FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patent Rules, 2003
Complete Specification
(See section 10 and rule 13)
Innovative Rigid Plastic Based Packaging System For Corrosive Food Product
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.

Innovative rigid plastic based packaging system for corrosive food product
Field of Innovation:
Present invention is related to food grade rigid packaging material. In particular present invention is related to thermoformable rigid food grade PVC based film or laminates. Still further present invention relates to thermoformable rigid food grade PVC based film or laminates which may have an Alu-like look in terms of opacity, colour and clearness of appearance, and which can be formed into any desired shape which is not possible with cold formable traditional Alu-alu laminates.
Still further, the present invention relates to thermo formable rigid food grade PVC based film coated with laminates of EVOH, nylon, acrylic co-polymer as second layer to this rigid PVC. With regards the lamination, the lamination thickness is between 20 to 400 mm. As mentioned earlier the lamination may be SCPP or SBPP or metalized (with aluminium) CPP or BPP, or metalized (with aluminium) SCPP or SBPP, all combinations used in a thickness range of 20 μm to 400μm.
Thus the present invention produces a material that can be formed into any desired shape which is not possible with aluminium based laminates or paper aluminium based laminates.

Background of Invention
Polymer based film and laminates fall into category of flexible packaging. These materials are typically produced in thicknesses ranging from 9 micron to 100 micron. The high volume in which these are produced is taking its toll on the environment. Indian tobacco market is huge given her 1.25 Billion population. As a standard practice an Indian tobacco product user disposes of the packaging material in a manner that is damaging to the environment, for example, by throwing it in non designated areas, thus compounding the disposal problem. The Indian Government and its Environmental department have taken several measures to address the situation including the recent blanket ban on this flexible packaging material for use as a packaging material for Tobacco. There is therefore a need to provide a non-flexible material that is environmentally less damaging and easy to dispose of and also practical to use as a packaging material for a general tobacco product user.
Polymer based film and laminates have replaced traditional packaging material like metal, paper etc. Polymer based materials and laminates consist of mainly PVC, PP, PE, Nylon, Pet, Apet, Petg, EVOH, Aclar, COC, Barex etc. Such polymeric packaging material, owing to the properties its ingredient materials, provides a viable alternative to conventional packaging materials. Polymeric based materials are inexpensive to synthesize and can be configured according to specific needs of packaging requirements of the end user. However, when it

comes to packaging of food products, the regulatory requirement of packaging materials are typically stringent. Furthermore, each polymeric film has its own barrier and mechanical properties and may not necessarily be sufficient to fulfill the requirement of active or corrosive food material. Therefore, this film is often laminated with one or more polymeric film or aluminum foil to enhance barrier properties and mechanical properties.
One such example is currently available and most often used in packaging Industry is Alu-Alu laminates or paper aluminium laminates. However, although aluminium based packaging laminates have advantages over other polymeric film, they have some serious drawbacks:
1. Laminates cannot be thermo formed.
2. Cavity formation has size limitation. Thus cavities of small or very large size cannot be formed. It is also very difficult to form small cavities with sounded shapes.
3. Alu-Alu films cannot be used to form cavities of large depths, for example, as there are limitations on the strain that these materials are able to withstand. Therefore, it is not suitable to pack more stuff that is low in density, which normally requires high packing volume and consequently deep cavities.

4. These laminates are brittle in nature therefore cold forming operation has to be carried out at slow speed leading to low product speed hence low product rate.
Cold formation operation involves large amount of mechanical force food leading great energy consumption. It is therefore requirement in the packaging film for providing an alternative laminates which has aluminium like gloss and provide required barrier property, while providing the material with the ability to be thermoformed.
Brief description of the figures:
Figure 1 shows a conventional packaging material
Figures 2-8 show various embodiments of the packaging material of the
invention
Figure 9 shows the lamination process
List of parts:
1- Base layer (PVC) 4- Colour lacquer layer
2- Lamination layer 5- Adhesive layer 3- Metallisation layer 6- Colour pigment

