FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patent Rules, 2003
Complete Specification
(See section 10 and rule 13)
A PVC-Based Packaging Material
ACG Pharmapack Private Limited
Dalamal House, 10th Floor, Nariman Point, Mumbai 400 021, Maharashtra, India. An Indian company registered under the Companies Act, 1956
The following specification particularly describes the invention and the manner in which it is to be performed.

A PVC-based packaging material
Field of the Invention
The Present invention relates to a Pharmaceutical grade thermoformable packaging material. In particular, the present invention relates to a thermoformable, rigid, pharmaceutical grade PVC based film or laminates. Still further, the present invention relates to a thermoformable rigid pharmaceutical grade PVC based Films or Laminates which has aluminium based PVC film like appearance and can be formed in to shapes which cannot be cold formed using aluminium based PVC laminates (referred to as alu-alu laminates in the rest of this document).
Background of the Invention
Polymer based films and laminates have replaced traditional packaging materials such as metal, glass and paper. These polymer based materials and laminates consist mainly of, PVC, PP, PE, nylon, PET, APET. These polymeric packaging materials, owing to their thermo-mechanical properties, offer a better alternative to the traditional packaging materials in the case of non-food and pharmaceutical products. Polymer-based materials are cheap to synthesize, and can be configured according to the specific packaging requirements.

However, when it comes to the packaging of the pharmaceutical and food products, the requirements of the packaging materials are more stringent than those required for non-food products. Further, each polymeric film has its own specific vapour/gas barrier and mechanical properties which often fall short of the requirements of the active drugs and food materials. To make up for the shortfall, conventional films made from polymeric materials are often laminated with one or more other polymeric films or aluminum foil to enhance barrier property and mechanical properties.
One such example is the co called 'alu-alu' laminated which are commercially available and most often used in the packaging industry for food and pharmaceutical products. An alu-alu laminate is produced typically by sandwiching aluminum foils of 30-60µ thickness between a PVC film of thickness 40-60µ and a 25-40µ thick polyamide film. This alu-alu laminate has water vapour and gas barrier value near to zero which is the best available performance out of the existing polymer based films and laminates. Further, as an aluminum foil is opaque, this laminate offer light shielding capacity to the laminate and protects the packaged product from interacting with light. It is also found that the aluminium constitutes anywhere between 45% to 60% of the weight of the final packaging film, which makes the film expensive to produce an dtransport.

However, the blister packs formed from this alu-alu laminates are prone to mechanical damage during the forming process. Additionally, blisters of small sizes or small radii or sharp curves cannot be formed as the films incorporating aluminium do not lend themselves easily to formation of such blisters. As a result of this, the smallest possible size of the blisters formed on the final product is often too large for packaging of the pharmaceutical tablets and capsules. This results in wastage of material and also increase in transportation costs.
There is therefore a need to provide an alternative to the existing alu-alu film products which will:
- Be less prone to mechanical damage during the blister forming process
- Allow forming smaller (than currently available) blisters which are close in size to the products to be packed
- Be cold formed
- Provide adequate light and vapour barrier properties suitable for pharmaceutical and food products
Thus, while aluminum based polymeric packaging laminates have distinct advantages over normal polymeric packaging films and laminates, there are

several limitations imposed by use of aluminium. For example, the blisters in the alu-alu based packaging laminates can be formed only by cold forming process aluminum does not soften at the temperatures normally used for thermoform'mg operations of PVC based packaging materials. Further limitations imposed by use of aluminium foils are:
1. Laminates cannot be thermoformed
2. Blister/cavity formation has size limitation, thus cavities of very small size cannot be formed, leading to wastage of the packaging material.
3. It is very difficult to achieve small round shaped cavities.
4. Cavities that are formed has not large depths, as the materials have limited mechanical strain capabilities, therefore, it is not suitable to large size tablets or capsules.
5. These laminates are flimsy in nature; therefore, cold forming operation has to be carried out at slow speed leading to the low production speed, in turn low production rate.
6. Cold forming operation involves large amount of mechanical forces leading to the great energy consumption.
7. During cold forming process there is greater likelihood of the damage of
the cavity portion in the form of crimps due to forces exerted during
forming operation

8. Aluminum is expensive as compared to polymeric films.
9. As aluminum based packaging laminates has WVTR nearly to zero, many times a product is over-packed as requirement of the packaging of the product are not as high provided by aluminum based packaging.
There is therefore a need in the packaging industry serving the food and pharmaceutical products for PVC based laminates which have high vapour/gas barrier and also gloss and shine and light shielding properties.
Objects and advantages of the invention:
One of the key objects of the present invention is to provide a laminate which has a high barrier to vapours/gases and has light shielding properties.
Another object of the present invention is to provide a PVC-based laminate:
1. That can be thermoformed
2. In which Blister/cavity of sizes close to the product to be packaged can be formed, leading to minimization of waste of the packaging material.
3. In which blisters/cavities of sharp curvatures can be formed.

4. In which it is possible to form cavities large depths than those permitted in the case of laminates that use aluminium foils, thereby permitting its use to package large size tablets or capsules.
5. In which the cold forming operation is carried out at a reasonably high production speed.
6. Which reduces the mechanical damage to the laminate during the process of cold forming.
7. Which reduce the production costs.
The present invention therefore aims to provide a laminate which has aluminum like gloss, can which has barrier properties for water and other gases suitable for packaging food and pharmaceutical products and at the same time can be thermoformed in desired shape.
Summary of the Invention
According to its one aspect, the present invention discloses a PVC-based packaging material incorporating aluminium gel or paste and which has aluminum like gloss and improved barrier properties.

