INNOVATIONS IN RIGID PACKAGING
185 Zaveri Bazar, Bank of India Bldg., 3rd Floor, Mumbai 400 002 Tel: +91-22-2344 3354/23443207 Fax: +91-22-23412922 Email: [email protected]
VINAY AGARWAL CREATIVE PLASTICS
IPI SEMINAR , MUMBAI , JANUARY 11, 2006
BRIEF INTRODUCTION
Creative Plastics Group 2005 Net Sales Rs. 140 Cr.
Plants 9 Nos.
Locations West, South & North India
Employees 550 Nos.
Corporate HQ Mumbai
HIGH QUALITY RIGID PACKAGING FOR:
Pharmaceuticals/Health Care
Personal Care
Others
Processes Extrusion Blow Molding
Injection Blow Molding
Injection Molding
Decoration
Design & Development
Extrusion Blow Molding
Among the largest EBM
equipment in India
Over 15 years experience
with Parison Programming
Equipment range from 2H x
2S upto 6H X 2S
Working closely with machine
manufacturers for developing
emerging technology
Injection Blow Molding
Expertise in IBM
Innovations and
breakthroughs achieved
in IBM
Taking the technology to
the next level
Largest in Asia Pacific for
IBM
Injection Molding
European High Speed machines made
in collaboration in India
Machines Installed with State of the
art cooling and De-humidifier System
Over 10 years of Expertise in running
Multi-Cavity Hot Runner Molds
Technical Expertise in handling
complicated In-Mold Closing System
Clean Room Manufacturing
Class 10000 Room Ideal for Pharmaceutical & Aseptic Packaging Controlled Temperature, Humidity and Air flow
Decoration UV Printing
World class UV Printing from Kammann, Germany High Outputs – 80 UPM – 3 colours Experienced Print Technicians
Labeling High Speed accurate labeling lines working at 120 upm Complete automation with unscramblers
Design & Development
2D Software – AUTOCAD
3D Software – Pro Engineer
- Alias Studio
- Mold Max
- Uni Graphics
Imaging - 3D Studio
NEED OF TODAY
Today all end-users are under tremendous pressure for cost reduction
Customers want packages which would deliver the performance at the lowest cost
This means we need the “Balance of Cost and Performance” for optimal packaging
MEETING THE CHALLENGES BY :
PARTNERING WITH THE CUSTOMERS WORKING FOR WIN-WIN OUT OF THE BOX THINKING INNOVATION TEAM WORK
Managing Innovation Ideas to the Market Place – 5 Gates Process
Business Strategy
Corporate Technology
Operations
IDEAS Idea Phase F
easi
bilit
y
Pro
cess
C
ap
ab
ilit
y
Imp
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en
tati
on
Lau
nch
Market Share Growth
SOME EXAMPLES 3 PIECE
INNOVATIVE CLOSURE
SATCHET UPGRADATION RIGID PACKS
MULTI COMPONENT REPLACEMENT WITH SINGLE BOTTLE
LIGHTWEIGHTING OF BOTTLES
UTILIZING EMERGING TECHNOLOGIES
• MULTI CAVITY EBM • CLARIFIED PP ISBM VERSUS PET • MULTI - STACK MOLDING • COMPRESSION MOLDING • FILLERS • BIO POLYMERS
MULTI CAVITY EBM CONSISTENT OUTPUT “MULLER” HEAD – GIVES EXCELLENT MATERIAL DISTRIBUTION ACROSS ALL CAVITIES PRECISE DIMENSIONAL CONTROL POSSIBILITIES OF LIGHT WEIGHTING DUE TO BETTER CONTROLS COMPLETE AUTOMATION – NO MANUAL INTERVENTION
Show Video
The solid resin is introduced into the hopper and, through the action of the rotating screw, is conveyed into the heated barrel. The screw in this section is feeding or conveying the solids and, hence, is quite deep. The geometry of the screw is such that the depth decreases in the transition zone, and the solids start to melt. Melting results from the shearing action of the screw as motor horsepower is converted into frictional heat. Barrel heaters are used for start up and to supplement the melting process. The melt continues to be pumped toward the discharge, or die end, of the extruder through the metering section of the screw. Metering is pumping at a given rate in a uniform manner, within close temperature and pressure tolerances.
