink wrap, films, squeezable bottles garbage bags, extrusion moldings, and laminates

High performance bags, cushioning films, tire separator films, industrial liners, elastic films, ice bags, bags for supplemental packaging and garbage bags

Molecular weight distribution is relatively narrow, has applications in injection moldings or flat yarns, and the latter type

Molecular weight distribution is wide, is used to make film products, hollow plastic products and pipes

Commercial Products
LDPE Grades

LLDPE Grades

HDPE Grades

Now when the basic distinction is clear, find out in detail about these 3 types of PE and see which one matches the best with your final application needs.

What is high density polyethylene (HDPE)?

What is high density polyethylene (HDPE)?
High Density Polyethylene (HDPE) is a cost-effective thermoplastic with a linear structure. It has no or low degree of branching. It is flexible, translucent/waxy, and weather resistant. The chemical structure of HDPE is:

HDPE is more rigid due to high crystallinity (> 90%). This also means it is less transparent than LDPE & LLDPE versions. HDPE also displays toughness at low temperatures.

How is HDPE manufactured?

HDPE is manufactured at low temperatures (70-300°C) and pressure (10-80 bar). It is derived from:

Either modifying natural gas (a methane, ethane, propane mix)

Or the catalytic cracking of crude oil into gasoline

Two major techniques to produce HDPE: Slurry Polymerization or Gas Phase Polymerization.

What are the properties of HDPE?

1. HDPE Melting point: 120-140°C

2. Density of HDPE: 0.93 to 0.97 g/cm³

3. Chemical resistance of HDPE:

Excellent resistance to most solvents

Very good resistance to alcohols, dilute acids and alkalis

Moderate resistance to oils and greases

Poor resistance to hydrocarbons (aliphatic, aromatic, halogenated)

4. Continuous temperature: -50°C to +60°C, relatively stiff material with useful temperature capabilities

5. Higher tensile strength compared to other forms of PE

6. Low-cost polymer with good processability

7. Good low-temperature resistance

8. Excellent electrical insulating properties

9. Very low water absorption

10. FDA compliant

Some grades are designed for your specific requirements like environmental stress cracking resistance (ESCR), high stiffness, low shrinkage, UV stabilized, etc. Check out HDPE grades here "
TIP: In case you have specific requirements, try using the "key feature" facet to narrow down your search.

What are the disadvantages of HDPE?

However, some grades have been smartly upgraded and offer some improved performance profiles.

What are the applications of HDPE?

Excellent combination of properties makes HDPE an ideal material in diverse applications across industries. Some of the major uses of HDPE include:

1. Packaging Applications - HDPE is used in several packaging applications including crates, trays, bottles for milk and fruit juices, caps for food packaging, jerry cans, drums, industrial bulk containers etc. In such applications HDPE provides the end product a reasonable impact strength.

2. Consumer Goods - Low cost and easy processability make HDPE a material of choice in several household/consumer goods like garbage containers, housewares, ice boxes, toys etc.

3. Fibers and Textiles - Thanks to its high tensile strength, HDPE is widely used for agricultural applications, such as in ropes, fishing and sport nets, nets as well as industrial and decorative fabrics.

Other applications of HDPE include pipes and fittings (pipes for gas, water, sewage, drainage, sea outfalls, industrial application, cable protection, steel pipe coating, large inspection chambers and manholes for pipe sewage etc.) due to its excellent resistance to chemical and hydrolysis, automotive - fuel tanks, wiring & cables - sheeting of energy, telecommunication cables.

What is low density polyethylene (LDPE)?

What is low density polyethylene (LDPE)?
Low-density Polyethylene (LDPE) is a semi-rigid polymer with low crystallinity (~50-60%). The LDPE is composed of 4,000-40,000 carbon atoms, with many short branches. Compared to HDPE, it has a higher degree of short and long side-chain branching. The chemical structure of LDPE is:

How is LDPE manufactured?

LDPE is produced at high pressure (1000-3000 bar) and temperature (80-300°C). It is derived via the free radical polymerization process.

Two basic processes to produce LDPE:

Stirred autoclave reactor

Tubular reactor

The tubular reactor has been gaining preference over the autoclave route due to its higher ethylene conversion rates.

What are the properties of LDPE?

