`Acknowledgement I am thankfu to Medca Appances and Packages Company for provdng necessary facty to carry out my tranng successfuy.It smydutytorecordmysncerethanksandgrattude towards the company stah who hepedmenbrngngthspro|ect totspresent form.The vauabe gudance and nterest taken bythem has been a motvator and source ofnspraton for me to carry out the necessaryproceedngs for the pro|ect to be competedsuccessfuy.4`5Chapter(1)Introducti`1.1 Company Profle Medca appances and packages company a manufacturng and tradng company producng drug packages and medca appances. Estabshed 1964.Its Pad n Capta s approxmatey 106 mon Egyptan Pound and t's totay ownedby Hodpharma.Medca appances and Packages Company s specazed n producng drug packages, medca appances, beds and chars. Its annua saes s approxmatey 55 mon EP.1.2 Blow Molding PlaticBow Modng s a hghy deveoped modng technoogy deveoped back n the ate 1800's to produce ceuod baby rattes. It s best suted for bascay hoow parts (such as pastc bottes) wth unform wa thcknesses, where the outsde shape s a ma|or consderaton. The rst poyethyene botte was manufactured usng the bow modng process n December of 1942. Ths was the rea begnnng of a huge ndustry whch currenty produces 30 to 40 bon pastc bottes per year n the U.S. aone.1.2.1 The Basc Process1. A thermopastc resn s heated to a moten state2. It s then extruded through a de head to form a hoow tube caed a parson. 6Figure 1: Blow Molding`3. The parson s dropped between two mod haves, whch cose around t. 4. The parson s nated. 5. The pastc sodes as t s cooed nsde the mod. 6. The mod opens and the nshed component s removed.1.2.2 VaratonsThere are basically four types of blow molding used in the production of plastic bottles, jugs and jars. These four types are: 1. Extrusion blow molding2. Injection blow molding. !tretch blow molding ". #eheat and blow molding. !"truion Blow Molding This form of blow molding consists of the cycle illustrated below. In most cases, the process is organi$ed as a %ery high production operation for ma&ing plastic bottles. The se'uence is automated and usually integrated with downstream operations such as bottle filling and labeling. It is usually a re'uirement that the blown container be rigid, and rigidity depends on wall thic&ness among other factors.Extrusion blow molding: (1) extrusion of parison* (2) parison is pinches at the top and sealed at the bottom around a metal blow pin as the two hal%es of the mold come together* () the tube is inflated so that it ta&es the shape of the moldca%ity* and (") mold is opened to remo%e the solidified part.7`Figure 2: Extrusion blow moldingIn#ection Blow Molding In this process, the starting parison is injection molded rather than extruded. + simplified se'uence is outlined in below. ,ompared to its extrusion-based competitor, the injection blow-molding process has a lower production rate, which explains why it is less widely used.Injection blow molding: (1) parison is injection molded around a blowing rod* (2) injection mold is opened and parison is transferred to a blow mold* () soft polymer is inflated to conform to a blow mold* and (") blow mold is opened and blown product is remo%ed$tretch %low molding is perhaps best &nown for producing ..E.T. bottlescommonly used for water, juice and a %ariety of other products. There are two processes for stretch blow molded ..E.T. containers. In one process, the machinery in%ol%ed injection molds a preform, which is then transferred within the machine to another station where it is blown and then ejected from the machine. This type of machinery is generally called injection stretch blow molding (I!/0) and usually re'uires large runs to justify the %ery large expensefor the injection molds to create the preform and then the blow molds to finish the blowing of the container. This process is used for extremely high %olume 8Figure 3: Injection blow molding`(multi-million) runs of items such as wide mouth peanut butter jars, narrow mouth water bottles, li'uor bottles etc.&he reheat and %low molding proce ('(B) is a type of stretchblow process. In this process, a preform is injection molded by an outside %endor. There are a number of companies who produce these 1stoc&1 preforms on a commercial basis. 