Summary of the invention:
The present invention provides a packaging material by laminating the base PVC film with EVOH, Nylon, Aclar, or CDC films. With regards the lamination, the lamination thickness is between 20 to 400 mm. As mentioned earlier the lamination may be SCPP or SBPP or metalized (with aluminium) CPP or BPP, or metalized (with aluminium) SCPP or SBPP, all combinations used in a thickness range of 20 μm to 400 urn. The packaging material is used to pack chewable paan masala, gutkha and other such products which are at present packaged in environmentally unfriendly thin plastic wrappers which typically clog up the country's drains and waterways.
Detailed description of the invention:
The mouth freshening chewable materials such as Gutkha, Paan Masala, Tobacco needs to be packed such that it is barricaded from Oxygen and moisture. Therefore the inventor have invented a special packaging material by laminating the base polymer film (1) with lamination (2) using materials such as EVOH, Nylon, Aclar, or CDC films. With regards the lamination, the lamination thickness is between 20 to 400 mm. As mentioned earlier the lamination may be SCPP or SBPP or metalized (with aluminium) CPP or BPP, or metalized (with aluminium) SCPP or SBPP, all combinations used in a thickness range of 20 μm to 400 μm

The base layer (1) is typically made of PVC of food or pharmaceutical grade as per EC Directives and devoid of plasticizer. The thickness of the base layer ranges between 100 μm to 800 μm
With regards the lamination layer (2), its thickness is between 20 to 400 mm. As mentioned earlier the lamination may be SCPP or SBPP or (with aluminium) CPP or BPP provided with a metalized layer (5) , or SCPP or SBPP provided with a metalized layer (5), all combinations used in a thickness range of 20 urn to 400 urn. Metal used is preferably aluminium.
Various embodiments of the present invention are shown in the figures provided
along with this description. These include
1 .Base PVC / adhesive / metalized CPP or BPP,
2. Base PVC/ adhesive/CPP or BPP,
3. Base PVC/adhesive/EVOH
4. Base PVC/adhesive/Alcar
5. Base PVC/adhesive/Nylon
The products of all above embodiments are optionally provided with a colour lacquer layer (4) as appropriate as below:
1. Colour lacquering on top of the film,
2. Colour lacquering on metallisation,

3. Colour lacquering sandwich between top layer and base layer,
4. Coloured top layer /pigmented top layer,
5. Pigmented top layer & then metalized,
6. Lacquered top layer and then metalized,
7. Based layer lacquered and then laminated, (outside)
8. Based layer pigmented and then laminated.
The material of the present invention may be used in producing two types of packaging for food grade materials such as gutkha: blisters or capsules. In the case of capsules, the blister itself forms the secondary packaging according to the invention.
The process of manufacturing the film is now disclosed.
The process of making the film of the present invention comprises the steps of lamination, lacquering, and barrier layer coating. Lamination may be using a dry lamination process or an innovative inline lamination process. In the case of the dry lamination process an adhesive (7) is used as a glue between the base layer and any other layer.

Lamination:
1. Dry lamination
The dry lamination process is well known to a person skilled in the art, however, it has been incorporated here for making this document self contained.
As shown in Figure 9, base PVC gets unwound from the unwinder and passes through the tray that contains water based adhesive which is applied to the web. The doctoring process ensures the uniform coating of the adhesive with the help of doctor blade on PVC. Gravure roller is designed in such way that it picks up the required amount of adhesive and deposited over the web. The viscosity of the adhesive is maintained and monitored throughout the process by adjusting temperature suitably. The deposited adhesive then travels through a specially designed tunnel-type oven with specific temperature zones and to provide a traveling path of approximately 10-12 m. The temperature in the oven is maintained in the range of 70 to 95°C to dry out the adhesive when it comes out of the tunnel. The metalized BPP or CPP film comes in contact with this web and both the films travel through nip roller whereby the two layers are stuck together under the action of the pressure. The composite layer thus formed passes over the drum that is equipped with chilled water circulation to help cool down the laminate. The controlled cooling also eliminated the cross linking of adhesive ensuring a good bonding between two layers of the laminate.