According to its another aspect, the present invention discloses a PVC-based packaging material of its first aspect which further laminated with polymers laminates such as ACLAR®, EVOH, COC, PVdC etc.
According to its yet another aspect, the present invention discloses a PVC-based packaging material of any of its earlier aspects which is further laminated with BPP, CPP, LDPE, LLDPE, HDPE to improve gloss.
According to its further aspect, the present invention also provides PVC-based packaging materials of its first and second aspect which further incorporate colour pigment or dye to produce materials of different colour shades.
The organic dyes are provided in predetermined weight ratio that is in the range between 0.004 to 5% w/w (with respect to the bulk used to form the film -including PVC and the laminates). More preferably this ratio is between 0.01 to 4.33% w/w. The amount of aluminium used in the making of the product of the invention is in the range between 0.05% to 0.8% w/w (with respect to the bulk used to form the film - including PVC and the laminates); more preferably between 0.08 to 0.5% w/w.
Brief Description of Figures:

Figure 1 shows a single layer film
Figure 2 shows a laminated film
Figure 3, 3a, 3b, and 3c show a laminated film with multiple layers
Figure 4 shows a schematic of the calendaring process
Figure 5 shows the blisters formed on a conventional aluminium/PVC film
Figure 6 shows the blisters formed on the film of the present invention
Detailed Description Of The Invention
Packaging protects packaged products from mechanical damage and degradation and it also needs to be presentable and attractive for consumer. Therefore, package should be sturdy as well as should enhance aesthetic appearance of the product. Traditionally, glass, wood and metal are the materials used for the packaging. However, there are disadvantages involved in using these materials such as glass is brittle in nature therefore, unable to provide sufficient mechanical strength to the package. Metals are not only expensive but there is also a possibility of leaching of toxic metal ions into the packaged product.
The discovery of polymers such as PVC, Nylon, PET, PE, and PP brought about a new era in the packaging industry. These polymers proved to be much better for

packaging purposes than the traditional packaging materials as they are lighter in weight, and most of them being chemically inert, acid- and alkali-resistant, and cost effective. Over the past couple of decades, these polymers have effectively entirely replaced the traditional packaging materials,
The industry dealing in packaging of medicinal and food products is governed by stringent regulations, first because the packaging materials comes in direct contact with the packaged products, and second, because keeping water, vapour and gases such as oxygen away from the packaged products is critical in maintaining efficacy of the drug. For example, water vapour in atmosphere can interact with drug and can form a hydroxide of the product which is not as effective as the original product; oxygen too reacts with many products from the medicinal and food category and forms oxidized products, which are inferior to the original products with regards the purpose for which they are developed. Thus it is critical that the materials used for the packaging medicines and food must provide a good barrier against water vapour and oxygen.
PVC is used for the most of the packaging applications because it is cheap to produce, chemically resistant and light in weight. However, when it comes to packaging of medicine, PVC pose serious problems like leaching of monomer vinyl chloride, has low value of barrier towards water vapour and oxygen.

In the currently available commercial packaging materials, the barrier property of PVC against water vapour and oxygen is enhanced by coating the PVC film with PVdC or laminating it with ACLAR®, EVOH, or COC. Alternatively, thin aluminum foil with combination of other polymers is another most often used packaging material for medicinal products as these laminates provide both good mechanical strength and good barrier property. Most commonly used aluminum based laminate is produced by sandwiching aluminum foil between PVC and polyamide, and which is commonly called an Alu-Alu laminate. This laminate provides almost 100% barrier towards water vapour and other gases. However, as we have discussed earlier, the Alu-Alu laminates have their own disadvantages.
In the first embodiment of the resent invention (see Figure 1), a PVC-based packaging material or film is disclosed. It comprises a first layer (1) of PVC in which a paste or gel made from aluminium powder (2) is incorporated.
In the second embodiment of the present invention (see Figure 2) the a PVC-based packaging film disclosed in the first embodiment is further laminated with a first lamination (4) to enhance its vapour/gas barrier and also its WVTR.

In the third embodiment of the present invention, the PVC-based packaging material disclosed in any of the earlier embodiments is further incorporated with at least one organic pigment or dye (3).
The present invention thus discloses a PVC-based packaging film which may optionally be in a laminated form and which has gloss like aluminum and has good vapour/gas barrier properties.
The organic dyes are provided in predetermined weight ratio that is in the range between 0.004 to 5% w/w (with respect to the bulk used to form the film -including PVC and the laminates). More preferably this ratio is between 0.01 to 4.33% w/w. The amount of aluminium used in the making of the product of the invention is in the range between 0.05% to 0.8% w/w (with respect to the bulk used to form the film - including PVC and the laminates); more preferably between 0.08 to 0.5% w/w. As discussed earlier, the weight of the aluminium in the currently available alu-alu packaging films is anywhere between 45% to 60% of the total weight of the packaging material. The product of the present invention thus drastically reduces the proportionate weight of the aluminium used in the packaging.