2actories buy the preforms and put them into a relati%ely simple machine which reheats it so that it can be blown. The %alue of this process is primarily that the blowing company does not ha%e to purchase the injection molding e'uipment to blow a particular container, so long as a preform is a%ailable from a stoc& preform manufacturer. This process also allows access to a large catalog of existing preforms. Therefore, the major expense is now for the blow molds, which are much less expensi%e than the injection molds re'uired for preforms.There are, howe%er, some drawbac&s to this process. If you are unable to find a stoc& preform which will blow the container you want, you must either purchaseinjection molds or ha%e your own pri%ate mold preforms injection molded, or you will ha%e to forego this process. 2or either type of stretch blow molding, handle ware is not a possibility at this stage of de%elopment. The stretch blow molding process does offer the ability to produce fairly lightweight containers with %ery high impact resistance and, in some cases, superior chemical resistance.3hether using the injection stretch blow molding process or the reheat and blowprocess, an important part of the process is the mechanical stretching of the preform during the molding process. The preform is stretched with a 1stretch rod.1 This stretching helps to increase the impact resistance of the container and also helps to produce a %ery thin walled container.1.2.3 Materas The extrusion blow molding process allows for the production of bottles in a wide %ariety of materials, including but not limited to: 45.E, 65.E, .., .7,, /+#E89, ..E.T., : #esin, ..E.T.;., and .olycarbonate. +s noted abo%e, a wide%ariety of shapes (including handle ware), si$es and nec&s are a%ailable. Injection blow molding allows for the production of bottles in a %ariety of materials, including but not limited to: 45.E, 65.E, .., .7,, /+#E89, ..E.T., and .olycarbonate./esides the ..E.T. noted abo%e for stretch blow molding, a number of other materials ha%e been stretch blown, including polypropylene. +s time goes on 9`and technology mo%es forward, more materials will lend themsel%es to stretch blow molding as their molecular structures are altered to suit this process.1.2.4 Bow Modng Machne Manufacturers 2or shuttle extrusion type machines /e&um, /attenfeld?0+# is a well-&nown brand. 2or stretch blow and reheat and blow type machines there are !idel, @issei and other machines produced by >ohnson ,ontrols and others. 2or wheel machines you might wish to contact >ohnson ,ontrols or 3ilmington 0achinery.1.) Platic Bag&hee are the three tep in*ol*ed in making any platic%ag+1. !"truding Platic ,ilm10Figure 4: Blown fle extrusion`2. Printing Bag3. Bag Making or -con*erting- Cear LDPE (ow densty poyethyene) pastc resn n peet forms vacuum fed from storage sos and bended wth varous addtves as requred for specc product appcatons. These mxes transform the pastc poymer to mprove ther basc mechanca, physca and chemca propertes nto a commercaproduct.Addtves combne to create the desred propretary bends of carty, strength, stretch abty, sea abty, scuh and tear resstance, UV protecton, bactera protecton, surface appearance, sp resstance and other propertes requred for the nshed product.If coored m s to be made, coored peets (caed "Master Batch") are added n bends from 1% to 25% to acheve dherent opactes and vrtuay any coor magnabe. Numerousresns, both LDPE and Lnear LDPE, are kept n stock to aow for the many dverse appcatons that are manufactured day.1. !"truding Platic ,ilm The bended resns are then fed nto extruders and meted at 380F. Screw drves force the moten mxture through a precson de where ar s ntroduced and a 'bubbe' s formed. Ths process s known as "bown m extruson".11Figure 5: Blending and Mixing esins`Ad|ustments to wa thckness and dameter are made n ths contnuous bubbe or tube. As t rses some 20 feet, t coos and s attened and wound under tenson nto 50 - 200 b. ros.Our ne-up of extruders gves us the exbty to reguary produce custom m orders. Ths aows aso for quck order fument where tubng may be avaabe n as tte as 2 or 3 days.2. Printing Bag12Figure !: Extruding "lastic FilmFigure #: "rinting Bags`From the extruders, the ros of m are devered to our prnt department. Fexographc stacked presses produce prnted m n up to 10 coors wth matte to goss to metac nshes.A smaer press does the ess compex |obs such as produce ro bag prntng and other 1 or 2 coor |obs.Ths versatty aows us to prnt sma quanttes of bags and aso to hande huge press runs of a week or more. We can consstenty meet deadnes whe achevng consstent, quaty resuts.). Bag Making or -con*erting-Ether pan ros from the extruder ne or prnted ros form our presses are devered to the bag makng area of our pant. A myrad of szes and optons are avaabe n essentay 3 types of bag converson: snge bags, bags on ros (perforated tear-oh) or bags on wre wckets.Ro