Grease masking packaging materials and methods thereof

Abstract

The present invention relates generally to the packaging materials. More specifically, the invention relates to materials and methods suitable for use as packaging materials whereby the appearance of grease, fat or oil staining on the packaging material is reduced or eliminated.

What is claimed is:  
     
         1 . A material for packaging grease, fat or oil-containing substances, wherein the material comprises: 
 a. a grease, fat or oil permeable substrate suitable for use as a packaging material, wherein the substrate has an inner and an outer surface;    b. a dark colored layer comprising a dark colorant and having an inner and an outer surface, wherein the dark colored layer is optionally applied from a solution comprising a dark colorant, and wherein the inner surface of the dark colored layer is disposed proximal to the outer surface of the substrate; and    c. a light colored layer having an inner and an outer surface, wherein the light colored layer is applied from a solution comprising a light colorant, and wherein the inner surface of the light colored layer is disposed proximal to the outer surface of the dark colored layer;    wherein one or more of the light colored or dark colorant-containing solutions each, independently, comprises a binder material at from about 17% to about 60% by weight of the respective colorant-containing solution, wherein the dark and light colored layers are selected to mask an appearance of grease, fat or oil staining on the packaging material, and wherein neither the dark colored layer nor the light colored layer comprises a non-leafing metallic ink.    
     
     
         2 . The packaging material of  claim 1 , wherein the inner surface of the light colored layer is adjacent to the outer surface of the dark colored layer.  
     
     
         3 . The packaging material of  claim 1 , wherein the inner surface of the dark colored layer is adjacent to the outer surface of the substrate.  
     
     
         4 . The packaging material of  claim 1 , wherein the dark colorant comprises one or more of: carbon black, raw sienna, burnt sienna, burnt umber, chrome black, high purity furnace black, black azo dyes or brown azo dyes.  
     
     
         5 . The packaging material of  claim 1 , wherein the dark colorant comprises carbon black.  
     
     
         6 . The packaging material of  claim 1 , wherein the light colorant comprises one or more of: titanium dioxide, calcium carbonate, calcium silicate, calcium sulfate, barium sulfate, natural clay, synthetic clay, magnesium oxide, magnesium silicate, zinc carbonate, zinc oxide or plastic pigment.  
     
     
         7 . The packaging material of  claim 1 , wherein the light colorant comprises titanium dioxide.  
     
     
         8 . The packaging material of  claim 1 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution comprises from about 0.01 to about 20.0% by weight of the dark colorant as measured by total weight of the solution.  
     
     
         9 . The packaging material of  claim 1 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution comprises from about 0.25 to about 4.0% by weight of the dark colorant as measured by total weight of the solution.  
     
     
         10 . The packaging material of  claim 1 , wherein the light colorant-containing solution comprises from about 30 to about 90% by weight of the light colorant as measured by total weight of the solution.  
     
     
         11 . The packaging material of  claim 1 , wherein the light colorant-containing solution comprises from about 40 to about 80% by weight of the light colorant as measured by total weight of the solution.  
     
     
         12 . The packaging material of  claim 1 , wherein the substrate comprises one or more dark colored outer plys, thereby providing the dark colored layer on the outer surface of the substrate.  
     
     
         13 . The packaging material of  claim 1  having a TAPPI brightness number of from about 60 to about 90.  
     
     
         14 . The packaging material of  claim 1 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution further comprises a sizing agent, dark colored pigment and water.  
     
     
         15 . The packaging material of  claim 14 , wherein the sizing agent comprises starch.  
     
     
         16 . The packaging material of  claim 1 , wherein the grease, fat or oil permeable substrate comprises paperboard, paper or fabric.  
     
     
         17 . The packaging material of  claim 1 , wherein the grease, fat or oil permeable substrate comprises paperboard.  
     
     
         18 . The packaging material of  claim 17 , wherein the paperboard comprises one or more of: SBS, SUS or recycled paperboard.  
     
     
         19 . The packaging material of  claim 1 , wherein the packaging material is suitable for use in packaging of human food, animal food, drugs or cosmetics.  
     
     
         20 . The packaging material of  claim 1 , wherein one or more of the dark or the light colorant-containing solutions each, independently, further comprise one or more of: water, dispersant, resin, surfactant, wetting agent, defoamer, thickener, starch, preservative or antioxidant.  
     
