| HS Code | 641202 |
| Material | Ethylene Vinyl Alcohol Copolymer |
| Oxygen Barrier | Excellent; maintains freshness by preventing oxygen ingress |
| Moisture Sensitivity | High; barrier properties degrade with increasing humidity |
| Aroma Flavor Retention | Superb; prevents flavor and odor migration both ways |
| Oil Grease Resistance | Superior; resistant to oils, fats, and food acids |
| Transparency | High clarity; allows visible product presentation |
| Thermoformability | Good; can be formed into trays, cups, and lids |
| Mechanical Strength | Strong; provides puncture resistance and structural integrity |
| Temperature Resistance | Suitable for refrigeration and moderate heat exposure |
| Food Safety Compliance | Meets FDA and EU food-contact regulations |
| Shelf Life Extension | Extends product shelf life by preserving vacuum or modified atmosphere |
As an accredited EVOH for Deli & Prepared Food Containers factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | EVOH resin supplied in 25 kg moisture-barrier bags, ideal for deli and prepared food container packaging. |
| Container Loading (20′ FCL) | EVOH resin packed in 25kg bags, loaded on pallets, secured for 20′ FCL container shipment, ensuring dry, clean transport. |
| Shipping | EVOH resin for deli and prepared food containers ships as sealed, moisture-proof bags or drums to prevent water absorption. Protect from humidity and extreme temperatures. Standard ground freight is suitable; no hazardous classification. Ensure dry storage and careful handling to maintain barrier performance and product integrity. |
| Storage | Store EVOH resin in a cool, dry, well-ventilated area, away from direct sunlight, heat, and strong oxidizers. Keep containers sealed to prevent moisture absorption, as EVOH is hygroscopic. Maintain stable temperatures, avoid excessive humidity, and use FIFO to prevent prolonged storage. Protect from physical damage and contamination. |
| Shelf Life | EVOH's oxygen barrier extends shelf life, keeping deli and prepared foods fresh, flavorful, and protected from spoilage. |
The base web for 200–500 g rectangular and round deli trays is a five-layer coextruded sheet in which the EVOH core is specified at 5–7% of total sheet thickness and the two maleic anhydride–grafted PP tie layers are each held at 2–3%. Compliance for the barrier layer is established under FDA 21 CFR 177.1360 for ethylene-vinyl alcohol copolymers, under EU Regulation (EU) No 10/2011 as amended for plastic food-contact materials, and through oxygen transmission testing on the flat sheet and formed part according to ASTM D3985-17 at 23°C and 0% RH. A 15 µm EVOH layer at 32 mol% ethylene typically reports 0.5 cm³/(m²·day·atm) or less at 0% RH, rising to 4–8 cm³/(m²·day·atm) at 85% RH. Sheet production is run on a three-extruder line with screw diameters of 75 mm, 45 mm, and 75 mm; the barrier extruder uses an L/D ratio of 30:1 and a melt pump to limit residence time. EVOH resin is pre-dried at 95–105°C for 4 h to less than 0.01 wt% moisture before entering the five-layer feedblock; melt temperature at the barrier extruder is held at 195–215°C, and any excursion above 220°C is limited to 15 min to prevent acetic acid odor generation and crosslinked gel defects. The coextruded melt is cast through a 900–1200 mm die onto a polished roll stack at 70–90°C, then reheated to 135–150°C for plug-assist thermoforming in steel-rule trim-in-place tools. Finished part types include 200–500 g trays for sliced turkey, ham, roast beef, and hard cheeses, sealed with PET/PE or OPET/EVOH/PE lidding under modified atmosphere of 30% CO₂ and 70% N₂; the buried EVOH layer limits oxygen ingress that would otherwise accelerate cured meat color loss and lipid oxidation.
In microwaveable and dual-ovenable prepared meal trays, the EVOH barrier core is buried at 4–6% of total sheet thickness between a CPET or mineral-filled PP outer layer and a food-contact PP homopolymer layer, with tie layers at 2–3% each. The EVOH layer is controlled under FDA 21 CFR 177.1360, while the outer CPET layer is governed by FDA 21 CFR 177.1630 when used; EU Regulation (EU) No 10/2011 applies to the finished tray, with migration testing conducted under the intended microwave reheating condition and the final oxygen barrier measured by ASTM D3985-17 at 23°C. Coextrusion is performed on a five-layer sheet line that isolates a 200–230°C EVOH melt from the 280–300°C CPET melt through a separate manifold and a thermally insulating feedblock design; pre-drying of EVOH at 90–110°C for 4–6 h to 0.01 wt% moisture, verified by Karl Fischer titration, is mandatory. Trim scrap from CPET/EVOH/PP sheet is not reincorporated into the food-contact layer unless compatibilized and analytically verified, because dispersed EVOH particles in PP can form pinholes in the sealing layer. Thermoforming uses oven sheet temperatures of 140–160°C, plug temperatures of 110–130°C, and mold temperatures of 170–190°C for CPET crystallization; the EVOH layer maintains layer continuity at sheet residence times below 20 s only if it is buried beneath at least 150 µm of outer CPET or PP. Terminal products include single-compartment and compartment trays for frozen lasagna, macaroni and cheese, curry, and rice bowls with capacities from 250–500 g, intended for microwave reheating to 80–100°C.