stock s oaded onto bag makng machnes where repettve bottom sea or sde sea convertng takes pace to produce ndvdua bags from the arge ros. Hoes, vents, sts, 13Figure $: con%erting`perforatons, hande punchng, wcket tng, header seang and zp ockng are some of the many optons avaabe n each producton run.Speca fodng |gs aow for gussetng as requred wth hgh speed, automatc wre wcket tng machnes agned for emcent producton.After the ros of tubng are converted nto one of many styes and types of bags, the bags are packed nto boxes, stacked and wrapped on paets n preparaton for shpment.1.4 Plastic containersPROCESS OF MANUFACTUREBow modng foows the same stages of manufacture as n|ecton modng. HDPE (Hgh densty poyethyene) s dea for ths type of manufacturng technoogy. The Steps n the formaton of any contaner (the de s changed for each product and Specc desgn) are.1. The pastc s fed n granuar form nto a 'hopper' that stores t.2. A arge thread s turned by a motor whch feeds the granues through aHeated secton.3. In ths heated secton the granues met and become a qud and theLqud s fed nto a mod.4. Ar s forced nto the mod whch forces the pastc to the sdes, gvngThe shape of the botte.14`5. The mod s then cooed and s removed.STEPS INVOLVING IN BLO MOUL!ING PROCESS15Figure &: 'lastic granules dro''ing on to screw t(readFigure 1): *uid 'lastic mo%ed b+ rotatingFigure 11: air blown into module ,orcing 'lastic`16Figure 12: bin remo%e ,rom mouldFigure 13:'lastic 'owder`1...Corrugated Card%oard 1...1 BackgroundMost tems at your favorte supermarket, dscount store, or shoppng ma were safey devered n boxes made of corrugated cardboard, and many are dspayed n the same boxes, whch were manufactured so they coud be opened and used for ths purpose. Other tems may arrve n ther own corrugated or uncorrugated paperboard boxes. Because corrugated cardboard s such a versate packagng matera, mons of tons are used each year to protect and dspay products. Durng 1992, more than 25 mon tons of corrugated cardboard were produced n the Unted States. Another 6 montons of uncorrugated boxboard or paperboard were aso produced for use n fodng cartons.Corrugated cardboard s a sth, strong, and ght-weght materamade up of three ayers of brown kraft paper. In 1884, Swedsh chemst, Car F. Dah, deveoped a process for pupng wood chps nto a strong paper that ressts tearng, spttng, and burstng. He named t the kraft process because t produces a strong paper that ressts tearng, spttng, and burstng.From the paper m, ros of kraft paper are transported to a corrugatng, or convertng, pant. At the pant, ayers of kraft paper are crmped and gued to form corrugated cardboard, whch s then cut, prnted, foded, and gued to make boxes. At 17`the begnnng of ths process, kraft ros from the paper m are oaded nto a huge machne caed a corrugator. A typca corrugator s as ong as a footba ed-300 feet (91.44 meters). Some ros of kraft paper are used as the corrugatng medum, and others are used as ners, the ayers of kraft paper gued on each sde of the medum. After the corrugator has heated, gued, and pressed the kraft paper to form corrugated cardboard, the contnuous sheet of cardboard s cut nto wde box banks that then go to other machnes for prntng, cuttng, and gung. Fnay, batches of nshed boxes are banded together for shppng to the food processor, toy maker, automobe parts dstrbutor, or any of the thousands of busnesses that depend on corrugated cardboard packagng.1...2 'aw MaterialFast-growng pne trees provde the prmary raw matera used to make corrugated cardboard. The argest packagng companes own thousands of acres of and where trees are matured, harvested, and repaced wth seedngs. After the treesare harvested, they are strpped of ther mbs; ony the trunks w be shpped by truck to a pup m. The argest packagng companes aso own the ms where trees are converted to kraftpaper. At the m, the harvested tree trunks are sub|ected to thekraft process, aso known as the sufate process because of the chemcas used to break down wood chps nto brous pup. After pupng and other processng, the bers are sent drecty to the paper machne where they are formed, pressed, dred, and roed nto the wde, heavy ros of kraft paper sent to corrugatng pants to be made nto cardboard.At the corrugatng pant, ony a few other raw materas are needed to make a nshed box. Corn starch gue s used to bondthe corrugated medum to the ner sheets. Because so much gue s used, ra cars or arge tanker trucks dever t as a dry powder that w be stored n huge sos at the corrugatng pant unt t s needed. Drawn from the so, the dry corn starch s mxed wth water