rigid and specialty container

8/3/2019 Rigid and Specialty Container

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Rigid and Specialty Containers

Bhupendra Singh


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PACKAGING FUNCTIONS

Package is the means of providing

PROTECTION CONTAINMENT

PRESENTATION

IDENTIFICATION/

INFORMATION

CONVENIENCEBRAND PROTECTION

Packaging must protect what it sells,

and sell what it protects


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Factors influencing Packaging Design & Selection

0 . Spoilage of Product

1 . Packaging Options

2 . Testing


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Spoilage of Product

0 . Spoilage of product results from

-Chemical Incompatibility between the ingredients of the product /

packaging material

-Moisture,

-Oxygen,

-Light &

-Temperature changes


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0 .1 Effects of Moisture

Y Crystalline substances absorb moisture, e.g. CaCO3, Na-Sulphate

Y Aspirin can be hydrolyzed by water absorption

Y Vitamins are also susceptible to moisture

Y Suitable packaging material should be used to prevent / reduce the effect of

water / moisture.

Spoilage of Product


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0 .2 Effects of Light& Oxygen

Y Light has a catalyzing effect on degradation by oxygen.

Y The degradation products may be toxic.

Y It is essential that light does not affect the product.

Y Suitable packaging material should be used (e.g. Amber colour glass Bottle)

to prevent / reduce the effect of light or the product should be modified if

possible.

Spoilage of Product


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0 .3 Effects of Heat

Y Heat can cause product to loose the water of crystallization & convert theproduct into amorphous state.

Y The rate of vaporization of some products are affected by changes in heat

(liquid products).

Y Many medications are deactivated / degraded by heat & exposure to light

further accelerate the heating effect.

Y Suitable packaging material with adequate protection from heat should be

used. Insulation may also be used along with coolant for long term transport

& storage.

Spoilage of Product


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0 .4 Effects of Other FactorsDistribution Hazards Mechanical Hazards of transportation

Climatic Hazards of distribution

Biological hazards of distribution

Compatibility

Spoilage of Product


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0 .4.1Mechanical Hazards of transport

Hazards of loading & Unloading

Drops, Height of drop

Hazards of Movements

Rail : (Shunting Shocks, Vibration, Acceleration / Deceleration hazards )

Road : (Vibration, Bouncing of load, Acceleration / Deceleration hazards )

Water : (Staking, Vibration hazards )

Air : (Low pressure, High frequency Vibration hazards )

Multi-modal Transport

Hazards of warehousing

Spoilage of Product


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0 .4.2 Climatic Hazards of distribution

Exposure to liquids/ water

Exposure to vapour/ humidity

Temperature Change (Low / High)

Pressure Changes (Low / High)

Dust storms

Spoilage of Product


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0 .4.3 Biological Hazards of distribution

Biological Hazards

Microorganisms

Fungi

Moulds

Bacteria

Insects

Beetle, Ants, Termites

Mites

Rodents

Spoilage of Product


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Types of Rigid Containers

Glass Containers

Metal Containers

Composite Containers Plastic Containers

Aerosol


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Glass containers.

Types - usp I, II, III.

I - neutral,ii - surface coated,iii limited alkalinity.

Shape affects strength - cylindrical bottles are common

due to its durability.

Hot - cold end coatings.

Very Limited usages in Agrochemical Industry


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Aluminum Collapsible Tube

The Sizes of Tubes generally used inIndustries and the capacities are asgiven below:

Tube Dia. Capacity

12.7 mm - 3 TO 5 g

16.0 mm - 10 g

19.0 mm - 15 g22.2 mm - 20 g

30.0 mm - 50 g

The Length of the tube is decided by thepurchaser.

Aluminum Containers

The Sizes of Aluminum Containers are as given

below:

50 ml

100 ml

250 ml

500 ml

1000 ml

5000 ml

As the sizes increases the cost of the container goesup drastically. And it is difficult to process.

