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 GPPS HIPS ABS SAN

Polystyrene
– – – –

• • •

PVC PET PC
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Materials Used

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Processes
Rigid Plastic Packaging Rigid Plastic Packaging
Injection Moulding Injection Moulding eg. containers, pails, closures eg. containers, pails, closures Blow Moulding Blow Moulding eg. bottles, jars eg. bottles, jars Thermoforming Thermoforming eg. cups, glasses, tubs, potion packs eg. cups, glasses, tubs, potion packs

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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 of Rigid Packages
• Testing can be divided in to two parts :
• Quality Control : Testing of incoming raw materials Testing of finished products

• Quality Assurance :

Plastics testing can be divided into testing of plastic raw materials ( generally granules ) & testing of finished products after moulding.

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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 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 Bloom

• •

Types of Additives
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Antioxidants UV Stabilizers PVC Stabilizers Plasticizers Flame Retardants SIip and Antiblock Agents Antistatic Agents Nucleating Agents Clarifying agents Chemical Foaming Agents 11. Antimicrobial 12. Lubricants (Internal and External) 13. Fillers and Reinforcements 14. Coupling agents 15. Antifogging additives 16. Acid Scavengers 17. Polymer Processing aids 18. Colourants 19. Flourescent Whitening agents

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Selection Criteria for Additives
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Property desired by the customer. Duration of Property desired. Polymer to be added to. Compatibility to the polymer. Temperature of processing and mode of processing. Mode of addition. Reaction with other additives in the system. Shelf life of the additive. Regulations and norms to be followed. Testing details. 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 Universal masterbatches. (Usually LLDPE based in India) Resin Specific masterbatches. (eg. PET based for PET, PC for PC etc.,)

• 1. 2.

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 – 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

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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 of filling, storage, handling and transportation.

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Innovations in Design
• Easy to carry & Innovative Closure device

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Innovations in Design
• Innovative Closure with Moisture absorber

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Innovations in Design
• 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
• 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.

F

H H C H F C F

H F2 F
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• The bulk properties of fluorine treated plastic container remains unchanged.

F

Fluorination Techniques

•Offline Direct Fluorination

•Inline/ Online Fluorination

1 F-C-H F-C-H F-C-H F-C-H

2

3

4

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

5

F

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

1

2

3

F

C

F

F

C

F

F

C

F
1000ml.

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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 gives peak absorbance at 930 – 1320 cm-1.

Before Fluorination

C-H Peak

After Fluorination
C-F Peak

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Applications for Fluorination Technology
Chemical, petrochemical, automotive, solvents, inks, hardener etc

Direct Printing Applications
Pesticide Packaging

Plugs for Solvent containers

Flavor Packaging

Oil Packaging

HDPE automotive fuel tanks

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Applications for Fluorination Technology Surface Treatment for Chemical Resistance

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Co-extrusion Technology
• Comprises of either three, 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 layer co-ex container: 1. PP / HDPE 2. Adhesive 3. EVOH / Nylon 4. Adhesive 5. Regrind / PCR 6. PP / HDPE These 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 crystalline structure, N-MXD6 has excellent gas barrier properties, especially in high humidity conditions as compared to N-6.
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Nanocomposites
• Nano-composites are of Recent origin but they promise to rule the future of the Rigid containers.

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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
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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 EAN prefix •
EAN Prefix indicates

1001 0 Prod no. CD

- 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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Real time locating system for Rigid Containers
Tagged Asset Tagged Tagged Asset Asset Reader To System

Tagged Asset Reader

Tagged Tagged Asset Asset Tagged Asset

Tagged Asset Reader Tagged Asset

500 - 1000 m

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Retail supply chain

Data Recorded on the System Serial number Production date Filling dates and sites Tare weight etc.

Supplier

Retailer

Consumer

RFID
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Questions ??

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
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