2. Inline lamination
The lamination takes place insitu with calendared PVC film. The PVC film is produced by thinning of sludge under the action of three pressing rollers in a calendaring device,, and then cooling the film at various temperatures with the help of take off rollers. A suitable colour pigment (8) is added to the base layer where a coloured product is desired. The custom made BPP or CPP metallised or non metallised film then unwinds through in-house made assembly and travels along with the hot PVC film. The two films are pressed together in hot condition to form a laminate. This process does not need any adhesives. The top layer film is formulated in such a way that it provides self-adhesion to hot PVC film in-situ, which ensures the high level of interlayer bond strength.
Interlayer Bond Strength:
Inter layer bond strength between polymeric substrate (the PVC) and metallised polymer layer for the currently available comparable packaging materials is found to be between 250 and 300 g for a 15 mm wide strip at cross head speed of 100 mm/min.
This is considered as excellent strength and there's no literature to suggest that higher bond strengths have been reported for similar products. It has also been noted that in the existing products that use metallised lamination, metal gets transferred to the PVC substrate and deteriorates the quality of lamination, subsequently leading to de-lamination.

In the present invention, the SCPP/SBPP is made in such a way that it will have the polar group formation on surface that enhances the bond between metal and polymeric substrate. When this metallised SCPP/SBPP or CPP/BPP get laminated with PVC and expose for interlayer bond strength measurement we achieve a bond of 450 g/15 mm at 100 mm/min cross head speed. And moreover the metal transfer from one layer to other is minimal results in higher shelf life of the product.
In summary, PVC laminate made using either of the two lamination processes is unique in that it enhances the inter layer bond strength between PVC and the BPP (or CPP) or any other similar material. It further allows the laminated film to be thermoformed in smooth way. The inter-layer bond strength obtained by the inline lamination process is favourably comparable with any of the off line lamination processes available.
Lacquering (optional in case of dry lamination)
The dry lamination machine is used for lacquering the film. Wherein the substrate comes to on grayure roller through unwinder and then gravure roller pick up the lacquer from the tray and deposits it on substrate. The doctoring technique is applied prior to deposition in order to ensure uniform deposition. The lacquered substrate travels through a controlled heating tunnel with a passage length of 10m where it's dried..

The food material may be packaged in individual pouches produced with the packaging material or packaged in thermoformed dimpled packaging. Experiments and results:
Several experiments were conducted to assess the vapour/gas resistance (measured as water vapour transmission resistance - WVTR measured in grams of vapour per sq meter per day) of the product of the invention. Several combinations of materials and their relative positioning, which have been listed earlier, were tested.
Examples 1 and 2 represent the experiments carried out on metallised products made using currently known processes.
Example 1
A 250 micron pharmaceutical grade PVC film roll devoid of plasticizer having 600 mm width was subjected to an unwinder of a gravure coating machine. Ester-acrylic based primer of viscosity of 26 to 32 sec. was applied using the gravure roller to the PVC film and extra primer was removed by doctoring process such that the primer thickness was 0.8 microns. The PVC film with the primer was sent through on-line ovens maintained at a temperature of 75" C using a conveyer belt at a speed of 30 m/min for drying the primer on the film. The drying

of the primer on.the film was confirmed by non tackiness and by non-blocking of rewinding at the rewinder roller.
The two layer film thus formed was transferred to a vacuum deposition machine. This machine had an in situ plasma device and was fitted with an evaporation boat in which material to be deposited was placed. The primer coated surface of the laminated film was first treated with plasma and thereafter was deposited with aluminum metal having 99.99% purity. Thickness of this deposited layer was 0.001 microns. The thickness was achieved by adjusting the speed, height of the gun and magnitude of vacuum.
This three layer film was exposed to a differential embossing grating process. A custom built machine was used for the embossing process. The three layered film was placed on an unwinder of this custom made machine followed by passing it through the roller maintained at a temperature of 130 to 150° C in order to soften it. A diamond pattern shim was pressed on the metallised side of the film to create a diffraction grating embossed effect on the film. The shim made for the above purpose was cut with a diamond pattern by using computerized laser cutting mechanism to avoid duplication of the pattern by anyone else.

