Plastics in Packaging

Introduction
l  Applications of plastics have increased at a much faster
rate than either metals or ceramics during the last 50
years
l  Many parts previously made of metals are now
being made of plastics
l  Plastic containers have been largely substituted for
glass bottles and jars

l  Total volume of polymers (plastics and rubbers) now

exceeds that of metals
Introduction
l  Almost unlimited variety of part geometries

l  Plastic molding is a net shape process

l  Further shaping is not needed

l  Less energy is required than for metals due to much

lower processing temperatures
l  Handling of product is simplified during production
because of lower temperatures

l  Painting or plating is usually not required

Introduction
l  To shape a polymer it must be heated so that it softens to
the consistency of a liquid

l  Due to its high molecular weight, a polymer melt is a thick

fluid with high viscosity

l  Most polymer shaping processes involve flow through

small channels or die openings
l  Significant pressures are required to accomplish the
processes
Plastic Extruder

l  Compression process in which material is forced to flow

through a die orifice to provide long continuous product
whose cross-sectional shape is determined by the shape
of the orifice
Plastic Extruder

Gear reducer
Feed hopper Heater bands
Feed throat

Exit
port

Hopper throat Screw

Cooling jacket
Variable speed motor
Plastic Extruder
l  Production of sheet and film by conventional extrusion,
using a narrow slit as the die opening.

l  Manifold spreads the polymer melt laterally

Plastic Extruder
Cast Film and Sheet Extrusion
Extruder

Extrusion
Die
Adjustable Pressure
(Restrictor) Bar
Adjustable
Die Lips
Plastic Extruder
Cast Film and Sheet Extrusion Line Layout

Extrusion die Chill roll Material roll

Extruder

Edge trimmer
Plastic Extruder
Cast Film and Sheet Extrusion Direction Orientation
From extruder
casting rolls

Rotation x 1 x2 x3 X4

Extrusion Die

Extruder

Casting Rolls

Tenter Clips Annealing Zone

Plastic Extruder
Three-Layer Co-extrusion

Extruder #1

Material #1
Extruder #2 Material #2
Material #3

Extruder #3
Plastic Extruder
Three-Layer Co-extrusion
film bubble

material 1

material 2

material 3
Plastic Extruder
Blown-film Die Cross-Section
Tube is drawn immediately upward while still molten and
simultaneously expanded
by air inflated into it Bubble constantly pulled up
through die. Bubble
Frost line

Cooling air Cooling air

Die core Die lip adjusting bolts
Die Body
Plastic from extruder

Blow-up air inlet

Plastic Extruder
Blown-film Die Cross-Section
Air pressure blown into tube must be kept constant to
maintain uniform film thickness and tube diameter.
Bubble constantly pulled up

Bubble
Frost line

Cooling air Cooling air

Die core Die lip adjusting bolts
Die Body
Plastic from extruder

Blow-up air inlet

Plastic Extruder
Blown-film process layout

Upper nip rolls

Collapsing frame

Plastic film bubble Slitter

Dual roll
Internal bubble cooling winder
Air ring
Circular
Extruder die
Plastic Extruder
Aluminum Foil
l  Most foils are supported with plastic and/or paper
l  Reflective of radiant heat
l  Conductive (induction sealing)
l  Decorative appeal: all reflective metallic are aluminum
l  Provides reflective metallic appearance
l  Improves moisture, aroma, light and oxygen barrier
Plastic Extruder
Aluminum Foil
Vacuum line

Rewind roll Unwind roll

Aluminum
wire Chilled roll
Aluminum vapor
Ceramic boat
Plastic Extruder
Laminate
l  A product made by bonding together two or more
materials
l  Aesthetic appearance: clarity, surface gloss

surface print

paper
printed polypropylene
polyethylene
metallized polypropylene
foil
sealing medium
sealing medium
Snack food bag
Basic food bag laminate
Plastic Extruder
Laminate - Laminated Collapsible Tube Construction

Injected molded tip Finished

tube1
Clear LDPE
Formed body
Printed white PE
paper
EAA
Foil
Sealing medium
High
barrier
Laminate insert
roll stock
Plastic Extruder
Laminate
Plastic Extruder
Laminate – Pouch Examples
Plastic Extruder
Laminate - Horizontal Form-Fill-Seal

Forming plow Open pouch

Side seal Filler #1

Filler #2
Filler #3
Close pouch
Top seal

Cut-off
Tension control
Unwind
Plastic Extruder
Laminate – Multi-Lane Form-Fill-Seal

Product dispensers

Vertical heat seals Horizontal heat seals

Four-sided seal pouches

(separated)
Injection Molding Extruders
l  Polymer is heated to a highly plastic state and forced to
flow under high pressure into a mold cavity where it
solidifies and the molding is then removed from cavity

l  Mold may contain multiple cavities, so multiple moldings

are produced each cycle

l  Two principal components:

l  Injection unit: melts and delivers polymer melt

l  Clamping unit: opens and closes mold each injection

cycle
Injection Molding Extruders
Injection Molding Extruders
Three-Plate Injection Mold
Injection Molding Extruders
Three-Plate Injection Mold
The distance between the
sprue and the gate must be
exactly the same for every
cavity

9
Injection Molding Extruders
Molding Undercut
Main body ring
Pedestal Body plug
plug

Gate

Pedestal ring
halves
Bottle-Making Terminology

l  Moyle: The pinch-off trim piece from an extrusion

blow-molded bottle
l  Parison: An initial shape that will be expanded into a
bottle or jar in a second step
l  Preform: Describes the parison when using injection
blow-molding
l  Finish: That part of a bottle or jar that accepts the
closure
Bottle-Making Terminology
Neck ring insert
Mold guide
pins

Cooling
channels
Mold cavity

Pinch-off insert
Flash pocket
Bottle-Making Terminology

1 1

2 1.  Neck-ring insert

2

2.  Cooling water ports

3.  Cut-off insert

3 3
Bottle-Making Terminology
Parison Expansion & Wall Thickness
Initial parison wall thickness expansion is equal in all directions

Parison continues stretching after the parison center freezes

Expanding parison freezes the moment

it touches the chilled mold wall

Parison continues stretching after the parison center freezes

As a result, corner wall thickness is significantly reduced

Bottle-Making Terminology
Bottle-Making Terminology

Preform carried
over on core pin
Air

Injection
mold
Blow mold Preform expanded
open closed to blow mold
Bottle-Making Terminology

Preform and core pin Core pin moves down, Preform blown to
clamped in blow mold stretching preform container shape
Bottle-Making Terminology
Blow position

Blow mold

Stripper plate rotating

Preforms

Core rod table

Injection mold

Extruder
Strip Injection
position position