CROSS-REFERENCE TO RELATED APPLICATIONS

[0001 ] The present application claims priority to U.S. Provisional Patent Application No. 63/407,585, which was filed September 16, 2022, the content of which is incorporated herein by reference in their entirety.

FIELD

[0002] The present application is in the field of polymeric films. More specifically, the present application relates to polymeric film compositions comprising bio-based and/or post-consumer recycled (PCR) resins and bags made thereof.

BACKGROUND

[0003] Packaging is instrumental in protecting food items, extending their shelf life and reducing food waste. For baked goods such as breads, bagels, English muffins, flatbreads (such as tortillas, wraps and naan breads), and fresh produce such as carrots, potatoes, apples, among others, polyethylene (PE) films and/or bags are the best packaging material, not only because they consume the least resources during manufacturing, but also by accounting for a minimal portion of the overall carbon footprint of the product. Furthermore, they help prevent food waste, which is a much larger contributor to climate change than the plastic bag itself.

[0004] During the past decade, climate change has become a major concern and priority for policy makers worldwide. People are more and more aware of the impacts of global warming. Greenhouse gas (GHG) emissions are now being measured and controlled by many industries and governments. At the consumer level, people are looking at ways to reduce their individual carbon footprint. More recently, many countries, cities, businesses and other organizations have made net-zero commitments to reduce their greenhouse gas emissions to as close to zero as possible.

[0005] As companies look for ways to minimize their environmental impact, they examine every step of the supply chain. Some companies have opted to offset emissions via the purchase of carbon credits (carbon offsetting), but there is a clear need to provide packaging solutions that generate lower or zero GHG emissions to help organizations reach their goals, while maintaining the performance of the packaging operations, shelf life and recyclability.

[0006] Many resin producers have been working to develop more sustainable materials and production processes to reduce their carbon footprint and fossil fuel usage. Some examples of this are bio-based and post-consumer recycled (PCR) resins. Bio-based plastics offer lower carbon footprint than traditional fossil-based plastics, they are produced from renewable sources and contribute to the circular economy. Bio-based polyethylene resins were initially produced from com, sugar cane and other food sources, but second-generation bio-resins are produced from waste byproducts from the forestry industry, used cooking oil, or other vegetable oil refinery wastes, and carry a negative carbon footprint, avoiding the conflict of food supply chain for human or animals. Post-consumer recycled (PCR) resins have been growing in use over the past several years and offer a lower carbon footprint than traditional resins while embracing the principles of the circular economy.

[0007] The use of PCR and bio-based resins has been previously considered mainly to reduce the use of fossil-based resins, but there is a need to go even further and develop a methodology to incorporate bio-based PE resins and/or recycled PE content in the packaging structure to create packaging solutions that generate zero greenhouse gas emissions (carbon neutral), and could even be carbon negative, without the need of further carbon offsetting.

[0008] As such, there is need to provide improved PE films and bags made thereof presenting a reduced carbon footprint.

SUMMARY

[0009] It has been advantageously shown herein that polymer compositions of the present application provide products with a reduced carbon footprint. The processes of the present application further provide for polymer composition having a reduced carbon footprint.

[0010] Accordingly, the present application includes a multilayered polyethylene polymer composition comprising: a first layer comprising about 60% to about 90% w/w of polymer A, about 10% to about 40% w/w of polymer B, a second layer comprising about 60% to about 90% w/w of polymer A and/or polymer C, about 10% to about 40% w/w of polymer B optionally at least one additional layer comprising about 60% to about 90% w/w of polymer A, about 10% to about 40% w/w of polymer B wherein the multilayered polyethylene polymer composition has a thickness of about 0.80 mil to about 5.0 mil; and wherein the polymer A is selected from linear low-density polyethylene (LLDPE); the polymer B is selected from low density polyethylene (LDPE); and the polymer C is selected from high density polyethylene (HDPE).