1. LDPE Melting point: 105 to 115°C

2. Density of LDPE: 0.910-0.940 g/cm³

3. Chemical resistance of LDPE:

Good resistance to alcohols, dilute alkalis and acids

Limited resistance to aliphatic and aromatic hydrocarbons, mineral oils, oxidizing agents and halogenated hydrocarbons

4. Temperature resistance up to 80°C continuously and 95°C for shorter times.

5. Low cost polymer with good processability

6. High impact strength at low temperature, good weatherability

7. Excellent electrical insulating properties

8. Very low water absorption

9. FDA compliant

10. Transparent in thin film form

What are the disadvantages of LDPE?

The presence of more branching in polymer chain brings certain drawbacks to LDPE performance. Such as:

Susceptible to stress cracking

Low strength, stiffness and maximum service temperature. This limits its usage in applications requiring extreme temperatures.

High gas permeability, particularly carbon dioxide

Poor UV resistance

Highly flammable

High-frequency welding and joining impossible

To overcome these challenges, several LDPE grades have been developed with improved properties such as UV stabilized, high strength, antiblocking, etc. Check out LDPE grades here "

Tip: Do not forget to use "Key Features" filter to explore other optimized grades of LDPE

What are the applications of LDPE?

LDPE uses majorly revolve around manufacturing containers, dispensing bottles, wash bottles, tubing, plastic bags for computer components, and various molded laboratory equipments. The most popular application of LDPE is plastic bags.

1. Packaging - Thanks to its low cost and good flexibility, LDPE is used in packaging industry for pharmaceutical and squeeze bottles, caps and closures, tamper evident, liners, trash bags, films for food packaging (frozen, dry goods, etc.), laminations etc.

2. Pipes and Fittings - LDPE is used to manufacture water pipes and hoses for the pipes and fittings industry due to its plasticity and low water absorption.

Other applications include consumer goods - housewares, flexible toys, agricultural films,  wiring & cables - sub-conductor insulators, cable jacketing.

What is linear low-density polyethylene (LLDPE)?

What is linear low-density polyethylene (LLDPE)?
The structure of linear low-density polyethylene (LLDPE) has a linear backbone with short and uniform branches (unlike longer branches of LDPE). These short branches are able slide against each other upon elongation without becoming entangled like LPDE. It is structurally similar to LDPE.

How is LLDPE manufactured?

LLDPE is produced by the polymerization of ethylene (or ethane monomer) with:

1-butene, and

smaller amounts of 1-hexene and 1-octene.

This process occurs using Ziegler-Natta or metallocene catalysts. In the present-day scenario, LLDPE has been quite successful in replacing LDPE thanks to the below-mentioned properties.

What are properties of LLDPE?

Very flexible with high impact strength

Translucent and natural milky color

Excellent for mild and strong buffers, good chemical resistance

Good water vapor and alcohol barrier properties

Good stress crack and impact resistance

Some grades are designed for your specific requirements like good processability, antiblocking, antioxidant, etc. Check out LLDPE grades here "

TIP: In case you have specific requirements, try using the "key feature" facet to narrow down your search.

What are the applications of LLDPE?

LLDPE is suitable for a variety of film applications such as:

general-purpose film,

stretch film,

garment packaging,

agricultural film, etc.

While LLDPE can compete HDPE and LDPE in variety of applications, the below mentioned table can be useful to ease down your selection process among three PE types.

What is ultrahigh-molecular-weight polyethylene (UHMWPE)?

What is ultrahigh-molecular-weight polyethylene (UHMWPE)?
Ultrahigh-molecular-weight polyethylene has a molecular weight between 3.5 and 7.5 million amu. This is about 10 times higher than HDPE resins.

Both HDPE and UHMWPE have similar appearances. But UHMWPE is tough, abrasion-resistant, and low-cost plastic. Suitable for industrial or manufacturing applications where friction or wear may be a concern.

How is UHMWPE manufactured?

UHMWPE is synthesized using metallocene catalysts and ethane units. These units are bonded together resulting in UHMWPE structure. This structure has 100,000 to 250,000 monomer units per molecule.

What are the properties of UHMWPE?

It has excellent mechanical properties such as high abrasion resistance, impact strength and low coefficient of friction.

The material is almost totally inert, therefore it is used in the most corrosive or aggressive environments at moderate temperatures.

Even at high temperatures, it is resistant to several solvents, except aromatic, halogenated hydrocarbons and strong oxidizing materials, such as nitric acid.

These special properties allow the product to be used in several high-performance applications.

UHMWPE is suitable for high wear applications such as tubes, liners, silos, containers and other equipment.