When hot-fill temperatures exceed 85°C, the EVOH layer in deli salad cups is specified at 6–10% of total sheet thickness to compensate for oxygen barrier loss caused by moisture plasticization from the filled product. The structure uses PP homopolymer on both the outer and food-contact sides at 80–90% combined thickness, with maleic anhydride–grafted PP tie layers at 2–4% each. Compliance is established under FDA 21 CFR 177.1360 and EU Regulation (EU) No 10/2011; hot-fill migration testing is performed with food simulants appropriate to the product type, and hydrated oxygen barrier is measured by ASTM D3985-17 at 23°C and 85% RH after the cup has been filled and cooled. The coextruded sheet is thermoformed into cups on a high-speed form-fill-seal line at 40–60 cavities per cycle using plug-assist pressure forming at sheet temperatures of 130–150°C; the trimmed flange exposes the EVOH edge, which can wick moisture and initiate delamination if the trim tool is dull or if the flange radius is less than 1.5 mm at the outer edge. The cup is filled at 82–95°C, sealed with a lidding film, and cooled through a water tunnel that reduces product temperature below 40°C within 20–30 min; EVOH barrier recovery after cooling is incomplete if the outer PP layer thickness is below 500 µm, because ambient humidity continues to plasticize the core. Terminal formats are 250–500 ml round and rectangular cups for chicken salad, pasta salad, fruit in syrup, and soups with snap-on or heat-seal lidding.
In retortable semi-rigid prepared food bowls, EVOH is used at 6–10% of total thickness with an ethylene content of 38–44 mol% to withstand thermal exposure at 121°C for 30–60 min. The barrier core is positioned between a PP outer layer of 250–400 µm and a PP food-contact layer of 100–200 µm, with maleic anhydride–grafted PP tie layers each at 3–5%. FDA 21 CFR 177.1360 applies to the EVOH layer, and the food processor must comply with 21 CFR Part 113 for low-acid canned or retorted foods; EU Regulation (EU) No 10/2011 applies to the finished article with total migration testing under the intended retort condition using acidic and fatty food simulants. The primary limitation in this configuration is that EVOH oxygen barrier after retort can decline by a factor of 5–10 because absorbed moisture disrupts hydrogen bonding in the vinyl alcohol segments; this decline is measurable by comparative ASTM D3985-17 values before and after retort. Manufacturers report that oxygen transmission rate at 23°C and 85% RH after retort should be measured after 24 h of conditioning to determine recovered barrier. Coextrusion uses a dedicated barrier screw with a melt pump and melt temperature of 200–220°C; retort-grade EVOH resin is pre-dried at 90–100°C for 4–6 h to below 0.01 wt% moisture. Thermoformed bowls are produced on pressure formers with plug temperatures above 120°C and mold temperatures of 60–90°C; after filling, heat-sealed foil or barrier lidding is applied. Published data for exact post-retort OTR recovery in this specific bowl geometry is limited; validation on the formed part is required. Terminal products include 200–400 g shelf-stable rice and meat bowls, stews, and soup bowls distributed at ambient temperature.
Portion-control cups for sauces, dips, and salad dressings keep the EVOH layer at 4–5% of total sheet thickness and use a 32 mol% ethylene grade, because the small diameter and shallow draw reduce corner thinning relative to deep-draw trays. FDA 21 CFR 177.1360 and EU Regulation (EU) No 10/2011 cover the finished cup; oxygen transmission rate is verified on the formed sidewall by ASTM D3985-17 rather than on flat sheet alone, because corner thinning can reduce local barrier thickness by 15–25%. The sheet line runs at 500–700 kg/h with a five-layer feedblock; EVOH is pre-dried at 90–105°C for 4 h, and the barrier extruder melt temperature is 190–210°C. Thermoforming is carried out on a 40–60 cavity tilt-mold form-fill-seal line with plug-assist, mold temperature of 10–20°C for rapid crystallinity set in the PP layer, and trim by matched metal punches. Terminal part sizes are 30–100 ml cups with foil or PET/PE lidding for ketchup, mustard, mayonnaise, BBQ sauce, salsa, and creamer; the EVOH layer is used to limit oxygen ingress below 0.5 cm³/(m²·day·atm) at 23°C and 50% RH for high-oil dressings over 6–12 months ambient distribution.