[0011 ] Also included is a polymeric film or sheet comprising the multilayered polyethylene polymer composition of the present application.

[0012] The present application further includes a process for manufacturing the multilayered polyethylene polymer composition, comprising blending polymers of each layer in desired proportions on different layer structures, coextruding the layers into multilayered polyethylene polymer composition.

[0013] Also included is use of the multilayered polyethylene polymer composition or the polymeric film or sheet of the present application in the preparation of plastic material and/or plastic packaging.

[0014] Further provided is use of the multilayered polyethylene polymer composition or the polymeric film or sheet of the present application in the manufacture or preparation of food packaging.

[0015] Also provided is use of the multilayered polyethylene polymer composition or the polymeric film or sheet of the present application in the manufacture or preparation of baked goods packaging. [0016] Further included is use of the multilayered polyethylene polymer composition or the polymeric film or sheet of the present application in the manufacture or preparation of fresh produce packaging.

[0017] A food packaging comprising the multilayered polyethylene polymer composition or the polymer film or sheet of the present application is also included.

[0018] A baked good packaging comprising the multilayered polyethylene polymer composition or the polymer film or sheet of the present application is also included.

[0019] A fresh produce packaging comprising the multilayered polyethylene polymer composition or the polymer film or sheet of the present application is also provided.

[0020] The present application also includes a method of producing carbon negative or carbon neutral plastic material and/or plastic packaging from cradle-to- customer comprising incorporating the multilayered polyethylene polymer composition or the polymer film or sheet of the present application in the plastic material and/or plastic packaging.

[0021 ] The present application further includes a method for reducing the carbon footprint of a polyethylene polymer composition manufacturing process to carbon neutral or carbon negative, comprising: determining the overall Greenhouse Gas Emissions (GHG) of an existing polyethylene polymer composition manufacturing process; selecting polymers to be replaced in the existing polyethylene polymer composition manufacturing process; determining raw materials and proportions of the raw materials to replace the selected polymers in order to reduce the overall GHG to zero or negative while maintaining desired properties of the polyethylene polymer composition.

[0022] A polyethylene polymer composition obtained by the method of the application is also included. [0023] Other features and advantages of the present application will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating embodiments of the application, are given by way of illustration only and the scope of the claims should not be limited by these embodiments, but should be given the broadest interpretation consistent with the description as a whole.

BRIEF DESCRIPTION OF DRAWINGS

[0024] The embodiments of the application will now be described in greater detail with reference to the attached drawings in which:

[0025] FIG.1 shows a wicket bag for baked goods packaging, according to exemplary embodiments of the application.

[0026] FIG.2 shows a flow diagram for an extrusion process flow, according to exemplary embodiments of the application.

[0027] FIG.3 shows a flow diagram for a supply chain of wicket bags delivered to customers in the US and Canada, according to exemplary embodiments of the application.

[0028] FIG.4 shows a flow diagram for a flexographic printing process flow, according to exemplary embodiments of the application.

[0029] FIG.5 shows a flow diagram for a bag making process flow, according to exemplary embodiments of the application.

DETAILED DESCRIPTION

I. Definitions

[0030] Unless otherwise indicated, the definitions and embodiments described in this and other sections are intended to be applicable to all embodiments and aspects of the present application herein described for which they are suitable as would be understood by a person skilled in the art.

[0031 ] As used in this application and claim(s), the words "comprising" (and any form of comprising, such as "comprise" and "comprises"), "having" (and any form of having, such as "have" and "has"), "including" (and any form of including, such as "include" and "includes") or "containing" (and any form of containing, such as "contain" and "contains"), are inclusive or open-ended and do not exclude additional, unrecited elements or process steps.

[0032] The term “consisting” and its derivatives as used herein are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, and also exclude the presence of other unstated features, elements, components, groups, integers and/or steps.