More crucially, it has been found that it can surprisingly be thermoformed in any desired shape and size. More surprisingly, the blisters that are formed in the material of the present invention can be of sharp curves and greater depth than the currently available alu-alu material. This is evident from the figures 5 and 6. Figure 5 shows the blister shape and size for a typical round-ended cylindrical capsule of 8.6mm diameter and 23.5mm length using conventional alu-alu film. The conventional blister's footprint on the film is of the size 24mm width and 39.2mm length. To accommodate ten capsules a film of 148mm x 90 mm is required. In contrast with this, the film of the present invention is capable of forming blisters of 25.8mm length and 10.5mm width, whereby ten capsules are accommodated in a film of 97mm x 68mm area. This represents a saving of over 50% over the area required for conventional film.
Furthermore, the lamination of the present invention is available in different shades of colour, unlike the presently available alu-alu material.
Achieving gloss like aluminum foil, without actually using an aluminium foil is a critical and inventive achievement. The present invention uses a gel or a paste formed using fine aluminium metal powder and incorporates it in the PVC base to achieve aluminium-like gloss.

In the case of laminates of colour of the present invention inventiveness lies in the proper mixing of the dyes or pigments with aluminum metal power paste in a predetermined proportions and PVC compound. PVC compound means PVC resin mixed with all the additives, lubricants and stabilizer necessary to form a rigid thermoformable PVC film.
The barrier property enhancement lamination material used in the invention is selected from a group comprising polymers such as ACLAR, PVdC, barrier improved PVdC.
The gloss forming lamination material used in the present invention is selected from a group comprising BPP, CPP, LDPE, LLDPE, HDPE etc. Lamination formed using these materials improves gloss of the packaging material as well as contributes to improving its barrier property.
In a particular embodiment of the present invention, the pigment used is Irodin.
The film of the present invention is found to be thenmoformable, rigid, pharmaceutical grade film with gloss like an alu-alu film. It is available in

different shades such as copper, gold, violet, green, amber, which is achieved by mixing at least one organic dye or inorganic pigment with fine aluminum powder in the gel form and adding it to the PVC layer. The mixing of these dyes/or pigment and fine aluminum powder paste with PVC compound is done in predetermined ratios to achieve desired shade with gloss.
Pigment such as Irodin, pink amber, Orange GIN, Orange 2811, Green GN, Light Peach, Violet RSB, Bright Yellow, Acrylamide Yellow, Yellow GG, Sumica Pearl are used to get the desired shade to the PVC film. Mixing proportion of the pigment with fine aluminum metal powder in the gel form with PVC compound is critical and are mixed in ratios between 0.004 to 0.75% w/w, preferably between 0.01 to 0.06% w/w.
A process of making the film of the present invention by the calendaring technique is now disclosed.
Calendaring process for manufacture of the PVC-based packaging material of the present invention: (commercial trial)
The film of the present invention was made by calendaring process (see Figure 4). Calendaring of PVC was done using the apparatus known as Calendar 1000

(Make Deistrouff with extruder as melt feeder and having a batch size capacity of 100 kG) and also an apparatus known as Calendar 2000 (Make: Crouss-Maffle with Kneeder as a melt Feeder with batch size capacity of 150 kG).
For calendaring of the PVC, PVC resin from Shintek, USA or PVC K 51 which is available from Reliance Industries (India) was used. Prior to calendering, PVC resin was mixed with all necessary lubricants, and additives. Aluminum in the form of fine powder, which is in compliance with food and safety regulations, was mixed with a carrier such as epoxidised soya bin oil, external and internal lubricant oils, liquid processing aids, or a combination thereof, to form a viscous liquid. Mixing of solvent with aluminum powder is one of the critical steps in obtaining a pharmaceutical grade PVC film that looks like an alu-alu film and which is rigid and thermoformable. Food and safety compliance was also ensured with regards all other components such as other organic dyes and inorganic pigments that being used in the formulation of PVC with different shade with aluminum like luster.
These dyes and pigments include but are not limited to irodin, pink amber, Orange GIN, Orange 2811, Green GN, Light Peach, Violet RSB, Bright Yellow, Acrylamide Yellow, Yellow GG etc but not limited to these dyes or pigments only.

One can use other available dyes or pigments also. Generally, PVC compound is mixed with the aluminum paste and at least one or more pigment or dye in a predetermined proportion to achieve desired shade. The mixing proportion is critical parameter and determined after lot of research and development.
Example of calendaring:
Calendaring of PVC compound mixed with aluminum powder paste and pigment(s) was done at the following conditions shown in following table 1: Batch size 175 kG Table 1

Raw Material Weight (kG)
PVC Resin 145.5
Additives (includes ESBO, Tin Stabilizer, E-PVC, Processing aid, Internal lubricant, External lubricant, Impact modifier, Ca-Zn stabilizer, Processing aid- Hot metal release agent, ) 25.55
Result of blending PVC resin and additives is a PVC compound to which pigments and aluminum powder in the form of paste are mixed in requisite proportions.