Blisters packs were formed from this laminate by thermoforming process which showed excellent thermoforming performance and showed the fine diamond holographic pattern even after the thermoforming process.
Specification of the film was as follows:
Total thickness 250 micron
Adhesion of embossed pattern with scotch tape test: passes
Thermoforming performance Excellent
Impact strength 953 g
Tensile strength -Longitudinal 511 kg/cm2
-Transverse 488 Kg/cm2
Elongation - Longitudinal 5%
Transverse 4.8%
WVTR 2.8 g/m2/day
Examples of tests carried out on the product of the invention
Rigid PVC of desired thickness (between 200 and 250 micron was been used in the examples that follow) that complies 21 CFR and FDA norms suited to use in pharmaceutical and food application was passed through corona treator. This treatment was provided to enhance polar group formation over the surface of the film which in turn results in better wet ability. This film was next passed through

a tray containing water-based adhesive comprising acrylates, polyurethane, and inomers cross linked with Isocyanate catalyst with heat or without cross linkers. This treatment was provided to enhance the interlayer bond strength between various layers of the film. An engrave gravure cylinder was next dipped into a tray containing the adhesive. The cylinder was rotated to pick up adhesive from the tray after which excess adhesive was wiped out with the help of a doctor blade to ensure uniform adhesive coating. The adhesive was then transferred over the substrate with the help of a rubber roller such that the substrate along with the adhesive achieves required weightage (gsm). Next, the substrate with the adhesive applied to it was passed through an oven maintained at a temperature between 85 to 95 degree centigrade providing a travel path of 12 m, in order to evaporate water from the adhesive. Cast PP or Blown PP having thickness of a desired thickness was next unwound from the unwinder and brought in contact with base PVC substrate as it came out from the oven. Both films were nipped together, and were passed over a chilled roller for adhesion to take place. To get the proper jellification of the adhesive one hot roller is provided over substrate at the time of nipping and the temperature of this steel roller is maintained in the range of 80 to 95 degree Centigrade.
Laminate made out of this process is then subject to various testing after proper curing period. Test results for this laminate is as mentioned below. The following

examples use various thicknesses of the PVC substrate and that of the Cast PP/Blown PP material.
In some other examples, the Cast PP or Blown PP film is metallised with 99.99% pure aluminum in vacuum metallization technique before applying to the substrate such that the metallised side of the CPP/BPP is outside.
In still some other examples, the Cast PP or Blown PP film is metallised with 99.99% pure aluminum in vacuum metallization technique before applying to the substrate such that the metallised side of the CPP or BPP is inside, that is it is in contact with the substrate.
In yet further examples 60 micron BPP metallised with 99.99% aluminum vapourisation as per prior art example subject to rotogravure printing and water base as well as solvent based roto gravure inks were used and these inks in various shades applied on metallised surface of this film.
Finally some examples reflect the lamination of various layers carried out as off line lamination (the dry process) and some others (as mentioned specifically) use inline lamination.

Example 2
Rigid PVC: 250 micron with corona treatment
SCPP : 75 micron
GSM 417 g/m2
Thickness 328 μ
Dimensional stability MD - (-2); TD - (1)
Tensile Strength MD - 567 kg/cm2; TD - 515 kg/cm2
% Elongation MD - 203; TD - 195
WVTR 2.33 g/m2.day
Example 3
Rigid PVC: 250 micron with corona treatment SBPP: 90 micron
GSM 426 g/m2
Thickness 343 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day

Example 4
Rigid PVC: 200 micron with corona treatment SCPP: 60 micron
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TP-545kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day
Example 5
Rigid PVC: 200 micron with corona treatment
Cast PP : 60 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique with the metal side in contact with the substrate
GSM 317 g/m2
Thickness 250 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD-507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.58 g/m2.day

Example 6
Rigid PVC: 200 micron with corona treatment
Blown PP: 60 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique, with the metal side out
GSM 317 g/m2
Thickness 300 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2 TD-507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.62 g/m2.day
Example 7
Rigid PVC: 200 with corona treatment
Cast PP : 60 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique, with the metal side out
GSM 317 g/m2
Thickness 300 n
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD-507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.62 g/m2.day

Example 8
Rigid PVC: 200 micron with corona treatment
Blown PP: 60 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique, with the metal side out
GSM 317 g/m2
Thickness 300 \x
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD - 507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.62 g/m2.day
Example 9
Rigid PVC: 200 micron with corona treatment
Cast PP: 60 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique, with the metal side in contact with the substrate
GSM 317 g/m2
Thickness 250 u
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD - 507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.58 g/m2.day

Example 10
Rigid PVC: 200 micron with corona treatment
Blown PP: 60 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique, with the metal face in contact with the substrate
GSM 317 g/m2
Thickness 250 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD - 507 kg/cm2