[0033] The term “consisting essentially of’, as used herein, is intended to specify the presence of the stated features, elements, components, groups, integers, and/or steps as well as those that do not materially affect the basic and novel characteristic(s) of these features, elements, components, groups, integers, and/or steps.

[0034] The terms "about", “substantially” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies or unless the context suggests otherwise to a person skilled in the art.

[0035] As used in the present application, the singular forms “a”, “an” and “the” include plural references unless the content clearly dictates otherwise. For example, an embodiment including “a component” should be understood to present certain aspects with one component, or two or more additional components.

[0036] In embodiments comprising an “additional” or “second” component, such as an additional or second compound, the second component as used herein is chemically different from the other components or first component. A “third” component is different from the other, first, and second components, and further enumerated or “additional” components are similarly different.

[0037] The term “and/or” as used herein means that the listed items are present, or used, individually or in combination. In effect, this term means that “at least one of” or “one or more” of the listed items is used or present. [0038] The term “composition of the application” or “composition of the present application” and the like as used herein refers to a composition comprising one or more components of the application.

[0039] The term “suitable” as used herein means that the selection of the particular composition or conditions would depend on the specific steps to be performed, the identity of the components to be transformed and/or the specific use for the compositions, but the selection would be well within the skill of a person trained in the art.

[0040] The term “carbon neutral” as used herein refers to a current state which is achieved when the Greenhouse gas (GHG) emissions associated with an entity, product or activity are reduced and offset to zero or substantially zero for a defined duration.

[0041 ] The term “cradle-to-consumer” as used herein refers to a particular boundary for product subjects, including the extraction and processing of raw materials (including any packaging materials), manufacture, storage, and distribution to first customer.

II. Polymer Compositions of the Application

[0042] It has been advantageously shown herein that polymer compositions of the present application provide for a reduced carbon footprint, such as zero or negative carbon footprint from cradle-to-customer. The processes of the present application further provide for polymer composition having a reduced carbon footprint, such as zero or negative carbon footprint from cradle-to-customer.

[0043] Accordingly, the present application includes a multilayered polymer composition comprising: a first layer comprising about 60% to about 90% w/w of polymer A, about 10% to about 40% w/w of polymer B, a second layer comprising about 60% to about 90% w/w of polymer A and/or polymer C, about 10% to about 40% w/w of polymer B, optionally at least one additional layer comprising about 60% to about 90% w/w of polymer A, about 10% to about 40% w/w of polymer B, and wherein the multilayered polymer composition has a thickness of about 0.80 mil to about 5.0 mil. [0044] In some embodiments, the multilayered polymer composition comprises three layers. In some embodiments, the multilayered polymer composition comprises five layers. In some embodiments, the multilayered polymer composition comprises seven layers.

[0045] In some embodiments, the polymer A is selected from linear low-density polyethylene (LLDPE).

[0046] In some embodiments, the polymer B is selected from low density polyethylene (LDPE).

[0047] In some embodiments, the polymer C is selected from high density polyethylene (HDPE).

[0048] The present application further includes a multilayered polyethylene polymer composition comprising: a first layer comprising about 60% to about 90% w/w of polymer A, about 10% to about 40% w/w of polymer B, a second layer comprising about 60% to about 90% w/w of polymer A and/or polymer C, about 10% to about 40% w/w of polymer B optionally at least one additional layer comprising about 60% to about 90% w/w of polymer A, about 10% to about 40% w/w of polymer B wherein the multilayered polymer composition has a thickness of about 0.80 mil to about 5.0 mil; and wherein the polymer A is selected from linear low-density polyethylene (LLDPE); the polymer B is selected from low density polyethylene (LDPE); and the polymer C is selected from high density polyethylene (HDPE).