     
         21 . The packaging material of  claim 1 , wherein the binder is present at from about 20 to about 50% by weight of the light or dark colorant-containing solutions.  
     
     
         22 . The packaging material of  claim 1 , wherein the binder comprises one or more of a naturally or synthetically derived binder.  
     
     
         23 . The packaging material of  claim 1 , wherein the binder comprises a latex polymer and a protein.  
     
     
         24 . The packaging material of  claim 23 , wherein the ratio of latex polymer to protein is from about 2:1 to about 10:1.  
     
     
         25 . The packaging material of  claim 1 , further comprising a printed layer adjacent to the outer surface of the light colored layer.  
     
     
         26 . An article prepared from the packaging material of  claim 1 .  
     
     
         27 . The article of  claim 26 , wherein the article further comprises a consumer good.  
     
     
         28 . The article of  claim 26  in the form of a wrap, pouch, bag, box, cup, tray, plate, can, tube or bottle.  
     
     
         29 . The article of  claim 26 , further comprising a food material comprising one or more of: sweets, chocolate, confectionery, pastries, biscuits, dairy products, powdery foodstuffs, frozen food, fresh and semipreserved foods, pet food, or carryout foods.  
     
     
         30 . The article of  claim 26 , further comprising a non-food material comprising one or more of: cosmetics, toiletries, pharmaceuticals, cigarettes, detergents, textiles, toys, games, tools, household appliances, pesticides, fertilizers, hobby items, paper products, cassettes, record sleeves, or auto parts.  
     
     
         31 . A material for packaging grease, fat or oil-containing substances, wherein the material comprises: 
 a. a grease, fat or oil permeable substrate suitable for use as a packaging material, wherein the substrate has an inner and an outer surface;    b. a dark colored layer comprising a dark colorant and having an inner and an outer surface, wherein the dark colored layer is optionally applied from a composition comprising a dark colorant, and wherein the inner surface of the dark colored layer is disposed proximal to the outer surface of the substrate; and    c. a light colored layer having an inner and an outer surface, wherein the light colored layer is applied from a composition comprising a light colorant and one or more of: polyethylene, polypropylene, polyester, polystyrene, or halogenated or non-halogenated vinyl polymer, and wherein the inner surface of the light colored layer is disposed proximal to the outer surface of the dark colored layer;    wherein the dark and light colored layers are selected to mask an appearance of grease, fat or oil staining on the packaging material, and wherein neither the dark colored layer nor the light colored layer comprises a non-leafing metallic ink.    
     
     
         32 . The packaging material of  claim 31 , wherein the dark colored layer is applied from the dark colorant-containing composition and the dark and light colored compositions each, independently, comprise from about 5 to about 40% colorant as measured by the total weight of each colored composition.  
     
     
         33 . The packaging material of  claim 31 , wherein the dark colored layer is applied from the dark colorant-containing composition and the composition comprises one or more of: polyethylene, polypropylene, polyester, polystyrene, or halogenated or non-halogenated vinyl polymer.  
     
     
         34 . An article prepared from the packaging material of  claim 31 .  
     
     
         35 . The article of  claim 34  in the form of a wrap, pouch, bag, box, cup, tray, plate, can, tube or bottle.  
     
     
         36 . The article of  claim 34  further comprising a consumer good.  
     
     
         37 . The article of  claim 34  further comprising a food material comprising one or more of: sweets, chocolate, confectionery, pastries, biscuits, dairy products, powdery foodstuffs, frozen food, fresh and semipreserved foods, pet food, or carryout foods.  
     
     
         38 . The article of  claim 34  further comprising a non-food material comprising one or more of: cosmetics, toiletries, pharmaceuticals, cigarettes, detergents, textiles, toys, games, tools, household appliances, pesticides, fertilizers, hobby items, paper products, cassettes, record sleeves, or auto parts.  
     