% Elongation MD - 64;TD - 49
WVTR 0.5S g/m2.day
Example 11
Rigid PVC - 200 micron with corona treatment
Blown PP - 60 micron metallised with 99.99% pure aluminum in vacuum
metallization technique and coloured with coloured surface in contact with base
PVC
GSM 327 g/m2
Thickness 260 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD - 507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.58 g/m2.day

Example 12
Rigid PVC - 200 micron with corona treatment
Cast PP - 50 micron having metallised with 99.99% pure aluminum in vacuum
metallization technique and printed with various colours and in contact with base
PVC substrate
GSM 317 g/m2
Thickness 250 u
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 532 kg/cm2; TD - 507 kg/cm2
% Elongation MD - 64; TD - 49
WVTR 0.62 g/m2.day
The following examples indicate results on product samples made using inline lamination.
Rigid PVC 200 micron thickness that complies 21 CFR and FDA norms suited to use in pharmaceutical and food application film is used in this application. 60 micron BPP film produced in such a way that during processing it is being blended with low molecular weight polymer that is compatible with thermoformable polypropylene and can exhibit sticking properties when lower temperature applied while lamination. The same film was optionally metallised with 99.99% pure aluminum and ensured that metallised portion is coming in

contact with PVC while inline lamination. This film is unwinded from unwinder and introduced it at one of the takeoff rollers of calendar where temperature is more than 100° C and then nipped it with rubber roller at the pressure of 6 kg/cm2 then allow it to cool down along with PVC film. This process which is nomenclature as in-line lamination gives strong inter layer bond between PVC and BPP, this bond is comparable with any of the off line lamination process.
Example 13
Rigid PVC : 200 micron
BPP - 60 micron (without metallization)
Inline lamination at more than 100° C and at a pressure of 6 kg/cm2
Test results of this specification is as mentioned below,
Construction 200 micron PVC / 60 micron BPP
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day

Example 14
Rigid PVC : 200 micron
BPP - 60 micron (metallized and metalized face in contact with PVC)
Inline lamination at more than 100° C and at a pressure of 6 kg/cm2
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day
Example 15
Rigid PVC : 200 micron
BPP - 60 micron (metallized and metalized face on the outside)
Inline lamination at more than 100° C and at a pressure of 6 kg/cm2
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54 g/m2.day

Example 16
Rigid PVC : 200 micron with pink pigment
BPP - 60 micron (metallized and metalized face on the outside)
Inline lamination at more than 100° C and at a pressure of 6 kg/cm2
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day
Example 17
Rigid PVC : 200 micron with green lacquer
BPP - 60 micron (metallized and metalized face on the outside)
Inline lamination at more than 100° C and at a pressure of 6 kg/cm2
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day

Example 18
Rigid PVC : 200 micron with blue pigment
BPP - 60 micron (metallized and metalized face on the outside)
Inline lamination at more than 100° C and at a pressure of 6 kg/cm2
GSM 326 g/m2
Thickness 263 μ
Dimensional stability MD - (-1); TD - (0)
Tensile Strength MD - 531 kg/cm2; TD - 545 kg/cm2
% Elongation MD - 120; TD - 111
WVTR 1.54g/m2.day
Various materials being used in Pharma industry to pack medicine as single dose in blister form, Cold Form Blister is the ultimate one that contains 15 micron Nylon/ aluminum foil 45 to 60 micron / 60 micron PVC this is also known as Alu-Alu structure and barrier of this material is almost "0" for gases as well as for water vapour. But being aluminum as one of the largest component in it, has limitation on forming cavity results in employing cold forming technique that hampers productivity, increase the area required hence need more material, bigger shape of blister results in additional expenses on secondary packing, increase in secondary packaging is also because of aluminum which is flimsy and not friendly for logistic. Over and above this it is opaque so one cannot see through the

product packed inside, requires lot of energy not only to form as blister but also while getting aluminum from earth. Cost of this material is Rs. 800 to 850 /kg.
There is one more polymeric material known as Aclar used for blister application having WVTR from 0.26 to 0.08 g/m2/day (38°C and 98 % Rh) available in 23, 51,76 and 102 micron need to laminate with rigid PVC for blister application and costing between Rs.1000 to 2000 /kg as barrier increases the cost also increases.
The following table provides a summary of the results presented earlier in terms of the most important parameters - the WVTR.