[0049] In some embodiments, about 30% to about 100% w/w of polymer A, B and/or C are bio-based and/or recycled polymers. In some embodiments, about 30% to about 90% w/w of polymer A, B and/or C are bio-based and/or recycled polymers. In some embodiments, about 50% to about 75% w/w of polymer A, B and/or C are biobased and/or recycled polymers. [0050] In some embodiments, the multilayered polymer composition has an Elmendorf tear strength of about 40g to about 450 g measured in machine direction. In some embodiments, the multilayered polymer composition has an Elmendorf tear strength of about 40g to about 300 g measured in machine direction. In some embodiments, the multilayered polymer composition has an Elmendorf tear strength of about 300g to about 1 ,600 g measured in transverse direction. In some embodiments, the multilayered polymer composition has an Elmendorf tear strength of about 350g to about 900 g measured in transverse direction.

[0051 ] In some embodiments, the multilayered polymer composition has a break strength of about 3,000psi to about 6,250psi measured in machine direction. In some embodiments, the multilayered polymer composition has a break strength of about 3,500psi to about 4,500psi measured in machine direction. In some embodiments, the multilayered polymer composition has a break strength of about 2,500psi to about 5,000psi measured in transverse direction. In some embodiments, the multilayered polymer composition has a break strength of about 2,500psi to about 4,000psi measured in transverse direction.

[0052] In some embodiments, the multilayered polymer composition has an elongation at break of about 300% to about 800% measured in machine direction. In some embodiments, the multilayered polymer composition has an elongation at break of about 350% to about 700% measured in machine direction. In some embodiments, the multilayered polymer composition has an elongation at break of about 400% to about 900% measured in transverse direction. In some embodiments, the multilayered polymer composition has an elongation at break of about 450% to about 750% measured in transverse direction.

[0053] In some embodiments, the multilayered polymer composition has a dynamic coefficient of friction of about 0.1 to about 0.3.

[0054] In some embodiments, the multilayered polymer composition has a water vapor transmission rate (WVTR) at 38°C of about 0.6 g.100in’ ² .day ¹ to about 1.5 g.100in’ ² .day ¹ . [0055] The multilayered polymer composition of any one of claims 1 to 17, having an oxygen transmission rate (OTR) at 23°C of about 300 Cc.100in’ ² .day ¹ to about 900 Cc.100in’ ² .day ¹ .

[0056] In some embodiments, a carbon footprint for manufacturing the multilayered polymer composition of the application is carbon neutral.

[0057] The present application further includes a polymeric film or sheet comprising the multilayered polymer composition of the present application.

[0058] Without being bound to theory, the above-mentioned properties are considered to be required to produce packaging for applications such as baked goods and fresh produce. In such applications, there is a need to provide strong film capable of withstanding automatic filling operations, where high speed packing and filling machines are generally used. For example, if the coefficient of friction is too high, then line speeds would be affected. Furthermore, good break/tear strength are required as many baked items have toppings such as seeds and grains with sharp edges that could puncture the film and compromise the integrity of the product. Also, for produce packaging for items such as potatoes, apples and carrots, the film needs to be strong enough to contain 2kg or more of product without breaking/tearing. Predetermined WVTR (water vapor transmission rate) and OTR (oxygen transmission rate) are thus desired to provide the required barrier properties of the film to guarantee a specific shelf-life for the target application.

[0059] Again without being bound to theory, seal strength of a packaging is also a key feature and could be negatively affected by a low tear strength. If the seal is not strong enough, then this could lead to holes in the film and bag, which could compromise the food safety, barrier properties and shelf-life of the product. Consumers also expect to clearly see the products and low haze is preferred, as well as gloss of at least 50 for the product to catch consumers’ attention and stand out on the shelf. A skilled person in the art would appreciate that specific properties of a packaging are desired and will depend on the starting materials (raw materials) used to produce the polymer composition from which the packaging is composed. As such, determining the nature of the starting materials and their proportions is crucial in obtaining predetermined desired properties of a polymer composition.

