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

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To System

500 - 1000 m

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Real time locating system for Rigid Containers

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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: bloompak@rediffmail.com , bloompack@rediffmail.com

www.bloompackaging.com,

Thank You

Questions ??