Metal Containers


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Preferred for Packaging of Powders, Granules

or Tablets in Bulk, Liquid Packaging for highly

volatile materials.

StrongWithstand vacuum and pressure

Non toxic

Excellent barrier property to

prevent bacterial spoilage and

leakage

Resistance to light penetration

Odour well retainedWhen decorated attractive

Properties of Tin Plate ContainerTypes of Containers

Two Piece Containers

Three Piece Containers

Metal Containers


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SPIRAL WINDING

Two or more plies of board are

superimposed and glued

together around a stationary

mandrel to form tube.

Only cylindrical shapes can be

obtained.

Composite Containers


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CONVOLUTE WINDING

Board from the reel is passed over gluing

rollers and feed into grippers in winding

mandrel ,then mandrel rotates to form

tubes.

Wide variety of shapes can be obtained

Composite Containers


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WHY PLASTICS FOR BOTTLES ?

Light weight v/s. Glass

Less prone to shatter (v/s. glass) upon impact

Design flexibility

Visual aesthetics

Tailor making (to suit packaging requirements)

(multilayer coex, chemical treatments)


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Plastic Containers

Accurate thickness Profile

From 20 ml to 20 liters

Injection Molding

Suitable for 20 ml to 1000 liters

Most widely used containers

Sturdy containers

Extrusion Blow

Molding

High Output

Accurate thickness Profile

Suitable for 20 ml to 250 ml

Injection Blow

Molding

Suitable for 20 ml to 2 liters

Not widely used inAgrochemicals

Injection StretchBlow Molding


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Plastic Containers


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Materials Used in plastic Containers

Polypropylene

Polyethylene HDPE

LDPE

LLDPE

EVA

Polystyrene GPPS

HIPS

ABS

SAN

PVC PET

PC

Plastic Containers


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Extrusion Blow Molding

Extrusion Pinch Off Blowing Cooling

Pinch Off

Plastic Containers


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Plastic Containers


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No ofLayers Combination of Layer Application

1 Nylon - Adhesive - HDPE/PP For pesticides and similar hazardous chemicals,

solvents etc. Reduce the evaporation of product

filled.

2 Nylon - Adhesive -

Regrind/recycled - HDPE/PP

For pesticidesand similar hazardous chemicals,

solvents etc. Reduce the evaporation of product

filled. Regrind from the machine is used for

economy. Recycled material also possible to

process.

Multilayer Blow Molding

Barrier Layers:

- Nylon

- EVA

- EVOH

Plastic Containers


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Injection Blow Molding Injection Stretch Blow

Molding

Plastic Containers


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Stretch Blow Molding

Plastic Containers


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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.

Plastic Containers


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Left Intentionally Blank


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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 molding.

Testing of Rigid Packages


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Tests

Testing procedures for todays discussion

Quality Control on plastic raw materials Melt Flow Index

Notched Izod Impact

Flexural Modulus

Quality Assurance of finished product

Stacking Test

Test for drop impact strength Test for closure effectiveness

ESCR tests

Vibration tests

Storage tests

Test for ink adhesion of printed container

Test for product resistance of printed containers Other tests as per requirement


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Melt Flow Index

Purpose

It measures the flow of a molten polymer through an extrusion plastometer under specific

temperature and load conditions

Reference

ASTM D 1238

Method

An extrusion plastometer consists of a vertical cylinder with a small (0.0825 - inch dia)

orifice at the bottom and removable piston on top. A charge of granules is placed in the

cylinder and preheated for several minutes. The piston is placed on top of the molten

polymer and its weight forces the polymer though the orifice to a collecting plate. The

amount of polymer collected after a specific interval is weighed and normalized to the

number of grams that would have been extruded in 10 mins at 2.16 kg weight.