     
         39 . A material for packaging grease, fat or oil-containing substances, wherein the material comprises: 
 a. a grease, fat or oil permeable substrate suitable for use as a packaging material, wherein the substrate has an inner and an outer surface;    b. a dark colored layer comprising a dark colorant and having an inner and an outer surface, wherein the dark colored layer is optionally applied from a solution comprising a dark colorant, and wherein the inner surface of the dark colored layer is disposed proximal to the outer surface of the substrate; and    c. a light colored layer having an inner and an outer surface, wherein the light colored layer is applied from a solution comprising a light colorant, and wherein the inner surface of the light colored layer is disposed proximal to the outer surface of the dark colored layer;    wherein one or more of the light colored or dark colorant-containing solutions each, independently, comprises a binder material at from about 17% to about 60% by weight of the respective colorant containing solution, wherein the dark and light colored layers are selected to mask an appearance of grease, fat or oil staining on the packaging material, and wherein both the dark colorant and light colorant containing solutions are aqueous.    
     
     
         40 . The packaging material of  claim 39 , wherein neither the dark colored layer nor the light colored layer comprises a non-leafing metallic ink.  
     
     
         41 . The packaging material of  claim 39 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution comprises a sizing agent, dark colored pigment and water.  
     
     
         42 . The packaging material of  claim 39 , wherein the sizing agent comprises starch.  
     
     
         43 . The packaging material of  claim 39 , wherein the grease, fat or oil permeable substrate comprises paperboard, paper or fabric.  
     
     
         44 . The packaging material of  claim 43 , wherein the substrate comprises paperboard comprising one or more of: SBS, SUS or recycled paperboard.  
     
     
         45 . The packaging material of  claim 39 , wherein the packaging material is suitable for use in packaging human food, animal food, drugs or cosmetics.  
     
     
         46 . The packaging material of  claim 39 , wherein the binder comprises one or more of: a naturally or a synthetically derived binder.  
     
     
         47 . The packaging material of  claim 39 , wherein the binder comprises a latex polymer and a protein.  
     
     
         48 . The packaging material of  claim 47 , wherein the ratio of latex polymer to protein is from about 2:1 to about 10:1.  
     
     
         49 . An article prepared from the packaging material of  claim 39 .  
     
     
         50 . The article of  claim 49 , in the form of a wrap, pouch, bag, box, cup, tray, plate, can, tube or bottle.  
     
     
         51 . The article of  claim 49  further comprising a consumer good.  
     
     
         52 . The article of  claim 49  further comprising a food material comprising one or more of: sweets, chocolate, confectionery, pastries, biscuits, dairy products, powdery foodstuffs, frozen food, fresh and semipreserved foods, pet food, or carryout foods.  
     
     
         53 . The article of  claim 49  further comprising a non-food material comprising one or more of: cosmetics, toiletries, pharmaceuticals, cigarettes, detergents, textiles, toys, games, tools, household appliances, pesticides, fertilizers, hobby items, paper products, cassettes, record sleeves, or auto parts.  
     
     
         54 . A method of making a packaging material that masks grease, fat or oil permeation in a grease, fat or oil permeable packaging material comprising the steps of: 
 a. providing a grease, fat or oil permeable substrate suitable for use as a packaging material, wherein the substrate has an inner and an outer surface;    b. selecting a dark colored layer having an inner and an outer surface and a light colored layer having an inner and an outer surface, wherein the layers are together suitable for masking an appearance of a grease, fat or oil permeation on the packaging material;    c. applying the dark colored layer proximal to the outer surface of the substrate, wherein the dark colored layer is optionally applied from a solution comprising a dark colorant; and    d. applying the light colored layer proximal to the outer surface of the dark colored layer, wherein the light colored layer is applied from a solution comprising a light colorant;    wherein one or more of the dark or light colorant-containing solutions each, independently, comprises a binder material at from about 17% to about 60% by weight as measured by weight of the respective solution, and wherein neither the dark colored layer nor the light colored layer comprises a non-leafing metallic ink.    
     
     
         55 . The method of  claim 54 , wherein the inner surface of the dark colored layer is adjacent to the outer surface of the substrate.  
     
     
         56 . The method of  claim 54 , wherein the inner surface of the light colored layer is adjacent to the outer surface of the dark colored layer.  
     
     
         57 . The method of  claim 54 , wherein the dark colorant comprises one or more of: carbon black, raw sienna, burnt sienna, burnt umber, chrome black, high purity furnace black, black azo dyes or brown azo dyes.  
     
     
         58 . The method of  claim 54 , wherein the dark colorant comprises carbon black.  
     
     
         59 . The method of  claim 54 , wherein the light colorant comprises one or more of: titanium dioxide, calcium carbonate, calcium silicate, calcium sulfate, barium sulfate, natural clay, synthetic clay, magnesium oxide, magnesium silicate, zinc carbonate, zinc oxide or plastic pigment.  
     