Some grades are designed for your specific requirements like wear-, chemical-, and impact resistance, etc. Check out UHMWPE grades here "

TIP: In case you have specific requirements, try using the "key feature" facet to narrow down your search.

Cross-linked Polyethylene (PEX or XLPE)

Cross-linked Polyethylene (PEX or XLPE)
High-density crosslinked PE is a form of polyethylene with a crosslinked structure. It is abbreviated as PEX or XLPE. It is specifically designed for critical applications.

How is crosslinked PE manufactured?

Chemical storage pipework systems,

Hydronic radiant heating and cooling systems, and

Insulation for high voltage electrical cables.

What are the properties of XLPE?

High and low temperature

Hydrolysis resistance

High electrical and insulation properties

High abrasion resistance

Potable water approved

High extrusion speed on standard lines

Lower cost

Mechanically tougher

Some grades are designed for your specific requirements like environmental stress cracking resistance (ESCR), flame retarded, processability, creep resistance, etc. Check out XLPE grades here "

TIP: In case you have specific requirements, try using the "key feature" facet to narrow down your search.

What are the features of XLPE cables?

XLPE cables are by far the most popular and XLPE offer unlimited benefits in several electrical applications thanks to its moisture-resistance, stress resistance and higher protection against heat deformation vs other comparable power cables. Especially when comparing XLPE vs PVC cables, XLPE power cable has:

Much longer service life

Better heat resistance, XLPE power cable can typically stand up to 260°C

Has better tensile strength and impact resistance

Higher eligibility for higher rated current applications

Here is the list of all XLPE grades suited for wires and cables "

How to process PE plastic?

How to process PE plastic?
Various forms of Polyethylene can be used in processes like injection molding, blow molding, extrusion and various film creation processes such as calendaring or blown film extrusion.

HDPE can be easily processed by injection molding, extrusion (tubes, blow and cast films, cables, etc.), blow molding and rotomolding. Being and ideal material for injection molding process, it is majorly used for batch and continuous production.

The most common processing technique used for LDPE is extrusion (tubes, blow and cast films, cables...). LDPE can be processed by injection molding or rotomolding also.

UHMWPE is processed variously by compression molding, ram extrusion, gel spinning, and sintering. It conventional methods such as injection, blow or extrusion molding, because this material does not flow even at temperatures above its melting point.

PE (mainly HDPE) is gradually gaining popularity as a 3D Printing material. Its strength, low density, and non-toxicity make it ideal for a wide range of 3D printed objects. Additionally, recycled PE grades and bio-based PE are also used for processing by 3D Printing. The sheer availability of PE is encouraging efforts to apply this material for additive manufacturing.

HDPE LDPE

Injection Molding

Melt temperature: 200-300°C

Mold temperature: 10-80°C

Drying is not necessary if stored properly

High mold temperature will improve brilliance and appearance of the part

Mold shrinkage lies between 1.5 and 3%, depending on processing conditions, rheology of the polymer and thickness of the final piece

Melt temperature: 160-260°C

Post mold shrinkage lies between 1.5 and 3.5%

Material Injection Pressure: Up to 150 MPa

Extrusion

Melt temperature: 200-300°C

Compression Ratio: 3:1

Cylinder Temperatures: 180-205°C

Pre-Drying: No, 3 hours at 105-110 C (221-230°F) for regrind

Melt temperature: 180-240°C

Higher melt temperatures are needed for extrusion-coating (280-310°C)

A three zone screw with an L/D ratio of around 25 is recommended

Melt temperature: 160-260°C

Post mold shrinkage lies between 1.5 and 3.5%

Which type of PE is recyclable?

Which type of PE is recyclable?
Resin Identification Code for two main forms of PE are:

LDPE and HDPE are non-biodegradable in nature. They contribute significantly to the world's plastic waste products. Both forms of PE are recyclable. They are used to produce bottles for non-food items, plastics for outdoor applications, compost bins, etc.

View several recycled PE grade options available today "

PE (HDPE and XLPE) is widely used for water-related applications.

HDPE pipes are used for non-potable water applications. For potable water, HDPE can be used for both hot water and cold-water service applications.

Cross-linked PE has become popular for potable water in recent years, but PEX requires special fittings and is not recyclable.

Drive your R&D efforts faster and in the right direction with a clearer view on plastics recycling material advances ( volume resins, upcycling additives, recyclate compounds...) and applications (packaging, consumer goods, automotive...). Take this exclusive course by Industry Expert Donald Rosato.

Are PE resins toxic?