Calendaring Parameters: The processing parameters that at which the film of the invention manufactured using materials shown in Table 1 was calendared are shown in Table 2.
Table 2:

Machine Parameters
Pre-Calendaring Parameters Unit Value
Hot Mixture Discharge Temperature °C 85
Cold Mixture Discharge Temperature °C 65
Screw Temperature °c 100
Barrel Temperature °c 110
Screw Speed rpm 56
Kramer Speed rpm 6.9
Process Temperature
Calendar Roll Temperature Unit Value
Kl °C 178
K2 °C 184
K3 °c 196
K4 °c 170
Take Off/2 °c 69
Take Off 3/4 °c 69
Tampering Roll 1 °c 68
Tampering Roll 2 °c 68
Take Off 5-7 °c 74
Tampering Roll 3 °c 31.8
Process Speed Unit Actual
Calendar Roll Kl m/min 17.0
Calendar Roll K2 m/min 18.9
Calendar Roll K3 m/min 24.1
Calendar Roll K4 m/min 28.6
Calendar Roll K5 m/min 35.9
Haul Off m/min 26.5
Tampering m/min 17.4
Take Off 1-2 m/min 35.6
Take Off 3-4 m/min 35.6.0

Take Off 5-6 m/min 34.2
Take Off 7-8 m/min 34.2
Line Speed m/min 26.5
The film of the present invention is smooth in texture and glossy in appearance. Due to the novel composition of the present invention, it is important to maintain key parameters at values that would achieve smoothness and gloss. Deviation from required values of temperature, for example, or speeds of calendar rolls, lead to process problems such as the film sticking to the rolls. This would not only lead to a substandard product but also wastage.
Another key aspect of the present invention is the thermoformability into shapes that are not possible to be formed using the currently available alu-alu films.
It is evident from comparisons of figures 5 and 6 that the blisters formed using the film of the present invention are contoured much closer to the tablet or capsule than those formed with the currently available alurninium/PCV laminates.
The various embodiments of the invention will now be described with the help of the examples that follow.

Experiments and Examples
Experiments were carried out on the following combinations:
- PVC base film with aluminium paste/gel
- PVC base film with aluminium paste/gel and organic dye pigments
- PVC base films with aluminium and organic dye pigments with lamination
The samples used for the examples described below were formed by adding pigments and additives to PVC compound and mixing in hot mixer for 5 min, at 78 to 88° C and then discharging to cold mixer at 60 to 70° C. The compound was further transferred to a hopper whose temperature was maintained at 115 to 125 °C and then melt that was produced was drawn in the form of semisolid form through extruder screw maintained at 100 to 110 °C and then calendared through calendar rollers. The temperatures and speed of the parts of the calendar machine were maintained as mentioned in Table no. 2. Aluminium paste and organic pigments or dyes were added to various samples as required.
Examplel: 250µ. PVC with aluminum paste and Sumica Pearl pigment
0.171 kG of paste of aluminum powder and 6.5 kG of Sumica Pearl™ pigments were added to the PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.

Properties of the film produced are as follows

Sr. no. Parameter Unit Value
1 Thickness M 250
2 GSM g/m2 338
3 Appearance Opaque silvery
4 Shrinkage % -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-550.6;T.D-500.7
6 Tensile Strength N/mm2 M.D.-54.089; T.D.- 48.47
Example 2: 250µ PVC with aluminum paste and Sumica Pearl and Pink Amber pigments
0.087 kG of Pink Amber pigment, 6.5 kG of Sumica Pearl™ pigment and 0.171 kG of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.
The properties of the film produced are as follows:

Sr. no. Parameter Unit Value
1 Thickness M 250
2 GSM g/m2 338
3 Appearance Shiny Gold
4 Shrinkage % - - 10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D-452.45
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633

Example 3: 250µ PVC with aluminum paste and Sumica Pearl and Light Peach pigments
6.5 kG Sumica Pearl™ pigment, 0.058 kG of Light Peach pigment and 0.171 Kg of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.
The properties of the film produced are as follows:

Sr, no. Parameter Unit Value
1 Thickness µ 250
2 GSM g/m2 338
3 Appearance Shiny copper
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D- 452.45
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 4: 250µ PVC with aluminum paste and Sumica Pearl
0.571 kG of paste of aluminum powder and 6.5 kG of Sumica Pearl™ pigments were added to the PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.
The properties of the film produced are as follows:

Sr. no. Parameter Unit Value
1 Thickness µ 250
2 GSM g/m2 338
3 Appearance Opaque Grayish
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-550.6; T.D- 500.7
6 Tensile Strength N/mm2 M.D.-54.089; T.D.- 48.47

Example 5: 200µ PVC with aluminum paste and Sumica Pear! pigments
6.5 kG Sumica Pearl™ pigment and 0.171 Kg of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the example.
The properties of the film produced are as follows:

Sr. no. Parameter Unit Value
1 Thickness µ 200
2 GSM g/m2 270
3 Appearance Opaque Silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m' M.D-500.12;T.D- 452.45
6 Tensile Strength N/nW M.D.-60.878; T.D.- 57.633
Example 6:125µ PVC with aluminum paste and Sumica Pearl pigments
6.5 kG Sumica Pearl™ pigment and 0.171 Kg of paste of aluminum powder were
added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the example.
The properties of the film produced are as follows:

Sr. no. Parameter Unit Value
1 Thickness µ 125
2 GSM g/m2 169
3 Appearance Opaque silver
4 Shrinkage % - - 10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D-452.45
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633

Example 7:100µ PVC with aluminum paste and Sumica Pearl pigments
6.5 kG Sumica Pearl™ pigment and 0.171 Kg of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. The properties of the film are as follows:

Sr. No. Parameter Unit Value
1 Thickness µ 100
2 GSM g/m2 135
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D- 452.45
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 8: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 60µ CPP (clear or coloured)
6.5 kG Sumica Pearl™ pigment and 0.171 Kg of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then laminated to 60 micron CPP clear or with various translucent/transparent colours like, blue, green, yellow, purple, violet, etc. to achieve the gloss/aesthetics as well as better barrier properties.

