Rigid and Specialty Containers

Bhupendra Singh

PACKAGING FUNCTIONS Package is the means of providing

PROTECTION
CONTAINMENT

IDENTIFICATION/ PRESENTATION INFORMATION

BRAND PROTECTION

CONVENIENCE

Packaging must protect what it sells,

and sell what it protects

Factors influencing Packaging Design & Selection

0 . Spoilage of Product 1 . Packaging Options 2 . Testing

Spoilage of Product

0.

Spoilage of product results from

- Chemical Incompatibility between the ingredients of the product / packaging material -Moisture,

-Oxygen,
-Light & -Temperature changes

Spoilage of Product

0 .1 Effects of Moisture Y Y Y Y Crystalline substances absorb moisture, e.g. CaCO3, Na-Sulphate Aspirin can be hydrolyzed by water absorption Vitamins are also susceptible to moisture Suitable packaging material should be used to prevent / reduce the effect of water / moisture.

Spoilage of Product

0 .2 Effects of Light & Oxygen

Y
Y Y Y

Light has a catalyzing effect on degradation by oxygen.

The degradation products may be toxic. It is essential that light does not affect the product. 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

0 .3 Effects of Heat
Y
Y

Heat can cause product to loose the water of crystallization & convert the product into amorphous state.
The rate of vaporization of some products are affected by changes in heat (liquid products).

Y
Y

Many medications are deactivated / degraded by heat & exposure to light further accelerate the heating effect.
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

0 .4 Effects of Other Factors Distribution Hazards Mechanical Hazards of transportation Climatic Hazards of distribution Biological hazards of distribution Compatibility

Spoilage of Product
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
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
0 .4.3 Biological Hazards of distribution Biological Hazards Microorganisms Fungi Moulds

Bacteria
Insects Beetle, Ants, Termites Mites Rodents

Types of Rigid Containers Glass Containers Metal Containers Composite Containers Plastic Containers Aerosol

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

Metal Containers
Aluminum Collapsible Tube The Sizes of Tubes generally used in Industries and the capacities are as given below: Tube Dia. 12.7 mm 16.0 mm 19.0 mm 22.2 mm 30.0 mm Capacity 3 TO 5 g 10 g 15 g 20 g 50 g Aluminum Containers The Sizes of Aluminum Containers are as given below:

50 ml 100 ml 250 ml 500 ml 1000 ml 5000 ml

The Length of the tube is decided by the purchaser.

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

Metal Containers Properties of Tin Plate Container

Strong Withstand vacuum and pressure Non toxic Excellent barrier property to prevent bacterial spoilage and leakage Resistance to light penetration Odour well retained When decorated attractive Types of Containers Two Piece Containers

Three Piece Containers

Preferred for Packaging of Powders, Granules or Tablets in Bulk, Liquid Packaging for highly volatile materials.

Composite Containers 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

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

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)

Plastic Containers
Accurate thickness Profile From 20 ml to 20 liters

Injection Molding

Extrusion Blow Molding

Suitable for 20 ml to 1000 liters Most widely used containers Sturdy containers

Injection Blow Molding

High Output Accurate thickness Profile Suitable for 20 ml to 250 ml

Injection Stretch Blow Molding

Suitable for 20 ml to 2 liters Not widely used in Agrochemicals

Plastic Containers

Plastic Containers Materials Used in plastic Containers

Polypropylene Polyethylene
HDPE LDPE LLDPE EVA GPPS HIPS ABS SAN

Polystyrene

PVC PET PC

Plastic Containers

Extrusion Blow Molding

Extrusion

Pinch Off
Pinch Off

Blowing

Cooling

Plastic Containers

Plastic Containers

Multilayer Blow Molding

No of Combination of Layer Layers 1 Nylon - Adhesive - HDPE/PP Application For pesticides and similar hazardous chemicals, solvents etc. Reduce the evaporation of product filled. For pesticides and 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.

Nylon - Adhesive Regrind/recycled - HDPE/PP

Barrier Layers: - Nylon - EVA - EVOH

Plastic Containers

Injection Blow Molding

Injection Stretch Blow Molding

Plastic Containers

Stretch Blow Molding

Plastic Containers
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.

Left Intentionally Blank

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 molding.

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

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

Impact Strength
Purpose In real world, materials are often subjected to sudden loads, falling objects etc. Impact testing 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

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

Stacking Test

Purpose

To observe buckling of containers under load or when stacked during transportation IS 10840 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

Reference

Method

Report

Look for permanent deformation

and damages on the packages, if not it passes the test.
Container Capacity (kg) 1 2 5 10 15 Load on 4 containers (N) 400 600 800 1200 1600

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 IS 7408 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. If containers failing in the first drop and on the same position on subsequent containers, then the same has to be reported

Reference

Method

Report

Test for Closure Effectiveness

Purpose

The test is conducted for observing effectiveness of closure and to check for leakage if any IS 7408 3 containers shall be used. Fill each container to its nominal capacity with the test load at ambient temperature. Close each container with closure as per recommended torque. Invert closure and keep for 24 hours. Examine for leakage after 24 hrs. If the liquid spills out, that implies the closure is not effective.

Reference

Method

Report

Test for Resistance to Environmental Stress Cracks (ESCR)

Purpose

To test the bottle / closures for stress cracking

Reference

IS 6312
Teepol B300 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 for 48 hours for containers more than 25 ltrs. The container is then checked for cracks developed if any and reported.

Test

Method

Report

Vibration Test

Purpose

The method helps to determine the ability of a closure (on a container) to prevent leakage due to transportation in vibration A vibrating table, aptitude of vibration 25mm and frequency 8 HZ IS 12512

Apparatus

Reference

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

Report

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

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

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

Processing

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

resin for blow moulding applications.

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

Types of Additives

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Antioxidants UV Stabilizers Plasticizers Flame Retardants Antistatic Agents Clarifying agents Chemical Foaming Agents Antimicrobial Fillers and Reinforcements Polymer Processing aids Colorants

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.

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

Decoration

UV Printing High Outputs 80 UPM 3 colours Labeling High Speed accurate labeling lines working at 120 upm Hot foil Stamping

Design & Development

2D Software AUTOCAD 3D Software - Pro Engineering

- Uni Graphics
Imaging - 3D Studio

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.

Innovations in Design

Innovative Vented Induction Sealing Wads

Normal Wad

Vented Wad

Innovations in Barrier Packaging

Barrier Solutions Fluorination Co-extrusion Sulphonation

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.

H H C H F C

H F2
F

The bulk properties of fluorine treated plastic container remains unchanged.

Fluorination Techniques

Offline Direct Fluorination

Inline/ Online Fluorination

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

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

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

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

Co-extrusion Technology

Comprises of either three, four or six layers, including HDPE and an inner EVOH or Nylon layer

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.

Sulphonation Sulphonation Technology

The containers are treated with SO3 gas on the Plastic Surface. Sulphonation of Plastic results in improved barrier Properties.

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.

Nanocomposites

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

Future Packaging

Biodegradable Packaging

Active Packaging

PLA (Polylactic Acid) PHAs , {PHBV (Polyhydroxy Butyrate Velarate)} Starch Blends

Antimicrobial Packaging Scavenger Packaging Intelligent Packaging etc.

Thank You