Rigid and Speciality Packaging
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Transcript of Rigid and Speciality Packaging
Rigid and Specialty Containers
Bhupendra SinghBloom Packaging Pvt. Ltd.
Topics for Discussion
• Rigid Containers
• Innovations in Rigid Containers
• Specialty Packaging
Some Examples
Materials Used in Rigid Packaging
• Polypropylene• Polyethylene
– HDPE– LDPE– LLDPE– EVA
• Polystyrene– GPPS– HIPS– ABS– SAN
• PVC• PET• PC
Materials Used
Injection M ouldingeg. containers, pails, closures
B low M ouldingeg. bottles, jars
Therm oform ingeg. cups, glasses, tubs, potion packs
Rigid P lastic Packaging
Injection M ouldingeg. containers, pails, closures
B low M ouldingeg. bottles, jars
Therm oform ingeg. cups, glasses, tubs, potion packs
Rigid P lastic Packaging
Processes
Extrusion Blow Molding
Extrusion Pinch Off Blowing Cooling
Pinch Off
Injection Blow Molding
Blow Molds
Material of Construction :
– Mild Steel
– Aluminum
– Beryllium Copper Essential requirements on the mould :
– Adequate cooling, preferably along the contours of the cavity
– Cooling of thicker areas of the article like neck, top and bottom pinch-offs.
– Surface Mating.
– Proper alignment of the two halves
– Sandblast finish for moulds of 5 litres and above of 40 / 50 mesh grit.
Modifications In Die Design
• Testing can be divided in to two parts :
• Quality Control : Testing of incoming raw materials
• Quality Assurance : Testing of finished products
• Plastics testing can be divided into testing of plastic raw materials ( generally granules ) & testing of finished products after moulding.
Testing of Rigid Packages
Processes
High Density Polyethylene (HDPE) and Polypropylene (PP) are the
most widely used resin for blow moulding applications.
Types of Blow Moulding :
– Extrusion blow moulding - Continuous type and Intermittent type
– Injection blow moulding
– Extrusion stretch blow moulding
– Injection stretch blow moulding
Processing Temperatures
Additives for Rigid Containers• What are Additives?• Why are they used?• Where are they used?• What are their functions?
• Plastics are being used in every possible application.
• Thermoplastic materials are processed in the molten state at high temperatures and under high shear. During their service life they have to survive severe exposure to conditions such as heat, light humidity, without changes in appearance or premature mechanical failure in some cases for several decades.
• WITHOUT SUITABLE ADDITIVES NONE OF THESE DEVELOPMENTS WOULD BE POSSIBLE
• ADDITIVES ARE THE MIRACLE WORKERS OF PLASTICS
Types of Additives
1. Antioxidants2. UV Stabilizers3. PVC Stabilizers4. Plasticizers5. Flame Retardants6. SIip and Antiblock Agents7. Antistatic Agents8. Nucleating Agents9. Clarifying agents10. Chemical Foaming Agents
11. Antimicrobial12. Lubricants
(Internal and External)13. Fillers and Reinforcements14. Coupling agents15. Antifogging additives16. Acid Scavengers17. Polymer Processing aids18. Colourants19. Flourescent Whitening agents
Selection Criteria for Additives
1. Property desired by the customer.2. Duration of Property desired.3. Polymer to be added to.4. Compatibility to the polymer.5. Temperature of processing and mode of processing.6. Mode of addition.7. Reaction with other additives in the system.8. Shelf life of the additive.9. Regulations and norms to be followed.10. Testing details.11. End use of the product.
Masterbatches
• What are they?
- Highly concentrated colour or additive carriers which have to be let down at a low percentage to improve the properties of the moulding / extrudate.
• Types of masterbatches
- Colour masterbatches and additive masterbatches
Colour Masterbatches
• Highly loaded with inorganic and organic pigments
• 2 types of colour masterbatches
1. Universal masterbatches. (Usually LLDPE based in India)
2. Resin Specific masterbatches. (eg. PET based for PET, PC for PC etc.,)
Shades are checked visually in a light booth and digitally using a colour spectrophotometer
Decoration
• UV Printing– High Outputs – 80 UPM – 3
colours
• Labeling– High Speed accurate labeling
lines working at 120 upm
• Hot foil Stamping
Design & Development
• 2D Software – AUTOCAD
• 3D Software –
- Pro Engineering
- Uni Graphics
• Imaging - 3D Studio
The IBC concept
Extremely light and space saving container system.