III. Methods and Uses of the Application

[0060] The multilayered polymer composition of the present application may be use for preparing a polymeric film or sheet. The multilayered polymer composition of the present application may be use for preparing a wicket bag. The multilayered polymer composition of the present application may be use for food packaging. The multilayered polymer composition of the present application may be use for packaging baked goods and fresh produce.

[0061 ] The present application further includes use of the multilayered polymer composition or the polymeric film or sheet in the preparation of plastic material and/or plastic packaging.

[0062] Further included is the use of the multilayered polymer composition or the polymer film or sheet of the present application in the manufacture or preparation of food packaging.

[0063] Also provided is the use of the multilayered polymer composition or the polymer film or sheet of the present application in the manufacture or preparation of baked goods packaging.

[0064] Also provided is the use of the multilayered polymer composition or the polymer film or sheet of the present application in the manufacture or preparation of fresh produce packaging.

[0065] A food packaging comprising the multilayered polymer composition or the polymer film or sheet of the present application is also included.

[0066] The present application also includes a baked good packaging comprising the multilayered polymer composition or the polymer film of the present application.

[0067] In some embodiments, the baked goods are selected from bread, bagel, English muffin, flatbread, tortillas, wraps and naan bread. [0068] In some embodiments, fresh produce are selected from potatoes, apples and carrots.

[0069] The present application also includes a method of producing carbon neutral or carbon negative plastic material and/or plastic packaging comprising incorporating the multilayered polymer composition or the polymer film or sheet of the present application in the plastic material and/or plastic packaging.

[0070] The present application also includes a method for reducing the carbon footprint to carbon neutral or carbon negative of a polyethylene polymer composition manufacturing process, comprising: determining the overall Greenhouse Gas (GHG) Emissions of an existing polymer composition manufacturing process; selecting polymers to be replaced in the existing polymer composition manufacturing process; determining raw materials and proportions of the raw materials to replace the selected polymers in order to reduce the overall GHG while maintaining desired properties of the polymer composition.

[0071 ] In some embodiments, the overall Greenhouse Gas (GHG) Emissions is determined according to The CarbonNeutral Protocol ISO 14067:2018. In some embodiments, the overall Greenhouse Gas (GHG) Emissions is determined according to the GHG Protocol Product Life cycle Standard ISO 14064 standards or PAS 2060 standards. A skilled person in the art would appreciate that any suitable method for determining the overall Greenhouse Gas (GHG) Emissions may be used.

[0072] In some embodiments, the raw materials comprise about 30% to about 100% w/w of bio-based and/or recycled materials. In some embodiments, the raw materials comprise about 30% to about 90% w/w of bio-based and/or recycled materials. In some embodiments, the raw materials comprise about 50% to about 75% w/w of bio-based and/or recycled materials.

[0073] In some embodiments, the carbon footprint is reduced to neutrality. [0074] In some embodiments, the method further comprises conducting the polymer composition manufacturing process using the determined raw materials and corresponding proportions to provide a carbon negative or carbon neutral footprint.

[0075] In some embodiments, the method further comprises testing the carbon negative or carbon neutral footprint polymer composition to determine that the desired properties have been maintained.

[0076] In some embodiments, the desired properties of the polymer composition are as defined above.

[0077] Also included is a polyethylene polymer composition obtained by the method of the present application.

IV. Methods of Preparing the Compounds and Compositions of the Application [0078] The present application also includes a process for manufacturing the multilayered polymer composition of the application, comprising blending polymers in different proportions on different layer structures, coextruding the layers into multilayered polymer composition.

[0079] The present application also includes a process for manufacturing a polymeric film, comprising blending polymers in different proportions on different layer structures, coextruding the layers into the polymeric film.

[0080] In some embodiments, the process further comprises printing and converting the multilayered polymer composition or polymeric film into bags for use in packaging of baked goods and fresh produce.

EXAMPLES

[0081 ] The following non-limiting examples are illustrative of the present application.