and other chemcas and pumped nto the corrugator to be spread on the corrugated medum as the ayersof ner are added. Other raw materas are used to nsh the corrugated cardboard after producton. Waxes made from 18`paramn or vegetabe os can be apped to make a water- or grease-resstant contaner for food products. Brghty coored nks are aso apped to create bod graphc desgns for sef-supportng dspays featurng product name, nformaton, and company name and ogo. Teams of saespeope and desgners work together to create the manufacturng and prntng patterns, caed des, that are used to cut and prnt a specc box desgn. The des are created n a pattern shop and transferred to the rotary de-cuttng equpment and prnters thatnsh the box banks.1...) /eignKraft paper has been manufactured snce 1906. Snce then, pupprocessng, paper makng, and corrugatng operatons have been deveoped to a hgh state of emcency and productvty. Today, n the corrugated cardboard ndustry, desgners are creatng nnovatve contaners that requre four-coor prntng and compex de-cuttng. These nnovatve contaners are desgned wth sophstcated software such as computer-aded desgn (CAD) programs, aowng a packagng desgner to branstorm dherent package desgns before manufacturng begns. A desgner usng a CAD program can ca up and modfy dherent desgns that have been stored n a computer desgn brary. Thus, exstng packages can generate new desgns. Many reta stores use such ght, strong, and coorfu contanersdrecty, as pont-of-purchase dspays.1...0 &he Manu1acturing Proce.19`Figure 14:Manu,acturing "rocess-Pulping the pine chip1- Manufacturng a corrugated cardboard box begns wth the pupng of wood chps n the kraft (sufate) process. Frst, tree trunks are strpped of bark and torn nto sma chps. Next, these chps are paced n a arge, hgh-pressure tank caed a batch dgester, where they are cooked n a souton, or quor, made of sodum hydroxde (NaOH) and severa other onc compounds such as sufates, sudes, and sutes. These strongy akane chemcas dssove the gnn, the gue-ke substance that hods the ndvdua wood bers together n a tree trunk.2- When the pressure s reeased after severa hours, the wood chps expode ke popcorn nto uhy masses of ber. Making kra1t paper3- After addtona ceanng and renng steps, a consstent surry of wood pup s pumped to the paper-makng machne, aso known as a Fourdrner machne. Ggantc, square structures up to 600 feet ong (182.88 meters), these machnes contan a wre mesh n whch the paper s ntay formed. Next, 20`the paper s fed nto massve, steam-heated roers and wde fetbankets that remove the water. At the end, the nshed medum, or ner, s roed for shpment. $hipping and toring the kra1t paper4 -Ros of kraft paper for corrugatng are avaabe n many szes to t the producton equpment at dherent corrugatng pants. The most common ro szes are 67 nches (170.18 centmeters) wde and 87 nches (220.98 centmeters) wde. An 87-nch ro of heaver paper can wegh up to 6,000 pounds (2,724 kograms). As many as 22 ros of 87-nch paper can be oaded nto one raroad boxcar for shpment to a corrugatng pant.5 -At the pant, the kraft paper s separated nto dherent grades, whch w be used for the medum and the ner. These dherent grades of corrugated cardboard can be made by combnng dherent grades of kraft paper. A knowedgeabe packagng specast works wth a customer to determne the strength requred for the corrugated cardboard contaner beng panned. Then, when a pant receves an order for contaners, a product engneer speces the combnaton of medum and nerto produce a cardboard to match the customer's requrement. Corrugating the card%oard6- Usng powerfu fork-fts, sked equpment operators seect, move, and oad ros of kraft paper at one end of the corrugator.21`Corrugated cardboard manufacture ncudes two key steps: makng kraft paper and corrugatng the cardboard. Kraft paper nvoves pupng wood chps and then feedng theresutng paper substance through massve steam roers that remove the water. Corrugatng s aso done n a machne that utzes heavy roers. One ro of cardboard s corrugated and then gued between two other ayers (ners) by the same machne. The gue s then cured by passng the cardboard over heated ros.Corrugated cardboard manufacture ncudes two key steps: makng kraft paper and corrugatng the cardboard. Kraft paper nvoves pupng wood chps and then feedng the resutng paper substance through massve steam roers that remove thewater.Corrugatng s aso done n a machne that utzes heavy roers. One ro of cardboard s corrugated and then gued between two other ayers (ners) by the same machne. The gue s then cured by passng the cardboard over heated ros.7- One