Deep-draw compartment trays for frozen and chilled prepared meals present the greatest EVOH layer distribution challenge because the plug-assisted draw ratio exceeds 3:1 in the corner radii between compartments, causing measurable barrier layer thinning. The EVOH layer is specified at 6–8% of flat sheet thickness with a 38 mol% ethylene grade to allow deeper flow without cracking; PP homopolymer outer and food-contact layers are balanced at 80–85% combined thickness, while tie layers are 2–4% each. FDA 21 CFR 177.1360 and EU Regulation (EU) No 10/2011 apply; oxygen transmission rate after thermoforming is measured according to ASTM D3985-17 at 23°C and 50% RH on the thinnest corner section, and the specified maximum is typically 2.0 cm³/(m²·day·atm) for the entire compartment. On the production floor, coextruded sheet is run through a twin-sheet pressure former or a four-station rotary former with articulated plug drives; sheet temperatures are maintained at 140–165°C for PP/EVOH/PP, and plug temperatures are set at 110–130°C to prevent cold-plug punctures. The EVOH layer is placed closer to the outer surface of the tray than the food-contact surface to reduce depth-related thinning across the compartment divider; however, this placement increases sensitivity to ambient humidity and requires a minimum outer PP thickness of 600 µm. Published data for exact layer-thinning distribution in this multi-cavity geometry is limited; formed-part measurement is required. Terminal products include multi-compartment trays for meat with starch, vegetable, and sauce components, with capacities from 400–800 g, sealed with anti-fog lidding after gas flushing.
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In deli and prepared food containers, ethylene-vinyl alcohol copolymer is placed as an internal oxygen-barrier core within coextruded polypropylene sheet rather than as a direct food-contact resin. Commercial extrusion grades specified for this application include EVAL™ F101B and EVAL™ H171B, corresponding to 32 mol% and 38 mol% ethylene comonomer, respectively; Soarnol™ DC3203F and ET3803 are used as equivalent alternatives. Melt flow rate is measured at 190°C under 2.16 kg according to ISO 1133-1:2022, with typical values 1.5–3.5 g/10 min. Density by ISO 1183-1:2022 is 1.14–1.19 g/cm³, and peak melting temperature by ISO 11357-3:2018 is 173–191°C. Degree of saponification exceeds 99%, leaving a hydroxyl-rich chain structure that reduces oxygen diffusion through interchain hydrogen bonding. The resin is dried in desiccant-wheel hopper dryers at 80–90°C for 4–6 h to a moisture content below 0.3 wt% as determined by Karl Fischer titration; ambient exposure above 60% RH for more than 2 h produces splay and gel particles in the barrier layer. In a typical deli tray, EVOH is encapsulated between polypropylene skins with maleic anhydride-grafted polypropylene tie layers and represents 5–10 wt% of total sheet thickness.
Model selection is determined by the water activity of the food and the converting process. EVAL™ F101B with 32 mol% ethylene provides the lowest dry-state oxygen transmission and is used in short-shelf-life deli packs and dry-to-intermediate moisture trays. EVAL™ H171B with 38 mol% ethylene is used for high-moisture prepared food trays and hot-filled containers up to 85°C because the higher ethylene content preserves a greater fraction of dry barrier at equilibrium relative humidity above 80%. Soarnol™ ET3803 in the same 38 mol% ethylene class may differ in molecular weight distribution and thermoforming tack; converters compare the two grades by gel-count quantification and adhesion tests with the selected maleated PP tie layer. A 44 mol% ethylene grade is available for very high-moisture structures but carries a further increase in dry-state oxygen transmission and lower softening temperature; published data for this configuration in deli trays is limited.
Moisture absorbed into the EVOH layer plasticizes the hydroxyl network and opens free-volume pathways for oxygen. For a 32 mol% ethylene grade, manufacturer technical bulletins list oxygen transmission at 23°C/0% RH in the range 0.03–0.08 cm³·20 µm/(m²·day·atm) when measured by ASTM D3985; the value rises to 2–5 cm³·20 µm/(m²·day·atm) at 65% RH and can exceed 10 cm³·20 µm/(m²·day·atm) at 90% RH. A 38 mol% ethylene grade has a higher dry-state oxygen transmission but retains more barrier under moisture; it is therefore assigned to deli meats and prepared foods with surface water activity above 0.95. The PP skins and tie layers slow moisture uptake, but the EVOH core reaches high equilibrium moisture within hours to days depending on sheet thickness and storage temperature. Because published data for oxygen transmission under real food contact conditions are limited, finished tray oxygen transmission is verified according to ASTM D3985 or ASTM F1927 on thermoformed specimens, not inferred solely from flat-film values.