Report

The result is stated as MFI of a material in g/10min


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Impact Strength

Purpose

In real world, materials are often subjected to sudden loads, falling objects etc. Impacttesting attempts to stimulate these conditions

Reference

ASTM D 256

Method

The specimen is a notched bar, is clasped upright in a rise with a notch facing forward. The

pendulum is released from a height of 2 feet, causing the specimen to shear from the

sudden transverse load. The residual energy in the pendulum hammer carries it upward,

the difference in the drop height and the return height represent the energy needed to

break the test bar

Report

The result is stated in J/m


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Flexural Properties

Purpose Flexural Strength is the measure of how well a material resists bendings - its

stiffness

Reference

ASTM D 790

Method

The end of the test bars are placed on two supports and a load is applied to the

middle. The flexural modulus is the ratio of stress is to strain

Report

The result obtained is denoted in MPa


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Purpose

To observe buckling of containers under load or when stacked during transportation

Reference

IS 10840

Method

4 containers shall be used for test. Fill containers with water to normal capacity and close

it with the closure. Apply top load uniformly on the containers

Report

Look for permanent deformation

and damages on the packages,

if not it passes the test.

Stacking Test

ContainerCapacity (kg)

Load on4 containers (N)

1400

2 600

5 800

10 1200

15 1600


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Test for Drop Impact Strength

Purpose

To ascertain the bottles / containers manufactured pass drop impact as some of them may

carry chemicals which in contact may be hazardous

Reference

IS 7408

Method

Select 6 containers divide 2 sets of 3 each. Fill each container to its nominal capacity with

water. First set of containers shall be dropped on the base from a height of 1.2 mtrs.

Second set shall be dropped on the side or on any external feature such as handles.

Examine containers for signs of rupture or leakage.

Report

If containers failing in the first drop and on the same position on subsequent containers,then the same has to be reported


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Test for Closure Effectiveness

Purpose

The test is conducted for observing effectiveness of closure and to check for leakage if any

Reference

IS 7408

Method

3 containers shall be used. Fill each container to its nominal capacity with the test load atambient temperature. Close each container with closure as per recommended torque.

Invert closure and keep for 24 hours. Examine for leakage after 24 hrs.

Report

If the liquid spills out, that implies the closure is not effective.


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Test for Resistance to Environmental Stress Cracks (ESCR)

Purpose

To test the bottle / closures for stress cracking Reference

IS 6312

Test

Teepol B300

Method The container is filled to nominal capacity with the test liquid and secured as for transport.

The container is then placed in over : 60C for 48 hours for containers upto 25 ltrs, 80C for48 hours for containers more than 25 ltrs.

Report

The container is then checked for cracks developed if any and reported.


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Vibration Test

Purpose

The method helps to determine the ability of a closure (on a container) to prevent leakage due totransportation in vibration

Apparatus

A vibrating table, aptitude of vibration 25mm and frequency 8 HZ

Reference

IS 12512

Method

Fill the container to normal capacity with product / water and then close the closure. Mount the

container upside down on the table for 1 hour. Check for leakage

Report

If the liquid spills out, then the closure is not effective


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Storage Test

Purpose

To test the loss in product filled in container Reference

IS 7394

Method

Fill the container to its nominal capacity. Seal the closure and weigh the container

accurately. Store the container for a period of 30 days at 27+/-2C. Determine the

loss of mass from the container Report

The loss in weight as per specifications


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Test for Ink Adhesion of Printed Container

Purpose

To test the adhesion of ink to the bottle / container surface Reference

IS 7408

Method

Apply two strips of 25mm wide transparent adhesive tape on the printed area,

one down the length of container and other around the circumference. Pass the

tape on the container and leave it for 15 hrs. Pull it slowly

Report

Record the degree of print removal as nil, slight and severe


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Test for Product Resistance of Printed Containers

Purpose To test the resistance of ink on the containers, getting washed away due to

incompatibility of the product

Reference

IS 7408

Method

The containers should be printed atleast 24 hrs before conducting the tests.