The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 310
2 Total GSM g/m2 393
3 Appearance Opaque silver with gloss
4 Shrinkage % - - 5 MD; + 2 TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D-452.45
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 9: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 60µ CPP (clear or coloured)
6.5 kG Sumica Pearl™ pigment and 0.171 Kg of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then laminated to 60 micron CPP clear or with various translucent/transparent colours like, blue, green, yellow, purple, violet, etc. to achieve the gloss/aesthetics as well as better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 310
2 Total GSM g/m2 393
3 Appearance Opaque silver with gloss
4 Shrinkage % - - 5 MD; + 2 TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D-452.45

Example 10: 200µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 60µ CPP (clear or coloured)
6.5 kG Sumica Pearl™ pigment and 0.171 Kg of paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 200 micron thickness is then laminated to 60 micron CPP clear or with various translucent/transparent colors like, blue, green, yellow, purple, violet, and so on.to achieve the gloss /aesthetics as well as better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 260
2 Total GSM g/m2 325
3 Appearance Opaque silver with gloss
4 Shrinkage % - - 5 MD; + 2 TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;TX>- 452.45
Example 11: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 51µ ALCAR
6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then laminated to 51 micron Aclar to achieve the gloss as well as better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 301
2 Total GSM g/m2 445
3 Appearance Opaque silver with gloss
4 Shrinkage % - - 5 MD; + 2 TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D-452.45
Example 12: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 51µ ALCAR
6.5 kG Sumica Pearl™ pigment and 0.571 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then laminated to 51 micron Aclar to achieve the gloss as well as better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 301
2 Total GSM g/m2 445
3 Appearance Opaque grayish with gloss
4 Shrinkage % - - 5 MD; + 2 TD
5 Tensile Impact Strength kJ/m2 M.D-500.12;T.D-452.45
Example 13: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 40gsm PVdC
6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process

having 250 micron thickness is then coated with 40 gsm PVdC to achieve better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 274
2 Total GSM g/m2 378
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-400; T.D- 350
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 14: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 60gsm PVdC
6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then coated with 60 gsm PVdC to achieve better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 286
2 Total GSM g/m2 398
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-400; T.D- 350
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633

Example 15: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 90 gsm PVdC
6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then coated with 90 gsm PVdC to achieve better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 305
2 Total GSM g/m2 428
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-350;T.D-300
6 Tensile Strength N/mm2 M.D.-60.878;T.D.- 57.633
Example 16: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 120gsm PVdC
6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the example. Film obtained from this process having 250 micron thickness is then coated with 120 gsm PVdC to achieve better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 323
2 Total GSM g/m2 458
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D- 300; T.D- 300
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 17: 250µ PVC with aluminum paste and Sumica Pearl pigments; laminated with 120gsm PVdC
6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 250 micron thickness is then coated with 120 gsm enhanced high barrier PVdC to achieve better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 323
2 Total GSM g/m2 458
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-300; T.D- 300
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 18: 120gsm PVdC sandwiched between 150µ and 100µ PVC sheets with aluminum paste and Sumica Pearl pigments

6.5 kG Sumica Pearl™ pigment and 0.171 Kg paste of aluminum powder were added with PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples. Film obtained from this process having 150 micron thickness is then laminated to 100 micron PVC already coated with 120 gsm enhanced high barrier PVdC to achieve better barrier properties.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Total Thickness µ 323
2 Total GSM g/m2 458
3 Appearance Opaque silver
4 Shrinkage % - - 10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-300; T.D- 300
6 Tensile Strength N/mm2 M.D.-60.878; T.D.- 57.633
Example 19: 250µ PVC with aluminum paste without any pigments or lamination
0.571 kG of paste of aluminum powder were added to the PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.
The properties of the film are as follows

Sr. no. Parameter Unit Value
I Thickness µ 250
2 GSM g/m2 338
3 Appearance Opaque Grayish
4 Shrinkage % - - 10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-550.6; T.D- 500.7
6 Tensile Strength N/mm2 M.D.-54.089; T.D.- 48.47

Example 20:250µ PVC with aluminum paste without any pigments or lamination
0.176 kG of paste of aluminum powder pigments were added to the PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.
The properties of the film are as follows:

Sr. no. Parameter Unit Value
1 Thickness µ 250
2 GSM g/m2 338
3 Appearance Opaque silver
4 Shrinkage % - -10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-550.6; T.D- 500.7
6 Tensile Strength N/mm2 M.D.-54.089; T.D.- 48.47
Example 21: 250µ PVC with pigments but without lamination
6.5 kG Sumica Pearl™ pigment was added to the PVC compound as given in Table 1 and calendared as per processes mentioned at the beginning of the examples.
The properties of the film are as follows