Drying of EVOH requires a desiccant-wheel dryer with outlet air dew point of −40°C or lower and airflow of 0.05 m³/min per kg/h throughput. Hopper loading and discharge must be sealed because EVOH pellets reabsorb moisture rapidly; hopper residence times should not exceed 4 h after drying at 80°C under demand. Moisture analysis is performed by Karl Fischer titration or a calibrated online moisture analyzer. Undried EVOH at 0.5–1.0 wt% moisture causes hydrolytic chain scission during extrusion, reducing melt viscosity and forming bubbles in the barrier layer. Sheet edge trim and start-up purge containing EVOH must be stored in moisture-proof containers before regrinding; otherwise the regrind contributes additional water to the PP layers and creates splay in the skins.
Coextrusion of PP and EVOH creates a thermal mismatch: PP skins typically require 220–250°C melt temperatures for stable sheet, while EVOH should not be held above 240°C for extended periods. Production sheet lines use separate extruders and a feedblock or multi-manifold die. The EVOH extruder is specified with 24:1–30:1 L/D and a medium-work barrier screw; barrel zones are profiled from 160–220°C, and adapter and die zones are held at 210–225°C. Screw speeds above 120 rpm on a 50 mm diameter extruder can cause shear heating and oxidized gel formation; gels appear as clear-to-brown specks in the sheet. Start-up and shutdown require purging the EVOH extruder with low-density polyethylene or polypropylene, and stagnant residence time above 10 min at 225°C promotes crosslinked deposits on die lips. Layer ratio stability is maintained by gravimetric feeders and melt pumps; pump pulsation above ±2% creates visible banding in the EVOH layer and barrier thin spots after forming.
Thermoforming of PP/EVOH/PP sheet is performed on rotary vacuum/pressure formers with plug assist at sheet surface temperatures of 155–180°C; the EVOH layer remains below its thermal degradation limit of 240°C. Cavity temperatures of 110–135°C and plug temperatures of 90–110°C are used to control PP crystallinity and post-forming shrinkage. Corner wall-thickness reductions of 50–70% concentrate stress in the barrier layer and lower effective oxygen barrier at tray corners. The forming window is governed by the PP homopolymer or impact copolymer skins, while the EVOH layer contributes stiffness and creates a discontinuity in extensional rheology. Plug materials with continuous use temperature above 180°C, such as syntactic nylon or PEEK, are used to prevent sticking. Barrier layer continuity is inspected by sectioning filled trays and examining the EVOH layer under polarized light microscopy at 10× magnification; layer breaks longer than 5 mm in the sidewall are rejected.
In sliced deli operations, the EVOH layer is specified to restrict oxygen ingress below the oxidative stability threshold of the packaged meat. For a 250 g pack of sliced turkey stored at 5°C and 50% RH under retail display lighting, converters often target a finished package oxygen transmission rate below 0.5 cm³/(m²·day·atm) to delay lipid oxidation and pigment browning. Tray body and lidding film are sealed through the PP skin layer at 140–160°C sealing bar temperature for 1–2 s; lidding films may also include EVOH or polyester barrier layers. Modified-atmosphere packaging of prepared foods with carbon dioxide/nitrogen blends shifts the barrier demand from oxygen ingress to carbon dioxide retention; EVOH provides carbon dioxide transmission rates approximately 3–5 times lower than its oxygen transmission rates in the dry state, but this relationship narrows under high humidity. PP/EVOH/PP deli trays are limited to microwave reheating with internal food temperatures up to 100°C; oven use above 120°C risks PP deformation, EVOH moisture swelling, and delamination.