Sr.
No Composite WVTR (g/m2/day)
1 PVC 250 urn (prior art) 3 to 3.5
2 Metalized PVC 250 urn (prior art) 1.8 to 2.5
5 PVC 200 nm/ 50 micron CPP or BPP metalized (metal outside) (more economical, environmentally friendly) 0.59 to 0.62
6 PVC 200 μm/ 50 micron CPP or BPP metalized (metal inside) 0.22 to 0.26
8 Metalized CPP or BPP 50 μm 0.45 to 0.60
9 200 micron PVC/60 micron CPP or BPP 1.4 to 1.5
Gutkha Testing pane]
Five people tasted Gutkha packed in our innovative pack. Out of these, three had never tested Gutkha in their life while two are regular Gutkha users. Packs were kept at room temperature as well as at 45° C and 75 % RH. Packs were remove at the interval of 2 weeks were subjected to weight gain testing, colour and appearance testing, flavor and taste. Following are the results of these tests.

STABILITY REPORT- INNOVATION
PVC/ Metalised
Gpac- PP) Date:09.06.2011

TEST CONDITION :- R.T
Blister
No. Initial Wt. Final Wt Weight Difference Colour Remarks
(g) (g) (g)
INITIAL 3 3.149 NA NA OK
1st WEEK 3 3.149 3.1512 0.0022 OK
2ND WEEK 3 3.149 3.1514 0.0024 OK
4TH WEEK 3 3.149 3.1520 0.0030 OK
6TH WEEK 3 3.149 3.1522 0.0032 OK
8TH WEEK 3 3.149 3.1529 0.0039 OK
10THWEEK 3 3.149 3.1532 0.0042 OK
12THWEEK 3 3.149 3.1535 0.0045 OK
14THWEEK 3 3.149 3.1555 0.0065 OK
16THWEEK 3 3.149 3.1553 0.0063 OK
18THWEEK 3 3.149 3.1559 0.0069 OK
20TH WEEK 3 3.149 3.1562 0.0072 OK
22ND WEEK 3 3.149 3.1576 0.0086 OK
23TH WEEK 3 3.149 3.1580 0.0090 OK
24TH WEEK 3 3.149 3.1583 0.0093 OK
25TH WEEK 3 3.149 3.1587 0.0097 OK
28TH WEEK 3 3.149 3.1590 0.0100 OK
30TH WEEK 3 3.149 3.1599 0.0109 OK
33TH WEEK 3 3.149 3.1602 0.0112 OK
36TH WEEK 3 3.149 3.1612 0.0122 OK
37TH WEEK 3 3.149 3.1634 0.0144 OK

TEST CONDITION :-40°C&75%RH
Blister
No. Initial Wt. Final Wt. Weight Difference Colour Remarks

INITIAL 3 3.3150 NA NA OK
1st WEEK 3 3.3150 3.3295 0.0145 OK
2ND WEEK 3 3.3150 3.3297 0.0147 OK
4TH WEEK 3 3.3150 3.3395 0.0245 OK
6TH WEEK 3 3.3150 3.3525 0.0375 OK
8TH WEEK 3 3.3150 3.3569 0.0419 OK
10THWEEK 3 3.3150 3.3621 0.0471 OK
12THWEEK 3 3.3150 3.3797 0.0647 OK
14THWEEK 3 3.3150 3.3825 0.0675 Slightly dark
16THWEEK 3 3.3150 3.3901 0.0751 Slightly dark
18THWEEK 3 3.3150 3.3986 0.0836 Reddish brawn
20TH WEEK 3 3.3150 3.4025 0.0875 Reddish brawn
22ND WEEK 3 3.3150 3.4100 0.0950 Reddish brawn
23TH WEEK 3 3.3150 3.4140 0.0990 Reddish brawn
24TH WEEK 3 3.3150 3.4175 0.1025 Reddish brawn
25TH WEEK 3 3.3150 3.4212 0.1062 Reddish brawn
28TH WEEK 3 3.3150 3.4289 0.1139 Reddish brawn
30TH WEEK 3 3.3150 3.4340 0.1190 Reddish brawn
33THWEEK 3 3.3150 3.4489 0.1339 Reddish brawn
36TH WEEK 3 3.3150 3.4541 0.1391 Reddish brawn
37THWEEK 3 3.3150 3.4580 0.1430 Reddish brawn

Above results shows that product is stable till 12 weeks at accelerated condition without changing its colour, flavour and taste. At the same time it is showing the stability till 37 week at room temperature.