Sr. no. Parameter Unit Value
1 Thickness µ 250
2 GSM g/m2 338
3 Appearance Perlaised
4 Shrinkage % - - 10MD; + 4TD
5 Tensile Impact Strength kJ/m2 M.D-550.6; T.D- 500.7
6 Tensile Strength N/MM2 M.D.-54.089; T.D.- 48.47

UV testing results:
One of the key aspects of packaging materials used for food or pharmaceutical
products packaging is their barrier properties against the ultra violet light. UV light Barrier properties of the film of the present invention were therefore evaluated.
Shimadzu's UV 1800 UV Spectrophotometer was employed for this experiment. 190 to 380 nm wavelength is being considered as UV range. Results are obtained in % transmittance. In case of GC PVC (prior art product) one can see that UV light is getting transmitted totally while when aluminium paste is used in same PVC then it shows an excellent resistance to UV transmittance. Hence the photosensitive product can easily pack into this film without loosing its potency.
Results of Ultraviolet ray testing are provided below.
Table 3: UV transmission values

250 mic 250 mic
PVC with
0.571 Kg
Aluminum
Paste and
6.5 kg
Sumica
250m ic 250 mic with pearl
250 mic 250mic GC Amber White black pigment
No. λ GCPVC UVPVC PVC opq\V3 powder (Example 4)

1 450 86.73 85.50 0.008 0.146 0.026 0.008
2 430 86.45 85.07 0.005 0.137 0.018 0.008
3 410 85.18 82.57 0.021 0.043 0.008 0.000
4 390 83.38 38.04 0.004 0.000 -0.002 -0.003
5 370 80.19 0.02 -0.017 0.006 -0.017 -0.012
6 350 77.00 -0.02 -0.027 -0.006 -0.014 -0.014
7 330 73.90 -0.012 -0.021 0.000 -0.009 -0.012

8 310 66.25 -0.017 -0.003 -0.008 -0.009 -0.006
9 290 36.48 -0.011 -0.009 0.000 -0.006 -0.006
Table 3 Continued...

Explanation of certain terms used in table 3:
250 mic GC PVC - glass clear rigid PVC
250 mic UV GC PVC - glass clear rigid PVC with UV absorber added,
250 mic Amber PVC - rigid PVC with Amber pigment in it which resist UV to penetrate up to certain limit.
250 mic White opaque - rigid PVC with Ti02 loaded which act as UV resistance.
Lab Test Values
As one of the key aspects of the present invention is its colour, tests were
performed to assess the strength of its colour and its opacity and light

250 mic PVC 250 250 250 mic.
250 mic Alum in mic. mic. PVC
PVC um PVC PVC with
Alumin paste with with 0.571
um 0.571 Alumin Alumin Kg
paste Kg and um um Alumin
0.571 6.5 kg paste Paste um
Kg and Sumica 250 0.650 0.610 Paste
6.5 kg pearl mic Kg and Kg and and 6.5
Sumica pigmen PVC 6.5 kg 6.5 kg kg
pearl t glass Sumica Sumica Sumica
pigment /Aclar clear pearl pearl pearl
Exampl Exampl Std pigmen pigmen pigmen
Ex.5 Ex.6 e4 el2 Sample t t t
0.085 0.107 0.284 0.002 0.012 0.336 0.006 0 0.002
0.073 0.092 0.24 0 0.008 0.403 0.002 0.002 0
0.046 0.061 0.18 0 0.005 0.552 0.002 0 -0.002
0 0.008 0.06 0 0 0.745 -0.009 -0.002 -0.003
0 -0.011 0.009 -0.015 -0.003 1.479 -0.009 -0.003 -0.002
-0.012 -0.011 -0.017 -0.012 0.009 1.984 -0.032 -0.034 -0.006
-0.015 -0.005 -0.005 -0.011 -0.011 1.416 -0.006 -0.005 -0.008
-0.003 -0.011 -0.006 -0.003 -0.005 0.996 -0.012 -0.009 -0.005
-0.002 0 -0.002 0.003 -0.005 0.703 -0.005 -0.008 -0.008

transmission. These measurements were made in accordance with the Hunter's LAB scale. Colour spectrophotometer was employed to measure the colour co-ordinates values of the samples; measurement was done over standard white and black background to understand the colour strength, opacity and light transmission. D 65 light source was used which is considered as standard light source in CIE as well as in hunter lab system.
L* - positive values shows lightness while negative value shows darkness
a* - positive value shows redness and negative value shows greenness
b* - positive value shows yellowness and negative value shows blueness
Table 4

Sample L* a* b* Remark
250 micRPVC with 0.171 Kg Aluminum Paste consider as standard (Example 1) 80.96 -1.794 0.329 Appeared as silver
200 micRPVC with 0.171 Kg Aluminum Paste ( Example 5) 83.683 -1.623 0.441 Appeared as silver
125 micRPVC with 0.171 Kg Aluminum Paste (Example 6) 82.90 -1.73 0.040 Appeared as silver
100 micRPVC with 0.171 Kg Aluminum Paste (Example 7) 80.158 -1.974 0.358 Appeared as silver
250 mic RPVC with 0.171 Kg Aluminum Paste laminated with clear 60 mic CPP (Example9) 81.441 -1.278 0.273 Appeared as glossy silver