     
         60 . The method of  claim 54 , wherein the light colorant comprises titanium dioxide.  
     
     
         61 . The method of  claim 54 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution comprises from about 0.01 to about 20.0% by weight of the dark colorant as measured by total weight of the solution.  
     
     
         62 . The method of  claim 54 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution comprises from about 0.25 to about 4.0% by weight of the dark colorant as measured by total weight of the solution.  
     
     
         63 . The method of  claim 54 , wherein the light colorant-containing solution comprises from about 30 to about 90% by weight of the light colorant as measured by total weight of the solution.  
     
     
         64 . The method of  claim 54 , wherein the light colorant-containing solution comprises from about 40 to about 80% by weight of the light colorant as measured by total weight of the solution.  
     
     
         65 . The method of  claim 54  having a TAPPI brightness number of from about 60 to about 90.  
     
     
         66 . The method of  claim 54 , wherein the dark colored layer is applied from the dark colorant-containing solution and the solution further comprises a sizing agent, dark colored pigment and water.  
     
     
         67 . The method of  claim 66 , wherein the sizing agent comprises starch.  
     
     
         68 . The method of  claim 54 , wherein the grease, fat or oil permeable substrate comprises paperboard, paper or fabric.  
     
     
         69 . The method of  claim 54 , wherein the grease, fat or oil permeable substrate comprises paperboard.  
     
     
         70 . The method of  claim 69 , wherein the paperboard comprises one or more of: SBS, SUS or recycled paperboard.  
     
     
         71 . The method of  claim 54 , wherein the packaging material is suitable for use in packaging human food, animal food, drugs or cosmetics.  
     
     
         72 . The method of  claim 54  further comprising the step of forming the packaging material into a wrap, pouch, bag, box, cup, tray, plate, can, tube or bottle, thereby forming an article.  
     
     
         73 . The method of  claim 72 , further comprising the step of including a packaged material in the article, wherein the packaged material comprises one or more of: sweets, chocolate, confectionery, pastries, biscuits, dairy products, powdery foodstuffs, frozen food, fresh and semipreserved foods, pet food, carryout foods, cosmetics, toiletries, pharmaceuticals, cigarettes, detergents, textiles, toys, games, tools, household appliances, pesticides, fertilizer, hobby items, paper products, cassettes, record sleeves, or auto parts.  
     
     
         74 . The method of  claim 54 , wherein one or more of the dark colored layer and the light colored layers each, independently, comprises one or more of: water, dispersant, resin, surfactant, wetting agent, defoamer, thickener, starch, preservative or antioxidant.  
     
     
         75 . The method of  claim 54 , wherein the binder comprises one or more of: a naturally or synthetically derived binder.  
     
     
         76 . The method of  claim 54 , wherein the binder comprises a latex polymer and a protein.  
     
     
         77 . The method of  claim 76 , wherein the ratio of latex polymer to protein is from about 2:1 to about 10:1.  
     
     
         78 . The method of  claim 54 , further comprising applying a printed layer adjacent to the outer surface of the light colored layer.  
     
     
         79 . A method for masking grease, fat or oil staining on a packaging material, wherein the method comprises the steps of: 
 (a) contacting the packaging material of  claim 54  with a grease, fat or oil containing material.    
     
     
         80 . A method of making a packaging material that masks grease and oil permeation in a grease, fat or oil packaging material, comprising the steps of: 
 a. providing a grease, fat or oil permeable substrate having an inner and an outer surface, wherein the substrate is suitable for use as a packaging material;    b. selecting a dark colored layer having an inner and an outer surface and a light colored layer having an inner and an outer surface, wherein the layers are together suitable for masking an appearance of grease, fat or oil permeation on the packaging material;    c. extruding a composition comprising a dark colorant proximal to the outer surface of the substrate, thereby providing the dark colored layer; and    d. extruding, either simultaneously or sequentially to step (c), a composition comprising a light colorant proximal to the outer surface of the dark colored layer, thereby providing the light colored layer.    
     
     
         81 . The method of  claim 80 , wherein the dark colored layer and light colored layer each, independently, comprises one or more of: polyethylene, polypropylene, polyester, polystyrene or halogenated or non-halogenated vinyl polymer.  
     
