Rigid and Speciality Container

8/14/2019 Rigid and Speciality Container

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Rigid and Specialty Containers

Bhupendra Singh

Bloom Packaging Pvt. Ltd.


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Topics for Discussion

Rigid Containers Innovations in Rigid Containers

Specialty Packaging


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Some Examples


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Materials Used in Rigid Packaging

Polypropylene

Polyethylene HDPE

LDPE

LLDPE

EVA Polystyrene

GPPS

HIPS

ABS

SAN

PVC

PET

PC


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Materials Used


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Injection Moulding

eg. containers, pails, closures

Blow Moulding

eg. bottles, jars

Thermoforming

eg. cups, glasses, tubs, potion packs

Rigid Plastic Packaging

Injection Mouldingeg. containers, pails, closures

Blow Mouldingeg. bottles, jars

Thermoformingeg. cups, glasses, tubs, potion packs

Rigid Plastic Packaging

Processes


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Extrusion Blow Molding

Extrusion Pinch Off Blowing Cooling


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Pinch Off


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Injection Blow Molding


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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.


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Modifications In Die Design


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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 moulding.

Testing of Rigid Packages


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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


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Processing Temperatures


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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 hightemperatures and under high shear. During their service life they have tosurvive severe exposure to conditions such as heat, light humidity,without changes in appearance or premature mechanical failure in somecases for several decades.

WITHOUT SUITABLE ADDITIVES NONE OF THESEDEVELOPMENTS WOULD BE POSSIBLE

ADDITIVES ARE THE MIRACLE WORKERS OF PLASTICS


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Types of Additives

1. Antioxidants

2. UV Stabilizers

3. PVC Stabilizers

4. Plasticizers

5. Flame Retardants6. SIip and Antiblock Agents

7. Antistatic Agents

8. Nucleating Agents

9. Clarifying agents10. Chemical Foaming Agents

11. Antimicrobial

12. Lubricants

(Internal and External)

13. Fillers and Reinforcements

14. Coupling agents15. Antifogging additives

16. Acid Scavengers

17. Polymer Processing aids

18. Colourants19. Flourescent Whitening agents


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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.


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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


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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


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Decoration

UV Printing

High Outputs 80 UPM 3colours

Labeling

High Speed accurate labelinglines 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


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The IBC conceptExtremely light and space saving containersystem.

Specially made for multi trip capabilities.

Large packaging unit size, reduces number ofunits to be handled. Lower cost of filling, storage, handling

and transportation.


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Innovations in Design

Easy to carry & Innovative Closure device


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Innovative Closure with

Moisture absorber


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Innovative Vented

Induction Sealing Wads

Normal Wad Vented Wad


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Innovations in Barrier Packaging

Barrier Solutions Fluorination

Co-extrusion

Sulphonation


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Direct Fluorination

F

FCFF

F

CH

H

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 polymerbackbone as shown in figure.

The bulk properties of fluorine treatedplastic container remains unchanged.


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Fluorination Techniques

1 2 3 4 5

F

Offline Direct Fluorination Inline/ Online Fluorination

1000ml.

1 2 3

F-C-HF-C-H

F-C-H

F-C-H

H-C-FH-C-F

H-C-F

H-C-F

F-C-HF-C-HF-C-H

CF F

CF F

CF F


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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 givespeak absorbance at 930

1320 cm-1.

C-H Peak

C-F Peak

Before Fluorination

After Fluorination


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Applications for Fluorination Technology

Chemical,petrochemical,

automotive,

Plugs for Solvent containers

HDPE automotive fuel tanks

Oil Packaging

Flavor Packaging

Direct PrintingApplications

solvents,inks,

hardener etc

Pesticide

Packaging


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Applications for Fluorination Technology

Surface Treatment for

Chemical Resistance


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Co-extrusion Technology

Comprises of eitherthree, four or six layers,

including HDPE and an

inner EVOH or Nylon

layer


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Co-extrusion Technology

Below is a typical cross section of a 6 layerco-ex container:1. PP / HDPE2. Adhesive3. EVOH / Nylon

4. Adhesive5. Regrind / PCR6. PP / HDPEThese process steps are the same as for

Extrusion Blow Moulding.


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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.


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New Resins in Market

N-MXD6 made from

Meta xylene Diamide Due to its unique

chemical composition

and crystallinestructure, N-MXD6has excellent gasbarrier properties,

especially in highhumidity conditionsas compared to N-6.


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Nanocomposites

Nano-composites

are of Recent

origin but they

promise to rule thefuture of the Rigid

containers.


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Whats - Nanocomposites

Nanocomposites particle size smaller than 1 X 10-9m

Platy / layered structures that need to be separated byhigh shear to attain the advantage of the nanoclay.

Very good overall physical properties at low additionlevels (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


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Biodegradable Packaging

PLA (Polylactic Acid)

PHAs , {PHBV

(Polyhydroxy Butyrate Velarate)}

Starch Blends


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Active Packaging

Antimicrobial Packaging

Scavenger Packaging

Intelligent Packaging etc.


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Innovations in Supply Chain

Bar Code and RFID Systems


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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 members identity

Prod. No. : Item identity allocated by manufacturer/importer

Check digit: Calculated from all preceding digits

Real time locating system for Rigid Containers


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Tagged

Asset

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ReaderTo System

500 - 1000 m

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Real time locating system for Rigid Containers

Reader

Reader

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Retail supply chain


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pp y

Supplier Retailer Consumer

RFID

Data Recorded on the System

Serial numberProduction date

Filling dates and sites

Tare weight etc.


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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 ??

Rigid and Speciality Container

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