Immerse or smear the containers with the product to the packed and leave for 1

hour. Rinse with cold water and leave to stand till dry. Rub container with dry

paper.

Report

Record degree of print removal as nil, slight or severe


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Processing

High Density Polyethylene (HDPE) and Polypropylene (PP) are the most widely used

resin for blow moulding applications.


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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 temperaturesand under high shear. During their service life they have to survive severeexposure to conditions such as heat, light humidity, without changes inappearance or premature mechanical failure in some cases for several decades.

WITHOUT SUITABLE ADDITIVES NONE OF THESE DEVELOPMENTS WOULD BEPOSSIBLE

ADDITIVES ARE THE MIRACLE WORKERS OF PLASTICS

T f Additi


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Types of Additives

1. Antioxidants2. UV Stabilizers3. Plasticizers4. Flame Retardants5. Antistatic Agents6. Clarifying agents7. Chemical Foaming Agents8. Antimicrobial9. Fillers and Reinforcements10. Polymer Processing aids11. Colorants

S l ti C it i f Additi


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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.

M t b t h


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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

D i


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Decoration

UV Printing

High Outputs 80 UPM 3 colours

Labeling

High Speed accurate labeling lines working

at 120 upm Hot foil Stamping


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Design & Development

2D Software AUTOCAD

3D Software

- Pro Engineering

- Uni Graphics

Imaging - 3D Studio

The IBC concept


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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 offilling, storage, handling and transportation.

I ti i D i


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Innovations in Design

Innovative Vented Induction Sealing

Wads

Normal Wad Vented Wad

I ti i B i P k i


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Innovations in Barrier Packaging

Barrier Solutions

Fluorination

Co-extrusion

Sulphonation

Direct Fluorination


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Direct Fluorination

F

F

C

F F

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.

Fl i ti T h i


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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

T ti f Fl i ti


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Testing of Fluorination

Fluorination treatmentis quantified using

Fourier Transformation

Infra Red Spectroscopy

(FTIR). C-H bond shows

peak absorption at 1440

1480 cm-1, while C-Fbond gives peak

absorbance at 930

1320 cm-1.

C-H Peak

C-F Peak

Before Fluorination

After Fluorination

Co extrusion Technology


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Co-extrusion Technology

Comprises of either three, four or six

layers,

including HDPE and an inner EVOH or

Nylon layer

Co extrusion Technology


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Below is a typical cross section of a 6 layerco-ex container:1. PP / HDPE

2. Adhesive3. EVOH / Nylon4. Adhesive5. Regrind / PCR6. PP / HDPEThese process steps are the same as for

Extrusion Blow Moulding.

Co-extrusion Technology

Sulphonation


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Sulphonation Technology

The containers are treated with SO3 gas on the Plastic Surface.

Sulphonation of Plastic results in improved barrier Properties.

Sulphonation

New Resins in Market


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New Resins in Market

N-MXD6 made from Metaxylene Diamide

Due to its unique chemicalcomposition and crystallinestructure, N-MXD6 hasexcellent gas barrier

properties, especially in highhumidity conditions ascompared to N-6.

Nanocomposites


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Nanocomposites

Nano-composites are of Recent origin but they promise to rule the future of

the Rigid containers.

Nanocomposites particle size smallerthan 1 X 10-9m

Platy / layered structures that need to beseparated by high shear to attain theadvantage of the nanoclay.

Very good overall physical properties at lowaddition levels (3-4 %)

Can behave as non halogenated flameretardants

Low part weight

Better Barrier properties

Disadvantage: Expensive filler at present

Application at the moment onlyautomotive

Technology is in Nascent Stage

Future Packaging


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Biodegradable Packaging

PLA (Polylactic Acid)

PHAs , {PHBV

(Polyhydroxy Butyrate Velarate)}

Starch Blends

Active Packaging

Antimicrobial Packaging

Scavenger Packaging

Intelligent Packaging etc.

Future Packaging


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Thank You

rigid and specialty container

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