It is evident from the foregoing discussion that the present invention has the following embodiments:
1. A packaging material for food and chewable mouth fresheners such as gutkha,
said packaging material made out of high barrier thermoforming film
comprising a substrate made of polyvinyl chloride characterized in that said
substrate is further applied with a lamination material,
2. A high barrier thermoforming film as disclosed in embodiment 1 characterized in that said lamination is made of a material selected from a group comprising polypropylene, cast polypropylene, blown polypropylene, special cast polypropylene, or special blown polypropylene.
3. A high barrier thermoforming film as disclosed in embodiments 1 to 2, wherein said film is further provided with a metallised layer, the metallised face being either in proximity with the substrate or on the outside face of said film.
4. A high barrier thermoforming film as disclosed in embodiment 3 wherein the metallization layer is achieved with fine metal powder.
5. A high barrier thermoforming film as disclosed in embodiments 3 and 4 wherein the metal used for metallization of said film is aluminium.
6. A high barrier thermoforming film as disclosed in embodiment 1 to 5 wherein the thickness of said substrata is in the range between 100 μm to 1000 μm.
7. A high barrier thermoforming film as disclosed in embodiment 3 to 6 wherein the metallised layer is of the thickness between up to 125 μm.

8. A high barrier thermoforming film as disclosed in embodiments 1 to 7 comprising the steps of providing a corona treated substrate and applying at least one of the following layers: i) a coating of moisture and vapour barrier material ii) a lamination layer, to said substrate, wherein either of the two layers may be optionally metallised, wherein in the case where said coating is applied it is applied using a dry lamination process and wherein when only a combination of a substrata and the lamination layer is used, a wet lamination process is used.
9. A process of making a high barrier thermoforming film as claimed in claim 8 wherein the metallised surface is either in proximity of the substrate or on the outside face of the composite film.
10. A process of making a high barrier thermoforming film as disclosed in embodiment 8 and 9 wherein the material used for lamination is selected from a group of materials comprising polypropylene, cast polypropylene, blown polypropylene, special cast polypropylene, or special blown polypropylene.
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 packaging material for food and chewable mouth fresheners such as gutkha, said packaging material made out of high barrier thermoforming film comprising a substrate made of polyvinyl chloride characterized in that said substrate is further applied with a lamination material.
2. A high barrier thermoforming film as claimed in claim 1 characterized in that said lamination is made of a material selected from a group comprising polypropylene, cast polypropylene, blown polypropylene, special cast polypropylene, or special blown polypropylene.
3. A high barrier thermoforming film as claimed in claims 1 to 2, wherein said film is further provided with a metallised layer, the metallised face being either in proximity with the substrate or on the outside face of said film,
4. A high barrier thermoforming film as claimed in claim 3 wherein the metallization layer is achieved with fine metal powder.
5. A high barrier thermoforming film as claimed in claims 3 and 4 wherein the metal used for metallization of said film is aluminium.
6. A high barrier thermoforming film as claimed in claims 1 to 5 wherein the thickness of said substrata is in the range between 100 μm to 1000 μm.
7. A high barrier thermoforming film as claimed in claims 3 to 6 wherein the metallised layer is of the thickness between up to 125 μm.
8. A high barrier thermoforming film as claimed in claims 1 to 7 comprising the steps of providing a corona treated substrate and applying at least one of the

following layers: i) a coating of moisture and vapour barrier material ii) a lamination layer, to said substrate, wherein either of the two layers may be optionally metallised, wherein in the case where said coating is applied it is applied using a dry lamination process and wherein when only a combination of a substrata and the lamination layer is used, a wet lamination process is used.
9. A process of making a high barrier thermoforming film as claimed in claim 8 wherein the metallised surface is either in proximity of the substrate or on the outside face of the composite film.
10. A process of making a high barrier thermoforming film as claimed in claims 8 and 9 wherein the material used for lamination is selected from a group of materials comprising polypropylene, cast polypropylene, blown polypropylene, special cast polypropylene, or special blown polypropylene.