General Methods

Materials [0082] A combination of different polymers is required to control the properties of the polymeric film. For baked goods or fresh produce packaging applications, a specific blend of food safe polyethylene (PE) grades is used in each layer of the film structure. Depending on the thickness, final application, and processing conditions, a combination of linear low density polyethylene (LLDPE), low density polyethylene (LDPE), and high density polyethylene (HDPE) polymers could be selected from Table 1 below.

Table 1. Example of polymers available for recipe formulation

* at 190 °C and 2.16 kg

Extruder characteristics

[0083] Mono or multilayer blown film extruders (1 , 3, 5 or 7 layers) are used to convert the plastic granules into thin polymeric films. As an example, a 3-layer blown film extrusion line manufactured by Windmdller & Hdlscher (W&H) was used to extrude films for baked good and fresh produce applications. This extrusion line has a 15.75- inch circular die with an adjustable gap of 49 to 88 mil. The symmetrical configuration of extruders (A/B/C) consists of a bigger central layer extruder (with 4.1 -inch screw diameter) that is sandwiched by two smaller extruders (with 2.87-inch screw diameter). Each extruder has 4 feeders the feeding system works based on gravimetric mechanism. The typical output of this extrusion line is 1500 Ibs/hour (1400 Ibs/hour to 1600 Ibs/hour) and can handle up to 6 rolls at the same time. This line is optimized for extrusion of thin polyethylene films (0.8 to 4 mil) and the thickness profile is controlled inline by an ultrasonic sensor. Depending on requested film dimensions and Blow Up Ratio (BUR), the layflat width varies from 56 inch to 83 inch. [0084] As another example, a 5-layer blown film manufactured by Windmdller & Hdlscher (W&H) was also used to extrude polyethylene film for baked good and fresh produce. This extrusion line has a 17.72-inch circular die with an adjustable gap of 49 to 88 mil. The symmetrical configuration of extruders (A/B/C/D/E) consists of a bigger central layer extruder (with 4.1 -inch screw diameter) that is sandwiched by two smaller extruders (with 2.8-inch screw diameter) and the two outer extruders (with 2.4-inch screw diameter). Extruders A, C, and E have 5 feeders and B and D have 4 feeders; all the feeding system works based on gravimetric mechanism. The typical output of this extrusion line is 1550 Ibs/hour (1450 Ibs/hour to 1650 Ibs/hour) and can handle up to 6 rolls at the same time. This line is optimized for extrusion of thin and thick polyethylene films (0.8 to 9.5 mil) and the thickness profile is controlled inline by an ultrasonic sensor. Depending on requested film dimensions and BUR, the layflat width varies from 63 inch to 101 inch.

Processing conditions

[0085] Examples of processing conditions for the 5-layer blown film extrusion line for a 1.20 mil film are shown in Table 2, and extruder processing conditions and temperature profiles can be found in Table 3.

Table 2. Example of extrusion processing conditions

Table 3. Example of extruder pressures and temperature profiles

Lab testing standards and machines

[0086] Different types of testing equipment were used to evaluate the physical and optical properties of the films.

[0087] Tear resistance was tested according to ASTM D1922-15 (Standard Test Method for Propagation Tear Resistance of Plastic Film and Thin Sheeting by Pendulum Method) using a Thwing-Albert ProTear machine.

[0088] Tensile properties of the films are measured per ASTM D882-18 (Standard Test Method for Tensile Properties of Thin Plastic Sheeting) using an Oakland Tensile Tester Series 1500 machine.

[0089] Haze percentage is measured per ASTM D1003-21 (Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics) using a BYK haze-gard i machine.

[0090] Gloss 45 degree is measured according to ASTM D2457-21 (Standard Test Method for Specular Gloss of Plastic Films and Solid Plastics) using a BYK microgloss 45° machine.

[0091 ] Dynamic coefficient of friction (COF) is measured per ASTM D1894-14 (Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheeting) using an Oakland Film Friction Tester Series 7000 machine.