Are PE resins toxic? In solid form, Polyethylene is considered as safe and non-toxic in nature. They could be toxic if inhaled and/or absorbed as a vapor or liquid (i.e., during manufacturing processes).

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Polyethylene (PE Plastic) - Structure, Properties & Toxicity

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Get detailed technical information on Polyethylene (PE). Advantages & disadvantages, properties, features, uses and its applications. A complete updated guide.

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Polystyrene is a synthetic polymer made from the monomer styrene. It is a widely used plastic material known for its lightweight, rigid, and insulating properties. There are two main types of polystyrene:

1)Expanded Polystyrene (EPS)
-produced by expanding polystyrene beads using heat and pressure. It's used for various applications, including packaging, insulation, and even as a lightweight building material.

2)Extruded Polystyrene (XPS)
-created by extruding melted polystyrene and blowing agents through a shaping die. XPS is also used for insulation purposes, including in construction and as insulation for refrigeration and cold storage.

suggestion desingn
Develop a design that aligns with the brand's identity. Use colors, typography, and imagery that resonate with the brand message.
Resouse: https://www.researchgate.net/publication/237669763_Thermal_insulation_properties_of_expanded_polystyrene_as_construction_and_insulating_materials

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In my opinion , the best solution packaging for this cafe to keep the drink beverages hot and with affordable cost is thermal insulation box method . So here is why :

Thermal insulated box
usually made of polystyrene , glasswool , rockwool , plastic that securely and connected together to prevent damage due to temperature fluctuations during transportation .

Thermal insulation box works with guarantee a stable temperature to keep food or drink products still in their best first temperature when it be put in the thermal insulated box after hours and yes it is cost-effective . Natural , formaldehyde-free material also makes it eco-friendly packaging

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Insulated Box Liner & Pouch | Advanced Insulation for Cold Chain Shipping

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this video explained how the polystyrene are made. this show that styrofoam cup does a good job at keeping drinks hot. This is due to styrofoam being created from 95% air and the rest is from other good insulation properties. Air is considered a good tool for insulation. polystyrene also durable and resistant to water damage.

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How Styrofoam Cups Are Made! - Steam Culture

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How to Choose the Right Material for your Microwave Application

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Polyethylene Terephthalate (PET)

PET is the most commonly used plastic material for consumable bottled liquids, such as soft drinks and bottled water, condiments, and other food products. It’s also used extensively in rigid food packaging applications due to its attractive price point and excellent clarity. The typical operating temperature of PET maxes out around 160°F, while the typical microwave heats the food up to around 212 °F. As a result, this material is not recommended for microwave or high heat / hot-fill packaging and processing applications, as the presence of high heat can cause the material to warp or the package to melt. For this reason you will see a clear PET container at the salad bar and not at the soup counter. In addition, PET containers are meant for single use, and are not intended for applications where re-heating or re-use is a requirement.

Polypropylene (PP)
PP has a high heat tolerance, making it the ideal material for packaging hot food or foods that require microwaving. This is due to PP’s high melting point - PP’s operating temperature range goes up to 295°F, with a microwavable & hot fill temperature of up to approximately 260°F. In addition, PP materials are generally considered safe for re-use and can be re-heated - so for applications such as pre-made meals or takeout containers, this material is ideal.

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Remember when we wrote the blog, "When it Comes to Material Selection, Not All Plastics are Created Equal?" Well this sentiment is especially true when it comes to selecting materials for food packaging applications that will undergo high heat conditions such as the microwave. Throwing a plastic container in the microwave for a couple of minutes or even the act of pouring a hot soup into a container that is not intended to withstand high heat conditions could be enough to warp the container and damage the contents.

Advancements in polymer technology have extended the operating temperature range of plastic materials so that certain resins can now withstand colder and hotter conditions than ever before. However, during the product development stage, if there is a chance that the packaging could undergo high heat conditions such as the microwave, the temperature profiles of different resin materials should be considered to ensure that the packaging will maintain it's integrity and keep the food safe.

Polyethylene Terephthalate (PET)

PET is the most commonly used plastic material for consumable bottled liquids, such as soft drinks and bottled water, condiments, and other food products. It's also used extensively in rigid food packaging applications due to its attractive price point and excellent clarity. The typical operating temperature of PET maxes out around 160°F, while the typical microwave heats the food up to around 212 °F. As a result, this material is not recommended for microwave or high heat / hot-fill packaging and processing applications, as the presence of high heat can cause the material to warp or the package to melt. For this reason you will see a clear PET container at the salad bar and not at the soup counter. In addition, PET containers are meant for single use, and are not intended for applications where re-heating or re-use is a requirement.