250 micRPVC with 0.171 80.486 -1.352 1.696 Appeared as silver
Kg Aluminum Paste coated but b value is more
with 90 gsm PVdC because PVdC coated
(Example 15) on it is bit yellow by nature
250micRPVC with 0.571 78.302 -1.457 - Appeared as grayish
Kg Aluminum 0.983
Paste(Example 19)
250 micRPVC with 0.171 73.74 9.43 4.26 Appeared as coppery
Kg Aluminum Paste and and is evident from
0.058 Kg light peach higher a* value
(Example 3)
250 micRPVC with 0.171 80.12 1.22 18.56 Appeared as golden
Kg Aluminum Paste and and higher b* values
0.087 Kg pink Amber V supported the same.
(Example 2)
As the aluminium content is varied the appearance of the film varies from silver to grey; silver shade representing low aluminium content and grey the high.
The other important aspect of the present invention it its barrier value against vapour/gas and water. Barrier tests were conducted, the results of which are presented below. (Tests were also carried out on the commercially available alu-alu material.)
Barrier value chart:
Water Vapour Transmission Rate (WVTR measured as g/m2/day) and Oxygen Transmission Rates (OTR measured as cc/m2/day) were evaluated using a MOCON machine.

Table 5 presents results of tests carried out on commercially available PVC-based laminates (termed PVC/PVDC - commercial, and PVC/ALCAR - commercial) and the film of the present invention (termed ALUKBLISS/PVDC, and ALUKBLISS/ALCAR) made using PVDC and ALCAR laminates.
Table 5a 1) WVTR:
Sr.No Structure PVC/PVDC -
Commercial ALUKBLISS/PVDC
PVDC
1 250uPVC/40GSM PVDC 0.61 0.64 (Example 13)
2 250µPVC/60GSM PVDC 0.471 0.48 (Example 14)
3 250µPVO90GSM PVDC 0M4 0.39 (Example 15)
4 250µPVC/120GSMPVDC 0.26 0.27 (Example 16)
5 250 PVC 3 3.5
ACLAR PVC/ACLAR
- Commercial ALUKBLISS/ACLAR
1 250µPVC/23µACLAR 0.218 0.218
2 250µPVC/51µACLAR 0.101 0.12 (Example 11)
3 250µPVC/76µACLAR 0.065 0.068
4 250µPVC/102µACLAR 0.06 0.062
Table 5b 2) OTR:
Sr.No Structure PVC/PVDC -
Commercial ALUKBLISS/PVDC
PVDC
1 250µPVC/40GSMPVDC 1.99 1.8 (Example 13)
2 250µPVC/60GSM PVDC 1.461 0.744 (Example 14)
3 250µPVC/90GSMPVDC 0.471 0.413 (Example 15)
4 250µPVC/120GSMPVDC 0.358 0.34 (Example 16)
5 250 PVC 18 16
ACLAR PVC/ACLAR
- Commercial ALUKBLISS/ACLAR
1 250µPVC/23µACLAR 12.11 12
2 250µPVC/51µACLAR 10.073 10 (Example 11)
3 250µPVC/76µACLAR 9.007 9
4 250µPVC/102µACLAR 8.301 8

It is evident from the above table that the film of the present invention provides acceptable level of WVTR and OTR for food and pharmaceutical product packaging.
Gloss:
The final important technical property of the material of the present invention is its gloss. The Gloss is not a purely physical quantity, but a physiologically influenced quantity. It is essential for determining the reflection properties of the surfaces. The usefulness of a measurement of the gloss value is on the possibility of quantifying and tracing changes in the test body surface.
Gloss values were measured using a gloss meter made by Rhopoint Instrumentation and are presented in Table 6
Table 6

Sr.No Sample tested Gloss Readings Avg Gloss
1 2 3 4
1 Example 20 74.1 74.8 75.1 76.5 75.1
2 Example 4 52.9 52.9 54.1 54.0 53.5
3 Example 1 49.7 50.0 50.0 49.9 49.9
5 Example 2 51.3 52.3 53.3 53.1 52.5
6 Example 3 57.5 58.1 56.9 57.5 57.5
7 Example 5 48.6 47.3 53.2 54.5 50.9
8 Example 6 42.0 43.1 43.2 43.3 42.9
9 Eaxmple 7 36.6 37.7 37.0 36.7 37.0
10 Example 14 98.9 98.9 103.7 105.8 101.8
11 Example 15 72.8 69.7 69.9 68.3 70.2

12 Example 12 92.0 92.1 93-0 93.2 92.6
13 Example 11 96.4 96.0 94.2 94.4 95.3
14 250µ Amber PVC 91.8 90.3 89.9 91.7 90.9
15 250 µ White PVC 66.4 66.4 72.8 64.5 67.5
16 Example 9 92.6 92.7 92.8 94.5 93.2
It is therefore evident that the product of the invention provides technical advances over the existing products, namely:
- It used proportionately far less quantities of aluminium in the final product
- It allows formation of blisters with sharper curves thereby making it more economomical packaging material
- It allows packaging to be formed in various colours, which has not hitherto been possible in an PVC-based aluminium laminate
While achieving the above technical advances, it has been possible to maintain important properties such as UV light resistance, WVTR and OTR at levels suitable for packaging of food and pharmaceutical products.
It is evident from the foregoing discussion that the present invention has the following items.
1. A PVC-based packaging film characterized in that said film is made of layer of a food-grade or pharmaceutical grade PVC material in which aluminium particles of fine size are dispersed by incorporation of a viscous

