blow moulding process & barrier containers part 4 testing

Assocomaplast - Centro Direzionale Milanofiori - Palazzo F/3 - 20090 Assago - Milan - Italy - tel +39 02 8228371 - fax +39 02 57512490 - e-mail: info@assocomaplast.org www.assocomaplast.org

Blow Moulding Process

& Barrier Containers

Part 4 Testing

AFNOR SN ÖNORM

Testing standards

Procedure

Equipment/materials

Calculation & records

Operator

Figures for absolute evaluation

and/or comparison

Testing standards

THERMAL: TEMPERATURE RESISTANCE (HEAT AND COLD)

PHYSICAL: MELT INDEX (MFI, I2) MELTING POINTDENSITY SOFTENING POINTMOLECULAR WEIGHT (MW, Mw, MN, Mz) THERMAL CONDUCTIVITYMOLECULAR WEIGHT DISTRIBUTION (MWD, U, D) SPECIFIC HEATVISCOSITY (VS. SHEAR RATE) HEAT CAPACITYMELT TENSION COEFFICIENT OF LINEAR EXPANSIONCRYSTALLINITY LEVEL ELECTRICAL: DIELECTRIC CONSTANT

LOSS FACTORMECHANICAL: TENSILE STRENGTH SPECIFIC RESISTANCE

ELONGATION SURFACE RESISTANCEMODULUS CONDUCTIVITYTEAR RESISTANCE OTHERS: ENVIRONMENTAL STRESS CRACK

RESISTANCE (ESCR)

TEAR PROPAGATION FORCE PERMEABILITY (WVTR, 02, N2, CO2, ETC.)FLEX. - RESISTANCE RESISTANCE TO BIODEGRADATION/PHOTOTORSION UV STABILITYHARDNESS RADIATION RESISTANCEIMPACT RESISTANCE (DDI, IZOD, CHARPY) FIRE RESISTANCEPUNCTURE RESISTANCE COEFFICIENT OF FRICTION (C.O.F.)

INDUCED BLOCKOPTICAL: CLARITY SHRINK

GLOSS SOLUBILITYHAZE IR & UV ABSORPTIONREFRACTIVE INDEX FATIGUE

CREEP WEATHER RESISTANCE MOISTURE ABSORPTION CHEMICAL RESISTANCE SEAL STRENGTH

Properties of thermoplastic resins

After de-flashing all bottles are checked for minimum top load,

presence of holes and for tight performance.

Default bottles are discarded immediately.

On line testing

ISO Standards, EN Standards, ASTM Standards, National Standards

Brand Owner Specifications, Customer Specifications

Raw materials: MI, MWD, viscosity, density, color, ESCR

Bottles: Top load, impact resistance, ESCR, barrier properties, optical and physical properties, chemical resistance

Blowmoulders need a QC Lab to guarantee quality consistency

Bottle testing

Topload

Displacement

Elastic deformation(resin dependent)

Buckling of bottle

Max. toploadCrossheadmoving down

Environmental stress crack resistance

measured on resin (plates)

Internal pressure test:

bottle filled 1/3 of volume with Igepal 10% solution

bottle closed with cap and pressurized (e.g. 400 mbar)

equipment placed in hot room (40°C)

timer detects time of failure (pressure loss)

P = 400 mbar

Environmental stress crack

resistance measured on bottles

Impact resistance according to ASTM D 2463 mostly measured by Bruceton staircase method especially important for dangerous goods packaging

Falling height and testing °T varies, according to application

Impact resistance by free falling

Test for containers for dangerous goods

EN ISO 16101:2004

Test for determination of chemical resistance

EN ISO 175:2000

Dangerous goods and Chemical

resistance

For performance evaluation of containers which is not possible to beevaluated according to standards, is used the “panel test” (Procedureis described in a standard).A number of “experts” is requested to evaluate separately the performance of an item (e.g. smell) and to report separately about their findings.

Panel test

Not legal ones:

Technical data sheet

Legal ones:

Sales specification/Contract

(M)SDS

Compliance Letter for Food Contact (Pharma, Toys)

Legal papers and not in the Blow

Moulding business

Show SDS

Basic food law: no adulteration of food

Composition: positive lists (e.g. monomers, additives)

Quantity limits

Residual limits

Purity requirements

Migration (EU): overall

specific

Extractables (FDA*)

* FDA = the US Food and Drug Administration

General requirements of food packaging

materials

Food laws (by country)– individual foodstuffs– general food additives– finished food contact articles

• paper• glass• ceramics• wood• plastics• etc.

Food contact regulations

Status in Europe today is a mixture of:• EU-Directives and National Regulations

EU-Directives:• Framework Directive (1989)

• Specific Directives (e.g. for Plastics)• EU-Directive 2002/72/EC

(+ pending 1:st amendment)– overall and specific migration– monomers + certain additives– quantity limitations

Food contact regulations (1)

Status in Europe today is a mixture of:

EU-Directives and National Regulations

National Regulations: Positive lists by country

(e.g. additives, polymerization aids, process aids, initiators,

catalyst residues) Implementation of EU-Directives into the national food contact

regulations (EU-Directive vs. EU-Regulation)

Food contact regulations (2)

European Union (EU) clearance

A) migration: < 0.05 ppm (50 ppb)

– 3 - 6 months

– 50 000 USD

B) migration: 0.05 ppm - 5 ppm

– about 1 year

– 180 000 USD

C) migration: > 5 ppm (< 60 ppm)

– up to 5 years

– up to 1.5 MM USD

Required toxicological (TOX) testing per

substance

films (50 - 200 µ) sheets (1 - 2 mm)

• Overall and Specific migration testing

(using specified Exposure Time & Temperature)

+ oil (olive oil)

+ Acetic acid (3%)

+ Ethanol (10 %)

+ hexane respectivly xylene

Food contact testing

• Extractables (FDA)

• Resin supplier migration tests

• It is the responsibility of resin converters and food packers to make

sure that finished articles meet the relevant migration limits

• Resin suppliers have no control over customers’ process conditions

– They cannot state migration compliance

Converter/Food packer responsability

On line

1. Leak test

Internal Lab

2. Dimensional and weight control3. Neck opening flatness4. Wall thickness control5. Barrier homogeneity6. Evaluation of capacity 7. Efficiency of sealing around the neck 8. Impact resistance by falling9. Leak test10.Burst resistance (by hydraulic internal pressure)

External Labs

10. Total migration11. Color

Quality Control Program/Barrier

Containers

On-line test

- Leak test (holes, thin places)

Lab tests

- Top load (compression resistance)

- Impact test (drop test)

- ESCR (bottles & resin)

- Weight and thickness distribution

- Optics and esthetic

- Ink adhesion

Quality Control Program/Moolayer

bottles

• Voluntary certification, which has the purpose to guarantee a consistent

high level of quality within the time

• The certification covers (or can cover): Manufacturing plants, Labs,

Offices and related working procedures and demands to keep records

and an up-date databank

• Certification is issued on the basis of internal and external audits, after

evaluation of activity records and QC data consistency.

ISO 9000 Certification

blow moulding process & barrier containers part 4 testing

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