Polypropylene (PP)

PP has a high heat tolerance, making it the ideal material for packaging hot food or foods that require microwaving. This is due to PP's high melting point - PP's operating temperature range goes up to 295°F, with a microwavable & hot fill temperature of up to approximately 260°F. In addition, PP materials are generally considered safe for re-use and can be re-heated - so for applications such as pre-made meals or takeout containers, this material is ideal.

It is important to note, however, which grade of PP you plan to use. There are three main grades of PP resin used today - homopolymer, random copolymer, and block (or impact) copolymer. Typically, homopolymer and block copolymer PP resins are better suited for high heat applications than a random copolymer. Furthermore, if the intention of the packaging is to go from a freezer to a microwave, a block copolymer will give the packaging better impact resistance a low temperatures than a homopolymer, ensuring that the packaging will not crack.
Click here to learn more about the three main grades of polypropylene in our blog post!
In food packaging, PP has typically been reserved for hot applications as its natural, milky or hazy appearance, is not ideal for applications that require consumer appeal. This has change, however, with the introduction of UltraClear Polypropylene , which allows for versatility among hot and cold applications without having to compromise on aesthetics.

Mineral Filled PP

Filled PP sheet products such as calcium carbonate filled polypropylene sheet or talc filled polypropylene sheet are commonly used in food packaging applications because the addition of mineral fillers allows this material to better combat temperature changes. The incorporation of both calcium carbonate and talc to this material results in an increased resistance to heat and better cooling characteristics. In addition, studies have shown calcium carbonate mineral filler to have increased success at higher loading levels. Impact Plastics has extrusion systems in place for mineral filler blending and has the capability to produce sheet with a mineral filler loading up to 40%.
Polystyrene (PS)
PS is seen most often in Styrofoam cups and meat trays, and in rigid packaging applications. The operating temperature of this material maxes out at around 185°F. As noted above, the typical microwave heats a food product up to around 212 °F. So while PS should not be put in the microwave, the maximum operating temperature suggests that this material can withstand a slightly lower heat than that of a microwave. However, it is important to note that if a hot item does come in a PS packaging, it is likely only intended for single-use only.

Impact Plastics recommends that our customers complete testing of all materials to ensure that the material meets the desired requirements of their application. To learn more about how our products can work with your application, click on the link to the left to talk to our team today !

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How to Choose the Right Material for your Microwave Application

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Not all plastic sheet can take the heat. Learn more about the temperature limitations of popular food packaging materials.

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smart packaging for checking the freshness of fruit

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SMART PACKAGING DESIGN

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1. Microwave-Safe Polyethylene Trays: Manufacturers can use specially designed polyethylene trays that are safe for microwave use. These trays can be designed with features like venting systems or microwave-safe coatings to ensure even cooking while maintaining the integrity of the packaging.

2. Dual-Layer Packaging: Create packaging with a dual-layer design, where the outer layer is made of regular polyethylene for strength and durability, while the inner layer is made of microwave-safe polyethylene. This way, the outer layer provides protection and stability, while the inner layer can handle the microwave heating.

3. Microwaveable Sealable Bags: For smaller frozen items, such as vegetables or single servings, manufacturers could create microwave-safe polyethylene bags with a resealable closure. These bags would need to be designed with proper venting mechanisms to release steam during microwave heating.

4. Steam Venting Lids: If the frozen meals are packaged in containers with lids, manufacturers can design lids with built-in steam vents. These vents release excess steam during microwave cooking, preventing the buildup of pressure while still keeping the contents contained.

5. Foldable Polyethylene Pouches:For items that require minimal cooking time, foldable polyethylene pouches with airtight seals can be designed. These pouches are easy to open, heat, and serve from, making them convenient for consumers.

6. Microwave-Safe Polyethylene Wraps:

For items that need to be wrapped, manufacturers could create microwave-safe polyethylene wraps that securely enclose the frozen meal while allowing steam to escape during cooking.