mixture containing fine aluminium powder in said PVC material during process of making the film.
2. A film as claimed described in item 1, in which said layer of PVC further comprises organic dye or colour pigments.
3. A film as described in items 1 and 2, in which said layer of PVC is further provided with a first lamination of a barrier enhancement polymer, said polymer selected from a group comprising ACLAR, PVdC, barrier improved PVdC, EVOH, and COC said first lamination being provided in at least one layer.
4. A film described in items 1 and 3, in which said layer of PVC is further provided with a second lamination of a gloss imparting polymer, said gloss imparting polymer being selected from a group comprising BPP, CPP, LDPE, LLDPE, HDPE, wherein said second lamination is made of at least one layer.
5. A described in items 1 and 4, wherein said viscous mixture is formed by mixing aluminum in the form of fine powder in a carrier which is selected from a group comprising epoxidised soya bin oil, external and internal lubricant oils, liquid processing aids, or a combination thereof.
6. A film described in items 1 and 5, wherein said organic colour pigment is selected from a group comprising Irodin, pink amber, Orange GIN, Orange

2811, Green GN, Light Peach, Violet RSB, Bright Yellow, Acrylamide Yellow, Yellow GG, Sumica Pearl, or any combination thereof.
7. A film described in items 1 and 6, wherein said organic pigment or dye
used is provided in a weight proportion of between 0.004 to 5% w/w,
preferably between 0.01 to 4.33% w/w with respect to the weight of the
film.
8. A film described in items 1 and 7, further wherein blisters are formed for accommodating pharmaceutical tablets or capsules.
9. A film described in items 1 and 8, wherein the depth of blisters is up to 15mm.
10. A film described in items 1 and 9, wherein said film is produced by calendaring process.
11. A film as claimed in claims 1 to 10, wherein the said aluminium powder is used in an amount between 0.05% to 0.8% w/w with respect to the weight of said film.
12. A film as claimed in claims 1 to 11, wherein the said aluminium powder is used in an amount between 0.08% to 0.5% w/w with respect to the weight of said film.
13. A film as claimed in claims 1 to 12 wherein the thickness of said layer of PVC is in the range between 60 to 800 microns.

14. A film as claimed in claims 1 to 13 wherein the thickness of said first and second laminations is in the range between 80 to 1000 microns.
While the above description contains much specificity, these should not be construed as limitation in the scope of the invention, but rather as an exemplification of the preferred embodiments thereof. It must be realized that modifications and variations are possible based on the disclosure given above without departing from the spirit and scope of the invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.

We Claim:
1. A PVC-based packaging film characterized in that said film is made of layer made from a food-grade or pharmaceutical grade PVC material in which aluminium particles of fine size are dispersed by incorporation of a viscous mixture containing fine aluminium powder in said PVC material during process of making the film.
2. A film as claimed in claim 1, which further comprises organic dye or organic colour pigments incorporated in said layer of PVC.
3. A film as claimed in claims 1 and 2, in which said layer of PVC is further provided with a first lamination of a barrier enhancement polymer, said polymer selected from a group comprising ACLAR, PVdC, barrier improved PVdC, EVOH, and COC said first lamination being provided in at least one layer.
4. A film as claimed in claims 1 to 3, in which said layer of PVC is further provided with a second lamination of a gloss imparting polymer, said gloss imparting polymer being selected from a group comprising BPP, CPP, LDPE, LLDPE, HDPE, wherein said second lamination is made of at least one layer.
5. A film as claimed in claims 1 to 4, wherein said viscous mixture is formed by mixing aluminum in the form of fine powder in a carrier which is selected from a group comprising epoxidised soya bin oil, external and internal lubricant oils, liquid processing aids, or a combination thereof

6. A film as claimed in claims 2 to 5, wherein said organic dye or organic colour pigment is selected from a group comprising Irodin, pink amber, Orange GIN, Orange 2811, Green GN, Light Peach, Violet RSB, Bright Yellow, Acrylamide Yellow, Yellow GG, Sumica Pearl, or any combination thereof.
7. A film as claimed in claims 2 to 6, wherein said organic pigment or organic dye used is provided in a weight proportion of between 0.004 to 5% w/w, preferably between 0.01 to 4.33% w/w with respect to said fine aluminum powder.
8. A film as claimed in claims 1 to 7, further wherein blisters are formed for accommodating pharmaceutical tablets or capsules.
9. A film as claimed in claim 8, wherein the depth of blisters is up to 15mm.
10. A film as claimed in claims 1 to 9, wherein said film is produced by calendaring process.
11. A film as claimed in claims 1 to 10, wherein the said aluminium powder is used in an amount between 0.05% to 8% w/w with respect to the weight of said film.
12. A film as claimed in claims 1 to 11, wherein the said aluminium powder is used in an amount between 0.08% to 0.5% w/w with respect to the weight of said film.

13. A film as claimed in claims 1 to 12 wherein the thickness of said layer of PVC is in the range between 60 to 800 microns.
14. A film as claimed in claims 1 to 13 wherein the thickness of said first and second laminations is in the range between 80 to 1000 microns.