[0092] Oxygen transmission rate (OTR) is measured per ASTM D3985-17 (Standard Test Method for Oxygen Gas Transmission Rate through Plastic Film and Sheeting Using a Colorimetric Sensor) using OX-TRAN® Model 2/21 , MH module machine.

[0093] Water vapor transmission rate (WVTR) is measured per ASTM F1249- 20 (Standard Test Method for Water Vapor Transmission Rate through Plastic Film and Sheeting Using a Modulated Infrared Sensor) using a PERMATRAN-W®Model 3/33, MG Plus master machine. Example of film for baked goods packaging applications

[0094] Table 4 provides examples of the properties of thin PE films for baked goods packaging applications.

Table 4. Examples of the film properties at different thicknesses (0.80mil to 3mil)

*MD machine direction and TD transverse direction

Example of wicket bags for baked goods packaging applications

[0095] Polyethylene wicket bags of 1.25mil in thickness were produced on a wicket bag machine, with a width of 10 inches, length of 16.5 inches, lip 1 .5 inches and 5/8 inch wicket holes, square bottom gusset 3.5 inches, printed in 10 colors with a flexographic printing press. These bags, as shown in FIG.1, are typically used for packing bread in automatic machines at commercial bakeries. Typical dimensions for wicket bags are shown in Table 5 below.

Table 5. Example of wicket bag dimensions for baked goods

Results

Assessment of carbon footprint

[0096] In order to assess the Greenhouse Gas Emissions (GHG) of the existing plastic packaging products for the selected applications and the new film compositions of the present invention, the technical specifications of The CarbonNeutral Protocol for products was used. Other standards could be used to determine carbon footprint of a product or process and this will be well within the purview of a skilled person in the art.

[0097] Accounting protocol was ISO 14067 :2018, Greenhouse gases — Carbon footprint of products — Requirements and guidelines for quantification. The assessment was performed for cradle-to customer extended until the point of delivery boundary systems.

[0098] A detailed mass and flow system diagram was built using the material and energy flows for the upstream, core and downstream stages as suggested by the Recommended Product Category Rules for Packaging products, using the Umberto LCA + software.

[0099] All GHGs recognized under the UN Framework Convention on Climate Change were quantified using Umberto LCA + software according to the criteria of The CarbonNeutral Protocol for quality assurance of the data sources for a 12-month data period in the different categories of emission sources indicated in Table 6.

Table 6. Categories of emission sources

[00100] The potential climate change impact of each GHG emitted and removed by the product system was calculated by the 100-year Global Warming Potential (GWP) given by the Intergovernmental Panel on Climate Change (IPCC) 2013 in units of “kg CO2e per kg emission.”

Example of carbon footprint of films for baked goods or fresh produce packaging applications

[00101 ] For example, all mass and flow balances were built using the Umberto LCA + software for an extrusion facility located in Quebec, Canada as shown in FIG.2.

[00102] The functional unit was determined to be 1 kg of extruded rollstock of clear polyethylene films suitable for baked goods or fresh produce packaging applications, in a thickness range of 0.80 mil to 5.0 mil produced in an extrusion facility located in Quebec, Canada, using a mix of extrusion lines of one, three and five layers, with distribution to first customers located in Quebec Canada, using a blend of raw materials in the range of 60 - 80 % Linear low density polyethylene (LLDPE) and 40 - 20 % Low Density Polyethylene (LDPE), produced in Canada and United States. Carbon Footprint was assessed to be 2.9331 kg CO2e/kg of extruded film as shown in Table 7:

Table 7: Carbon footprint of films for baked goods or fresh produce packaging applications for the period January to December 2021

Example of carbon footprint of wicket bags for baked goods packaging applications

[00103] For example, all mass and flow balances were built using the Umberto LCA + software for a set of one extrusion and two converting facilities in Quebec, Canada as shown in FIG.3. The converting facilities include printing and bag making processes are shown in FIG.4 and FIG.5, respectively.