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If we look at the plastics identification codes, microwaveable packaging is classified as number 2 – high–density polyethylene –, and number 5 – polypropylene. It is important to avoid number 7 – mixture of other plastics – due to the danger of them releasing substances such as Bisphenol A.

https://www.spg-pack.com/en/blog/what-are-the-requirements-for-microwaveable-plastic-packaging/

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What Food Containers are Microwavable? (farah case 2)

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What Food Containers are Microwavable? (farah case 2)

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https://youtu.be/XK-z13XB6UY

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Polystyrene

Polystyrene is a synthetic polymer made from the monomer styrene. It is commonly used in the production of foam materials, such as Styrofoam, which are used for insulation, packaging, and various other applications.

There are two main types of polystyrene:

General-Purpose Polystyrene (GPPS): This type is transparent, rigid, and brittle. It is often used for products like disposable cutlery, CD cases, and cosmetic packaging.

High-Impact Polystyrene (HIPS): HIPS is tougher and more impact-resistant due to the addition of a rubbery material during its production. It is used in products like refrigerator liners, toys, and packaging materials.

Both types of polystyrene have various applications based on their properties and characteristics.

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What Food Containers are Microwavable?

https://youtu.be/XK-z13XB6UY

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Polystyrene

Polystyrene is a synthetic polymer made from the monomer styrene. It is commonly used in the production of foam materials, such as Styrofoam, which are used for insulation, packaging, and various other applications.

There are two main types of polystyrene:

General-Purpose Polystyrene (GPPS): This type is transparent, rigid, and brittle. It is often used for products like disposable cutlery, CD cases, and cosmetic packaging.

High-Impact Polystyrene (HIPS): HIPS is tougher and more impact-resistant due to the addition of a rubbery material during its production. It is used in products like refrigerator liners, toys, and packaging materials.

Both types of polystyrene have various applications based on their properties and characteristics.

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Design Packaging for plastic bags and shrink wrap

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PP has a high heat tolerance, making it the ideal material for packaging hot food or foods that require microwaving. This is due to PP’s high melting point - PP’s operating temperature range goes up to 295°F, with a microwavable & hot fill temperature of up to approximately 260°F. In addition, PP materials are generally considered safe for re-use and can be re-heated - so for applications such as pre-made meals or takeout containers, this material is ideal.

Choosing the right material for a microwave application involves considering factors like dielectric properties, thermal conductivity, and mechanical stability. Look for materials with low loss tangent and high permittivity for efficient signal transmission. Additionally, ensure the material can handle the temperatures generated during microwave operation and offers good mechanical strength. Conduct thorough testing and simulations to verify the material's suitability for your specific application.

https://blog.impactplastics.co/blog/how-to-choose-the-right-plastic-sheet-for-your-microwave-application#:~:text=Polypropylene%20(PP),to%20approximately%20260%C2%B0F.

Polypropylene containers are freezer and microwave-safe, and they are perfect for heat-and-eat applications, shelf life extension, deep-freeze applications, and more. They are available in high barrier (EVOH/PP) varieties and soft copolymer options to prevent cracking when exposed to extreme cold. Polypropylene containers come in colorless, black, white, and custom prints, and they are available in a range of standard or customized designs.

Depending on the type of polypropylene container you choose, they can withstand temperatures ranging from 37° F to 212F (3° C to 100° C) or -40° F to 257° F (-40° C to 125° C) with deep freeze material. Common applications include soups, seafood, poultry, meat, dips, and frozen foods.

https://www.p5pkg.com/frozen-food-packaging/#:~:text=Polypropylene%20containers%20are%20freezer%20and,when%20exposed%20to%20extreme%20cold.

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Plastics

HDPE, LDPE, and Polypropylene are the most common plastics used for making frozen food packaging. These types of plastic can withstand a wide range of temperatures, making them perfect to store perishable goods like groceries or meats. They also prevent them from being damaged by outside elements during transportation to and from the grocery store.

PE

Polyethylene (PE) films are a good choice for food distribution during transportation, handling, and storage. Not only do they offer significant resistance to low-temperature conditions like -40 degrees Fahrenheit but also provide high mechanical strength with puncture capability during cold weather seasons.

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Frozen food packaging must prioritize food quality and safety. And that begins with selecting the proper substrates.

Your packaging materials have to keep food fresh while remaining leak proof and durable. Plus, they must be grease resistant and able to tolerate extreme temperature changes.

Fortunately, there are several food packaging options available that help frozen food brands meet a variety of other business goals, including sustainability.

Frozen Food Packaging Materials

From petroleum-based products such as shrink wrap and individually quick frozen (IQF) polyethylene to cardboard and aluminum, frozen food packaging comes in a wide variety of materials. While some are more sustainable than others, each has its benefits.