ro of medum s oaded to run through the corrugatng ros, and a ro of ner s fed nto the corrugator to be |oned wth the corrugated medum. Lner from another ro traves up over the corrugatng ros aong a at structure caed the brdge. Ths ner w be gued to the corrugated medum ater n the process.8- For a arge producton run, addtona ros are oaded nto automatc spcers. Senstve detectors check the ros of paper feedng nto the corrugator. When a ro s neary empty, the corrugator contro system starts a spcer, and paper from the new ro s |oned to the end of the paper gong through the 22Figure 15: .orrugating t(e cardboard`machne. Thus, producton of corrugated cardboard s contnuous, and no producton speed s ost.9- The medum tobe corrugated s fednto the gant,eectrcay drvenroers of thecorrugator, rstthrough the preheatngroers and then ntothe corrugatng ros.Steam at 175 to 180pounds of pressureper square nch (ps) s forced through both sets of roers, and, as the paper passes through them, temperatures reach 350 to 365 degrees Fahrenhet (177 to 185 degrees Cesus).10- The corrugatng ros are covered wth I O utes -horzonta, parae rdges ke the teeth of massvey wde gears.When the hot paper passes between the corrugatng ros, the utes trap and bend t, formng the mdde part of a sheet of corrugated cardboard. Each corrugatng machne has nterchangeabe corrugatng ros featurng dherent ute szes. Instang a dherentA nshed pece of corrugated cardboard conssts of a snge corrugated ayer sandwched between two ner ayers. ute szen the corrugator changes the wdth of the corrugated medum.11- The medum traves next to a set of roers caed the snge-facer gue staton. Here, one ayer of ner s gued to the medum. Starch gue s carefuy apped to the corrugated edges of the medum, and the rst ayer of ner s added. From the snge-facer, the medum and ner go to the doube-backer gue staton where the other ayer of ner from the brdge s added foowng the same procedure. Contnung through the corrugator, the cardboard passes over steam-heated pates thatcure the gue. ,orming the %lank into %o"e12- At the end of corrugator, a stter-scorer trms the cardboard and cuts t nto arge sheets caed box banks. Box banks pop out of the stter-scorer ke wde sces of toast and sde nto an automatc stacker that oads them onto a arge, 23Figure 1!`rong patform. From here, they w be transported to the othermachnes that w convert them nto nshed contaners. Skedproducton workers use a computer termna and prnter to prepare a |ob tcket for each stack of box banks produced by the corrugator. Wth the |ob tcket, workers can route the stack to the rght fabrcaton machnes, caed exos (the name s short for exographc machne). A exo s a wde, at machne that processes box banks.13- Prntng des and de-cuttng patterns I 3 are prepared n apattern shop on arge, exbe sheets of rubber or tn. The des and patterns are oaded onto the arge roers n the exo, and the box banks are automatcay fed through t. As each bank passes through the roers of the exo, t s trmmed, prnted, cut, scored, and, n a prnter-foder-guer, foded and gued to form a box. From the exo, the nshed boxes are automatcay stacked and sent to a bandng machne to be wrapped for shppng. Other equpment n a corrugatng pant ncudes stand-aone de-cutters, de-cutters wth prnt statons, and machnes known as curtan coaters that appy a wax coatng to frut, vegetabe, and meat contaners. Box banks requrng ony smpe, one-coor prntng and de-cuttng can be run through a stand-aone de-cutter, prnt staton, and curtan coater to produce water- or grease-resstant contaners. 1.... manu1acturing fgure24Figure 1#: First/ t(is mac(ine rolls out a w(ole lot o, rec+cled 'a'er to be s'lit u' into one wa%+ s(eet o, 'a'er called a *ute w(ic( sits between two *at s(eets called liners- 0(e+ ,orm a corrugated board-Figure 1$: 0(e 'a'er t(en goes t(roug( two rollers called a corrogater- 1ot steam is s'ra+ed on t(e cardboard w(ile anot(er roller glues one side o, t(e *ute-`25Figure 23: 2ext/ a trimmer cuts t(roug( t(e cardboard wit( ex'ert 'recision to ma3e *a's and (andles-Figure 24: 0(is next mac(ine stac3s t(e boards in 4uantities o, between 25 and $) boards- 0(e mac(ine t(en ,eeds t(e next mac(ine at a ra'id rate o, $/))) boards 'er (ourFigure 2):2ext/ a ra5or t(in circular saw cuts eac( side o, t(e cardboard-Figure 1&: 6 mac(ine t(en ad(eres two liners to (old t(e box toget(er and strengt(en t(e board-Figure 22t(e corrogater7s fnal use is to se'arate t(e boards into la+ers using t(ese aluminum tongs-Figure 21:0(e corrogater mac(ine t(en cuts t(e board as man+ as nine times/ de'ending on t(e si5e o, t(e box-`1.2 