     
         82 . The method of  claim 80 , wherein the dark colored layer and the light colored layer each, independently, comprise from about 5 to about 40% colorant as measured by total weight of each individual layer.  
     
     
         83 . The method of  claim 80 , wherein the light colored layer comprises one or more of: titanium dioxide, calcium carbonate, calcium silicate, calcium sulfate, barium sulfate, natural clay, a synthetic clay, magnesium oxide, magnesium silicate, zinc carbonate or zinc oxide.  
     
     
         84 . The method of  claim 80 , wherein the light colored layer comprises titanium dioxide.  
     
     
         85 . The method of  claim 80 , wherein the substrate comprises paperboard comprising one or more of: SBS, SUS or recycled paperboard.  
     
     
         86 . The method of  claim 80 , wherein the packaging material is suitable for use in packaging human food, animal food, drugs and cosmetics.  
     
     
         87 . The method of  claim 80  further comprising forming the packaging material into a wrap, pouch, bag, box, cup, tray, plate, can, tube or bottle, thereby forming an article.  
     
     
         88 . The method of  claim 87  further comprising including a packaged material in the article comprising one or more of: sweets, chocolate, confectionery, pastries, biscuits, dairy products, powdery foodstuffs, frozen food, fresh and semipreserved foods, pet food, carryout foods, cosmetics, toiletries, pharmaceuticals, cigarettes, detergents, textiles, toys, games, tools, pesticides, fertilizers, household appliances, hobby items, paper products, cassettes, record sleeves, or auto parts.  
     
     
         89 . A method for masking the appearance of grease, fat or oil staining on a packaging material, wherein the method comprises: 
 (a) contacting the packaging material of  claim 80 , with a grease, fat or oil containing material.    
     
     
         90 . A method for making a packaging material that masks grease, fat or oil permeation in a grease, fat or oil permeable packaging material, comprising the steps of: 
 a. providing a grease, fat or oil permeable substrate having an outer surface and a dark colored outer layer having an inner and an outer surface, wherein the substrate is suitable for use as a packaging material; and    b. extruding a composition comprising a light colorant proximal to the outer surface of the dark colored outer layer, thereby providing a light colored outer layer, 
 wherein the dark colored layer and the light colored outer layer are selected so as to mask the appearance of grease, fat or oil staining on the packaging material, thereby providing a packaging material suitable for masking the appearance of grease, fat or oil on the material.  
   
     
     
         91 . The method of claim  90 , wherein the dark colored outer layer is obtained by extruding a composition comprising a dark colorant proximal to the outer surface of the substrate prior to the extrusion step.  
     
     
         92 . The method of claim  90 , wherein the dark colored outer layer is obtained by applying a solution comprising a dark colorant to the outer surface of the substrate prior to the extrusion step.  
     
     
         93 . The method of claim  90 , wherein the dark colored outer surface is obtained by placing a dark colored paper or fabric layer on the outer surface of the substrate prior to the extrusion step.  
     
     
         94 . The method of claim  90 , wherein the dark colored outer surface is obtained by including one or more dark colored plys in the outer surface of the substrate prior to the extrusion step.  
     
     
         95 . A method for masking grease, fat or oil staining on a packaging material method, wherein the method comprises: 
 a. contacting the packaging material of claim  90  with a grease, fat or oil containing material.    
     
     
         96 . A method for making a material for masking grease and oil permeation in a grease, fat or oil permeable, substrate, comprising the steps of: 
 a. providing a grease, fat or oil permeable substrate having an inner and an outer surface, wherein the substrate is suitable for use as a packaging material;    b. selecting a dark colored layer and a light colored layer wherein the layers are together suitable for masking grease, fat or oil permeation in the substrate;    c. extruding either simultaneously or sequentially a composition comprising a dark colorant and a composition comprising a light colorant, thereby forming a laminate material having an inner and an outer surface, wherein the light colored layer forms the outer surface of the laminate material and the dark colored layer forms the inner surface of the laminate material;    d. applying the inner surface of the laminate material to the outer surface of the substrate, 
 thereby providing a packaging material suitable for masking the appearance of grease, fat or oil on the material.  
   
     
     
         97 . A method for masking grease, fat or oil staining on a packaging material, wherein the method comprises: 
 a. contacting the packaging material of claim  96 , with a grease, fat or oil containing material.