Let's consider a few of the more common substrate options.

Coated Natural Kraft (CNK) Paperboard

Reinforced with a coating to preserve the integrity of food against the wear and tear of the thawing process, CNK paperboard is a hardy but adaptable substrate. CNK is constructed from softwood fibers that provide superior strength and protection, whether products are refrigerated or frozen.

Its surface layer consists of hardwood fibers and clay-based coating that's optimal for printing. CNK's burnished, glossy surface is ideal for sophisticated graphic designs and decorative effects whose integrity won't be compromised by exposure to extreme temperature changes or condensation.

CNK's low-caliper construction enables it to retain rigid shape at lower weight than similar substrates-thus reducing cost.

If you're looking for a material whose structure is wildly adaptable, CNK is a great choice. It can easily accommodate windowing and other advanced custom designs.

Solid Bleached Sulfate (SBS) Paperboard

Consisting of a whitened chemical pulp derived from virgin timber, SBS is a medium-density material option well suited for printing. Like CNK, it is clay coated to preserve the integrity of both the food and packaging.

SBS also has the advantage of accommodating embossing, foil stamping, and creasing while withstanding extremely cold freezer temperatures. Their eye-catching visual designs help these products stand out in the frozen food section.

Poly-Coated Paperboard

For products that require direct contact with food and a grease barrier, poly-coated substrates are very effective. They are a popular food packaging choice because they're also heat resistant, a much sought-after feature for microwaved products.

Notably, poly-coated paperboard is not recyclable, which gives environmentally conscious brands some reason to pause when considering it as a frozen food packaging material.

Other materials for frozen food packaging include shrink wrap and aluminum.

Shrink wrap is a heat-sealed film that quickly covers and protects a product. It's worth noting shrink wrap is petroleum based. If you're an environmentally friendly brand, you may want to consider other more renewable alternatives, if not at least being judicious with how much shrink wrap you use in frozen food packaging.

Frequently formatted as trays for frozen food, aluminum is often used to package casserole dishes, lasagna, and complete meals. Aluminum is considered food-grade material by the U.S. Department of Agriculture, as well. It has the added benefit of recyclability, however, that requires cleaning residual food off the aluminum before recycling, which some consumers may not be willing to do.

Sustainability in Frozen Food Packaging

Put simply, more consumers are looking for food brands that help them make sustainable purchases. According to an October 2021 report from marketing insights resource Think With Google, 82% of consumers place a high priority on sustainability.

So what does that mean for frozen food packaging?

In addition to practicing right-size packaging principles, localizing supply chains, and limiting their carbon footprint, frozen food brands can achieve their sustainability goals by implementing a few sustainable substrate alternatives into their packaging solutions.

Post-Consumer Recycled Paperboard

By integrating post-consumer recycled paperboard into packaging (and signifying it on the label), you communicate to consumers your commitment to sustainability while enjoying the packaging benefits of paperboard.

Bio-Polymers

Biodegradable protein alternatives, such as casein, are sustainable and many magnitudes greater at keeping out oxygen and other contaminants compared to petroleum-based plastic wraps. They are extracted from biomass and synthesized, providing brands with a sustainable option that avoids the landfill.

Your food stays fresh longer while reinforcing your brand as a leader in sustainability.

Working With an SQF-Certified Packaging Manufacturer

Some food printing and packaging manufacturers are more committed to food safety than others. To be confident your packaging partner maintains the highest global health and safety standards, collaborate with one that is Safe Quality Food (SQF) certified.

Recognized by the Global Food Safety Initiative (GFSI), the SQF certification accounts for everything relating to industry, customer, and regulatory requirements and entails every aspect of the supply chain.

SQF safety categories include primary production, food retail, manufacturing, food packaging, storage and distribution, and quality.

Ultimately, there are many packaging solutions available, which can be rather daunting.

So, whether your brand emphasizes sustainability or goes a more traditional, frozen food packaging route, you'll want to consult an experienced printing and packaging partner. They'll ensure you combine the proper blend of substrates, adhesives, and decorative effects capable of withstanding extreme temperature changes, condensation, and a variety of storing conditions.

Oliver is an SQF-certified printing and packaging company with more than 250 years of combined experience across multiple industries. Contact us today to learn more about which frozen food packaging solutions are right for your brand.

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What Materials Are Used in Frozen Food Packaging?

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In addition to coated natural kraft paperboard, shrink wrap, wax-coated cardboard, aluminum, and solid bleached sulfate paperboard, several biodegradable and sustainable materials are available for frozen food packaging.