[00104] The functional unit was determined to be 1 kg of printed wicket bags for baked goods packaging applications, in a thickness range of 0.80 mil to 5.0 mil produced in an extrusion facility and two different converting facilities located in Quebec, Canada, using a mix of extrusion lines of one, three and five layers, flexographic printing up to ten colors and wicket bag converting machines, with distribution to first customers located in Canada and US, using a blend of raw materials in the range of 60 - 80 % Linear low density polyethylene (LLDPE) and 40 - 20 % Low Density Polyethylene (LDPE) with the addition of solvent based inks for flexographic printing produced in Canada and United States. Carbon Footprint was assessed to be 3.6061 kg CO2e/kg of wicket bags for the Cradle-to-customer boundaries as shown in Table 8.

Table 8. Carbon footprint of wicket bags for baked goods packaging applications for the period January to December 2021 Design of polyethylene film composition for carbon neutral packaging (PE films and wicket bags)

[00105] Considering the carbon footprint for extruded film and wicket bags as described above, the next steps consisted in finding raw materials with lower carbon footprint, while maintaining the film properties. An assessment of existing food safe bio-based and PCR resins was carried out and several polyethylene resin suppliers were identified as potential sources of raw materials (see Table 9).

Table 9. Examples of resins with lower carbon footprint

[00106] Using Umberto LCA + software according to the criteria of The CarbonNeutral Protocol, as described in section IV, different modeling scenarios were considered, for production of both extruded film and wicket bags, incorporating different ranges of bio-based and PCR resins. The objective of the LCA modeling was to find the correct proportion of bio-based and/or PCR resin required to neutralize the emissions of the other raw materials, manufacturing processes and distribution, with the goal of producing a carbon neutral film and/or wicket bags. Table 10 below shows an example of the amount of bio-based and/or PCR resin required to produce carbon neutral products (films and wicket bags).

Table 10. Example of film composition to produce carbon neutral products (films and wicket bags)

[00107] Based on the above, different examples of film recipes for carbon neutral films for baked goods packaging applications were produced on three (3) and five (5) layers extrusion lines. These films are using different percentages of bio-based and PCR resins to create carbon neutral packaging.

Example 1 - three layers film

[00108] Table 11. Example of three layer film recipe for 1.25mil carbon neutral film for baked goods packaging applications using bio-based resins

Example 2 - five layers film

[00109] Table 12. Example of five layer film recipe for 1 ,25m il carbon neutral film for baked goods packaging applications using bio-based resins

Example 3 - five layers film

[00110] Table 13. Example of five layer film recipe for 1 ,25m il carbon neutral film for baked goods packaging applications using bio-based and PCR resins

Results

[00111] The properties below show film performance using the film recipes described above in Examples 1 , 2 and 3. These properties fall within the range of properties of standard film and would satisfy the requirements of the target applications. Properties for Examples 1 and 2 (Table 14) are prophetic and are based on tested properties obtained for Example 3 (Table 15).

[00112] Table 14. Prophetic properties of 3-layer and 5-layer Carbon Neutral films with bio-based resins (Examples 1 and 2)

[00113] Table 15. Tested properties of 5-layer Carbon Neutral films with biobased resins and 30% PCR content (Example 3).

[00114] While the applicant's teachings described herein are in conjunction with various embodiments for illustrative purposes, it is not intended that the applicant's teachings be limited to such embodiments as the embodiments described herein are intended to be examples. On the contrary, the applicant's teachings described and illustrated herein encompass various alternatives, modifications, and equivalents, without departing from the embodiments described herein, the general scope of which is defined in the appended claims.

REFERENCES [00115] Natural Capital Partners, The CarbonNeutral Protocol - Technical Specification and Guidance. 2022: p 34-53