Specially made for multi trip capabilities.Large packaging unit size, reduces number of
units to be handled. Lower cost of filling, storage, handling and transportation.
Innovations in Design
• Easy to carry & Innovative Closure device
Innovations in Design
• Innovative Closure with Moisture absorber
Innovations in Design
• Innovative Vented Induction Sealing Wads
Normal Wad Vented Wad
Innovations in Barrier Packaging
Barrier Solutions• Fluorination• Co-extrusion• Sulphonation
Direct Fluorination
F
FC
FF
F
CHH
HH
F2
• The fluorination process is based on the formation of a fluorocarbon barrier layer on the polymer surface.
• The basic reaction which occurs with HDPE is a substitution of fluorine in place of hydrogen atoms on the polymer backbone as shown in figure.
• The bulk properties of fluorine treated plastic container remains unchanged.
Fluorination Techniques
1 2 3 4 5 F
•Offline Direct Fluorination •Inline/ Online Fluorination
1 2 3F-C-HF-C-H
F-C-H
F-C-H
H-C-FH-C-F
H-C-FH-C-F
F-C-HF-C-HF-C-H
CF F
CF F
CF F
Testing of Fluorination
• Fluorination treatment is quantified using Fourier Transformation Infra Red Spectroscopy (FTIR). C-H bond shows peak absorption at 1440 – 1480 cm-1, while C-F bond gives peak absorbance at 930 – 1320 cm-1.
C-H Peak
C-F Peak
Before Fluorination
After Fluorination
Applications for Fluorination TechnologyChemical, petrochemical,automotive,
Plugs for Solvent containers
HDPE automotive fuel tanksOil Packaging
Flavor Packaging
Direct Printing Applications
solvents,inks, hardener etc
Pesticide Packaging
Applications for Fluorination Technology
Surface Treatment for Chemical Resistance
Co-extrusion Technology
• Comprises of either three, four or six layers,
• including HDPE and an inner EVOH or Nylon layer
Co-extrusion Technology
Below is a typical cross section of a 6 layer co-ex container:1. PP / HDPE2. Adhesive3. EVOH / Nylon4. Adhesive5. Regrind / PCR6. PP / HDPEThese process steps are the same as for Extrusion Blow Moulding.
Sulphonation Technology
• The containers are treated with SO3 gas on
the Plastic Surface.
• Sulphonation of Plastic results in improved barrier Properties.
New Resins in Market
• N-MXD6 made from Meta xylene Diamide
• Due to its unique chemical composition and crystalline structure, N-MXD6 has excellent gas barrier properties, especially in high humidity conditions as compared to N-6.
Nanocomposites
• Nano-composites are of Recent origin but they promise to rule the future of the Rigid containers.
What’s - Nanocomposites
• Nanocomposites – particle size smaller than 1 X 10-9m• Platy / layered structures that need to be separated by
high shear to attain the advantage of the nanoclay.• Very good overall physical properties at low addition
levels (3-4 %)• Can behave as non halogenated flame retardants• Low part weight• Better Barrier properties• Disadvantage:
– Expensive filler at present– Application – at the moment only automotive– Technology is in Nascent Stage
Biodegradable Packaging
• PLA (Polylactic Acid)• PHAs , {PHBV
(Polyhydroxy Butyrate Velarate)}• Starch Blends
Active Packaging
• Antimicrobial Packaging• Scavenger Packaging• Intelligent Packaging etc.
Innovations in Supply Chain
Bar Code and RFID Systems
Bar codes on Retail items – EAN or UPC
890 1 0 0 0 0 1 0 0 1 0
EAN prefix Prod no. CD• EAN Prefix indicates
- the country of EAN membership
- EAN member’s identity
• Prod. No. : Item identity allocated by manufacturer/importer
• Check digit: Calculated from all preceding digits
Tagged
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To System
500 - 1000 m
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Real time locating system for Rigid Containers
Reader
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Retail supply chain
Supplier Retailer Consumer
RFID
Data Recorded on the SystemSerial numberProduction dateFilling dates and sitesTare weight etc.
Bhupendra Singh
Bloom Packaging Pvt. Ltd.167- Ready Money Terrace, Dr. A.B. Road, Worli Naka, Worli, Mumbai – 400 018
Tel No. : 022-24970561, 32501137, 32501128
Email: [email protected] , [email protected]
www.bloompackaging.com,
Thank You
Questions ??