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This slide explained types of packaging materials for fruits and vegetables

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There two types of Polyethylene which is HDPE and LDPE :
HDPE :
It is one of the world’s most versatile plastics. As such, petroleum features in an impressive variety of applications. When it comes to food packaging, you can find this jack-of-all-trades plastic in your:
-Freezer bags
-Juice bottles
-Pouches & sachets
You can also find HDPE in products like water bottles, margarine and butter tubs, and box liners. Its high impact resistance and melting point are part of what make HDPE plastics so popular.

LDPE :
LDPE is a great material for a wide range of manufacturing applications. Manufacturers often use it to create various containers, wash, and dispense bottles, plastic computer parts, and molded lab equipment. However, this highly durable material is also a valuable asset in the creation of numerous types of food packaging. For example
-Squeeze bottles
-Cling and shrink wraps
-Pouches and plastic fruit cups
You can also find LDPE in bread and frozen foods packaging and flexible lids. In short, it’s a very versatile plastic that you can use for various purposes.

https://capitalresin.com/7-types-of-plastic-used-in-food-packaging/

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Breathable packaging film using polyethylene film

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It is very demanding to store and cut flowers due to continuous biological metabolism. To keep vegetables and fruits fresh, packaging film are used. This video explained the way the company want to developed the breathable packaging film. This packaging film have micro holes either one side or both by controlling air permeability. This packaging is also reusable

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1. The suitable packaging material to retain the freshness of fruits and vegetables also being environmentally friendly

High Density Polyethlene (HDPE)
By preventing moisture loss and reducing exposure to outside contaminants, HDPE is known for its excellent moisture barrier characteristics, which aid in maintaining the freshness of fruits and vegetables. Compared to certain other polymers, HDPE is considered to be much more environmentally friendly. It can be recycled, and a lot of recycling facilities will take HDPE materials.
-https://www.p5pkg.com/blog/types-of-plastic-food-packaging/#:~:text=HDPE%20is%20the%20most%20widely,needs%20to%20hold%20its%20shape
-https://www.azocleantech.com/article.aspx?ArticleID=255

2. Design packaging that can be recommend to overcome the problem

1. Consider using reusable and refillable packaging
- Reusable or refillable packaging, which allows for multiple uses of the product, is a consideration when designing environmentally friendly packaging. From this, consumer are able to pick the fresh produce for the next shopping without having to use the in store plastic which are not recyclable. -https://www.linkedin.com/advice/0/what-some-best-practices-eco-friendly-packaging-design

2. Provide a smart packaging design
-These innovative sensing systems typically monitor the production of gas, humidity, temperature, and microorganism growth in packaged food. For example, manufacture can stick a freshness detector sticker on fruits or vegetables to see the level of freshness. From this,consumer will become aware of the freshness.
-https://pubs.acs.org/doi/10.1021/acssensors.9b00440
-https://www.indiatimes.com/technology/news/smart-packaging-invention-harvard-nanyang-558145.html
-https://youtu.be/d0hz5ArpI2k

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Color Changing Smart Labels - Freshness Indicator in Food Packaging

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Case Study 3: Polystyrene (PS) - Insulating Hot Beverages                                                             Scenario: A café chain is looking for a packaging solution for their hot beverages, such as coffee and tea, that keeps the drinks hot while also being cost-effective.              

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Case Study 3: Polystyrene (PS) - Insulating Hot Beverages                                                             Scenario: A café chain is looking for a packaging solution for their hot beverages, such as coffee and tea, that keeps the drinks hot while also being cost-effective.              

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Case Study 2: Polypropylene (PP) - Microwavable Convenience Scenario: A frozen food manufacturer wants to create packaging that allows consumers to easily microwave their frozen meals while maintaining the integrity of the packaging.        

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Case Study 2: Polypropylene (PP) - Microwavable Convenience Scenario: A frozen food manufacturer wants to create packaging that allows consumers to easily microwave their frozen meals while maintaining the integrity of the packaging.        

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Case Study 1: Polyethylene (PE) - The Versatile Barrier              Scenario: A food company is looking to package its fresh produce, specifically fruits and vegetables, in a way that maintains their freshness while also being environmentally friendly.                      

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Case Study 1: Polyethylene (PE) - The Versatile Barrier              Scenario: A food company is looking to package its fresh produce, specifically fruits and vegetables, in a way that maintains their freshness while also being environmentally friendly.                      