PVDC retains oxygen barrier at high relative humidity and provides low water vapor transmission, but it cannot be coextruded as the same type of barrier layer without thermally stable formulations and corrosion-resistant equipment because degradation releases hydrogen chloride at PP processing temperatures. Polyamide 6 is more tolerant of moisture than EVOH and thermoforms readily, but its oxygen barrier at equivalent thickness is 20–60 times lower than dry EVOH, requiring thicker layers or smaller package surface area to meet deli oxygen limits. Polyethylene terephthalate offers stiffness and clarity but requires a thicker sheet or coating to approach deli-level barrier. EVOH is selected when a transparent coextrudable layer must deliver oxygen transmission below 0.1 cm³·20 µm/(m²·day·atm) under dry conditions; the trade-off is the requirement for tie layers and the loss of barrier at equilibrium relative humidity above 70%.
| Barrier material | Oxygen transmission at 23°C, 0% RH (cm³·20 µm/(m²·day·atm)) ASTM D3985 | Oxygen transmission at 23°C, 65% RH (cm³·20 µm/(m²·day·atm)) ASTM D3985 | Water vapor transmission at 38°C, 90% RH (g·20 µm/(m²·day)) ASTM F1249 |
|---|---|---|---|
| EVOH 32 mol% | 0.02–0.08 | 1.5–5.0 | 15–35 |
| EVOH 38 mol% | 0.05–0.15 | 2.0–6.0 | 15–30 |
| PVDC extrusion grade | 0.1–0.5 | 0.5–1.0 | 0.5–2.0 |
| PA6 | 15–30 | 20–40 | 40–80 |
| PET | 70–120 | 70–120 | 15–25 |
These values are typical published ranges from resin supplier technical bulletins and are not purchase specifications; finished package testing on the actual tray geometry is required because corner thinning and layer distribution affect the measured transmission.
Post-industrial trim from PP/EVOH/PP sheet carries fractional EVOH into the reclaim. Regrind addition up to 20 wt% in the PP skin or regrind layer is common; above this level, dispersed EVOH domains can create voids during sheet extrusion and reduce dart-drop impact resistance at 4°C. The regrind stream is dried to below 0.2 wt% moisture and passed through a 40–60 mesh screen pack to remove char and gel particles. Melt-pump discharge stability of ±2% is required to maintain EVOH layer thickness; fluctuations generate barrier thin spots in tray corners after thermoforming. In thin-wall deli cups with sidewall target thickness below 0.30 mm, the EVOH layer may thin to 0.005–0.008 mm; flat-section oxygen transmission testing becomes unreliable because of cylindrical geometry, and destructive layer analysis is used instead.
Adhesion between the EVOH layer and PP skins depends on the maleic anhydride graft level and tie-layer thickness. Tie resins with anhydride graft content 0.5–1.5 wt% are processed at 5–10 µm thickness. Peel adhesion below 4 N/15 mm at 23°C after steam exposure indicates insufficient tie-layer coverage or moisture at the interface; delamination initiated at tray corners is the primary field failure mode. The tie layer is specified by ASTM F904 peel testing on coextruded sheet before and after 2 h immersion in water at 85°C to simulate hot-fill conditions.
Before commercialization, converters obtain food-contact statements from the EVOH supplier. Verification for European markets follows EU Regulation (EU) No 10/2011 Article 18 and Annex I; overall migration testing is conducted according to EN 1186 with simulant B (3% acetic acid) for acidic deli products and simulant D2 for fatty prepared foods. The PP food-contact layer, not the EVOH core, controls migration; tie-layer and skin materials must meet FDA 21 CFR 177.1520 for olefin polymers. EVOH grades may be authorized through specific Food Contact Notifications, and the FCN number, maximum layer thickness, and food-type restrictions must be confirmed in the supplier documentation.
| Control point | Standard or method | Acceptance criterion |
|---|---|---|
| EVOH layer continuity | Microtome sectioning and polarized light microscopy | No layer break longer than 5 mm in formed tray wall |
| Oxygen transmission of formed tray | ASTM D3985 | <0.5 cm³/(m²·day·atm) at 23°C/50% RH |
| Interlayer adhesion | ASTM F904 | Peel force >4 N/15 mm |
| Overall migration | EN 1186 | <10 mg/dm² |
| Moisture content before extrusion | Karl Fischer titration | <0.3 wt% |
Production-scale failure modes observed on actual sheet lines include barrier-layer banding from gear-pump pulsation above ±2%, gel specks from EVOH stagnation at die lips, and tray corner delamination caused by tie-layer starvation at high draw ratios. When hot-fill temperatures approach 85°C, PP/EVOH/PP structures require thicker EVOH layers or lower fill temperatures because moisture uptake accelerates once the PP skins begin to soften. In microwavable prepared-food applications, the package must be assessed after 1,200 W reheating for 2 min because steam generation inside the food can exceed the WVTR capability of the PP skins and create localized moisture pockets at the EVOH interface. Published data for this specific configuration is limited; therefore, converters relying on EVOH for deli trays should qualify each commercial grade with the selected tie resin, PP skin, regrind ratio, and thermoforming tool layout rather than transferring a previously validated structure without trial runs.