Aluminum tu%e26Figure 25ubber blades ensure t(is mac(ine cuts onl+ t(e 'arts it7s su''osed to-Figure 2!0(e boxes are 'rocessed at an ama5ing rate o, &) boxes 'er minute- 0(e unused/ cut o8 'a'er goes down below/ w(ere it is rec+cled as man+ as six more times-Figure 2$:0(e boxes are t(en 'ut in large 'iles and t(en sent o8 to be s(i''ed awa+-Figure 2#: 6 bending mac(ine t(en ,olds t(e boxes along lines alread+ made b+ t(e corrogater- 9lue is t(en a''lied to t(e 'laces w(ic( will come toget(er to,orm t(e box- 6not(er mac(ine t(en ,olds t(e glued sections-Figure 3)0(e+7re t(en mixed 'er,ectl+ ,or just t(e rig(t color combinations on t(e cardboard boxesFigure 2&:0o 'ut t(e 'ro'er writing on t(ese boxes/ t(ere7s an in3 3itc(en were o%er 5/))) colors are s+stematicall+ 'oured into t(ese containers-Figure 310(e boxes are fnall+ read+ to s(i' and carr+ nearl+ an+t(ing +ou could imagine-`Figure 32: 6luminum tubes,ollapsible aluminium tubes are manufactured by means of a complex process, made of se%eral different technological operations. 3hat we are tal&ing about is a continuous, fully automatic process: tubes are ne%er manipulated and are automatically transported through a series of machines, starting from when aluminium slugs are loaded into the press until the boxing machine. 0echanical process Internal lac'uering machine .rinting process End of the line1.2.1 Mechanical proce(.ress, trimming machines, burrs remo%al system, accumulator ) The process starts when aluminium slugs, coming from the tumbling department, are loaded into the press feeding de%ice* such slugs are lifted, selected and then automatically transported into the hori$ontal press, where they are cold extruded.27` !lugs are pressed between the puncher and the die and pressure is such to generate a plastic deformation of the aluminium. Thus the aluminium goes through the die and the puncher, forming the tubes body. The material speed generates, in one single step, the tubes shape and causes an increase in its temperature up to 2AA B,* the semi-finished products which arri%es from the press is then transported to the trimming machine by means of an automatic con%eyor belt. In this machine the tubes are threaded, headed and cut down to the desired length. +t the end of such operations the tubes ha%e reached the final dimension. The tubes shoulders are then polished by means of a rotating brush to ma&e it perfectly smooth and glossy. 6a 0etallurgica is also e'uipped with some automatic systems for the disposal of burrs generated by the extrusion process. +ll possible wastes are automatically extracted and suc&ed out by the centrali$ed collection system* the aluminium scraps are then fully recycled.Internal lacquering machine(Anneang oven, spray-coatng machne, poymerzaton oven, accumuator) If we mo%e on along the production process, we can see that the con%eyor belt which mo%es the semi-finished products out of the trimming machine, lay them on a small accumulator which joins the machines responsible of the aforesaid mechanical process and the next step during which the products annealed to become collapsible at "AA B,* the materials the semi-finished products are made of, after ha%ing being extruded and therefore ha%ing been affected by the abo%ementioned plastic deformation, ha%e recrystali$ed and hardened, and, to ma&e the tubes collapsible again, they shall be exposed to such high temperatures into a o%en. 2urthermore, heat inside the furnace gets rid of all the lubricating materials residuals, so that tubes are perfectly clean and highly saniti$ed.28`Tubes can now mo%e on to the internal lac'uering stage which creates an inner film which allows tubes to be filled in with any &ind of materials. The internal lac'uer machine applies a coating layer by means of se%eral spraying guns which rotate and slide at the %ery same time. Tubes are then polymeri$ed at a %ariable temperature, depending on the &ind of lac'uer in use, approximately reaching up to AA B,. The aforesaid operations are extremely important since they affect the tubes resistance to aggressi%e agents and on its capability to preser%e the organoleptic properties of the product inside the tubes.Immediately after tubes are collected into a second de%ice which ta&es the tubes to the printing machines, wor&ing as a sort of accumulator in case of idles phases affecting the production line.+ll the aforesaid operations are mainly mechanical and they define the tubes dimensions.Printing proce(Base coatng machne, ohset prntng machne, ashng and dryng ovens) The rst machne nvoved n the prntng process s the base coatng machne whch appes a ayer of base coatng on the outsde of the tubes.Tubes are then transported nto a ash dryer where the base coatng dres up at a temperature rangng from 110 and 140 C.The coated and dred tubes then reach the prntng machne where nks are apped through an oh-set process n order to obtan the desred desgn.Fnay, tubes go through a dryer, where nks are xed onto the base coatng. Temperatures, n ths case, range from 140 to 170C.29`!nd o1 the line(accumuator, eak contro machne, cappng machne, atex machne, boxng machne)The ne ends wth severa dherent machnes:an accumuator, a eak contro machne, a cappng machne, a atex machne anda boxng machne.A producton nes are equpped wth a eak contro machne and makes sure a tubes are 100% eak free. Ths machne s equpped wth a cuttng-edge transport system whch moves the tubes accordngto aad|ustabe speed system, and stops them at a workstaton where a sophstcated eak contro system checks, by means of an ar ux bown nto the tubes at a gven pressure, whether thetubes body and membranes are damaged, torn or perced, and then gets rd of the fauty tubes.The cappng machne screws the caps onto the tubes and, f necessary, appes the pastc nsert. In case of speca exgences, further toos mght be added to the machne n order to make t sutabe for dherent appcatons such as quaty contros or the appcaton of securty sea.The atex machne appes some atex at the tubes openng, as asecond seang devce amed at ncreasng the content safety after the tubes have been ed n. The atex s ad on two tubesat the same tme by means of two centrfuga unts. After the atex has been apped, tubes are transported to the packagng area where they are put nto ther boxes.A sensor s ocated nto the boxng machne, n order to have the tubes counted whe they are put nto the boxes, row by row,30`unt boxes are fu. Tubes whch are automatcay pushed nto the boxes by means of some pushers and are then ready for quaty contros and for beng sent to the warehouse. Here the boxes are stacked on the paets and paets are covered n a pastc m, ready to be shpped.6ubricated aluminium slugs are used with purity of CC,DE.,ylindrical shape of the can is achie%ed by cold extrusion.+ cutting e'uipment pro%ides the expected length, brushingis applied during the same process if necessary.,ans are prepared for internal and external treatment byproper washing in order to get perfect cleanness.Internal surface is coated by protecting lac'uer which isadapted to the claim of filling material and circumstances ofutili$ation (epoxy-phenol gold, epoxy-phenol pigmented ormycoflex).The external surface of the cans can be white coated,brushed or pearlised./y special &ind of offset printing, lithography of maximumF colours is possible. Protectve externa nsh can be executed byshny, mat or mxed ehect.31`7arieties of shoulder types (round, groo%ed, tapered, shaped)and rims (rolled or turned) by utili$ing up to A stations resultthe final shape of the can body.4oneycomb units are modelled from the cans which are seton palettes (E=#, =! or special =! palettes), co%ered bytransparent or blac& shrin&-foil, made ready for safetytransportation.32`Chapter(2) ClaicControl33`2.1 I3&'4/5C&I43Control engineering s based on the foundatons of feedback theory and Lnear system anayss, and t generates the concepts of network theory and Communcaton theory. Accordngy, contro engneerng s not mted to any engneerng dscpne but s appcabe to aeronautca, chemca, mechanca, envronmenta, cv, and eectrca engneerng.A control ytem s an nterconnecton of components formnga system conguraton that w provde a desred system response. The bass for anayss of a system s the foundaton provded by near system, whch assumes a causeehect reatonshp for the components of a system. A component or process to be controed can be represented by a bock as shown n Fgure 33.An open-oop contro system utzes a controer or contro actuator to obtanthe desred response as shown n Fgure 2. The open-oop contro system utzes an actuatng devce to contro the process drecty wthout usng devce. An exampe of an open-oop contro system s an eectrc toaster.+ closed-loop control system (2igure ) utili$es an additional measure of the actual output to compare the actualoutput with the desired output response. The measure of the output is called the feedback signal. + feedback contro system s a contro system that tends to mantan a reatonshp of one system varabe to another by comparng functons of these varabes and usng the dherence as a means of contro. As the system s becomng more 34Figure 33: "rocess under controlFigure 34: :'en;loo' control s+stem