Screw is Heart of Extrusion Process
A Good Screw Design Provides:
• Optimum Output • Good Mixing/Homogeneity • Freedom from Pulsation • High Quality Parison
SCREW
Design Parameters
• L/D Ratio
• Flight Profile – Feed, Transition, and Metering
• Compression Ratio
SCREW
CONVENTIONAL SCREW
• FEED SECTION – Solids conveying, some compaction and little heating • BEGINNING OF TRANSITION – Resin heated and compressed • TRANSITION 1 – More melting and more compression. Melt pool formed • TRANSITION 2 – Melting continues, shear rate increases, melt pool increases and
solids bed decreases • METERING 1 – Only less efficient melting occurs. Unmelted pellets distributed in
melt pool • METERING 2 – Non-uniform melt with viscosity and temperature gradients
Melt Profile in a Conventional Screw
BARRIER SCREW
• FEED – conveys solids, little melting and some compaction • TRANSITION 1 – A second flight is started, called barrier flight to separate solid
and melt channels • TRANSITION 2 – Melting continues as solid pressed and sheared against barrel
and melt collected in melt channel • Melt channel is deep, giving low shear and reducing overheating of melt. Solid
channel becomes shallower, giving efficient frictional melting • Solid bed continues to get shallower and finally disappears • All resin is melted uniformly
Melt Profile in a Barrier Screw
BARRIER SCREW
• Better mixing and homogeneity (more uniform melt) • Greater output (at same RPM) • Reduced weight variation • Higher quality parison (for bottle formation)
The Key Advantages of a Barrier Screw Design are:
Die Head controls parison quality Die Head directs melt flow from horizontal to vertical
DIE HEAD AND DESIGN
Die head for side entry, with mandrel extended to the top of the die body for support. (Here the parison programmer can be connected.)
TYPES OF DIE HEADS
Die head with mandrel supported by torpedo and spider arrangement allowing top concentric entry.
TYPES OF DIE ORIFICE
Parison wall thickness control is usually brought about by the raising or the lowering of a mandrel within the die ring to give a controllable variation in the mandrel/die clearance. The mandrel is actuated by hydraulic, pneumatic, or mechanical means. The thickness control movement is programmed to operate with each parison production cycle. Parison produced using wall thickness control, sometimes called differential parison extrusion, have a constant outside diameter, but with stepped variation of wall thickness to cater not only for draw-down and die swell effects, but also to give the blown article a constant wall thickness, irrespective of their final form.
Parison Wall Thickness Control
Effect of Parison Programmer on Parison Thickness and Bottle Wall Thickness
A parison programmer is a device that can change the gap between the die and mandrel while the parison is extruded. The wall of the parison is ringed with sections of thinner and thicker material. These rings are located to correspond to specific sections of the bottle. For many blow-molded articles, parison programming can reduce article weight and cost, and improve quality, performance, and strength.
MOLDS
MOLD DESIGN • Avoid sharp corners • Generous radii
BLOW AIR • Blow quickly • Hold under pressure • Higher blow pressure gives improved
dimensional stability
EBM TECHNOLOGIES
EFFICIENCY
EFFICIENCY
EFFICIENCY
CONSISTENCY
CONSISTENCY
CONSISTENCYQUALITY
QUALITY
QUALITY
COST
COST
COST
0
20
40
60
80
100
120
LOCAL ASIAN EUROPEAN
EFFICIENCY CONSISTENCY QUALITY COST
MULTI CAVITY EXTRUSION TECHNOLOGIES ADVANTAGES
COMPLETE AUTOMIZATION LIGHTWEIGHTING COOLING EFFICENCIES HIGHER EFFICIENCY REDUCTION IN WASTAGE/REJECTION REDUCTION IN COST
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Advantages of PP
Recent Breakthroughs in PP resins & Stretch Blow Technology have made PP more appealing and cost competitive versus PET “Practical” clarity of PP is equivalent to PET Excellent moisture barrier Excellent balance of stiffness, impact strength, heat resistance and chemical resistance Hot-fill performance Micro-wave able Retort sterilizability
Economics of OPP versus PET
Conversion Cost
With Recent Breakthroughs in PP preform designs, resins, additives and ISBM process, PP could be processed at same rate as PET
No drying needed for PP (lower energy cost)
PP could be processed on PET equipment with minor modifications
Same/Lower Conversion cost for PP vs. PET
New Markets for ISBM PP
Still Water
Flavored/Vitamin Waters
Baby Bottles
Ready to Drink Teas
Shampoos/Detergents
STACK MOLDING
A method of molding parts on multiple mold faces
• Single face mold
• Two face stack mold
• Four face stack mold
INJECTION MOLDING
Stack Molds
In this type of mold the mold cavities are placed one behind the other instead of side by side. Stack molds only need a clamp force sufficient for one “stack” of molds. Their major drawback is the difficulty in getting plastic through the stack to all the cavities.
STACK MOLDING
DOUBLE STACK/ FOUR FACE STACK MOLD
CYCLE TIME Cycle Time
Single Face Mold
Two Face Stack Mold
Four Face Stack Mold
STACK MOLDING
8 secs.
13 secs.
10 secs.
STACK MOLDING MAJOR BENEFITS
1. Lower per unit manufacturing costs
2. Increases production capacity of a given molding facility
3. Reduces production lead times – fast inventory build-up
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Advantages of Compression Molding
• High Volume Applications • Better Impact (lower MI resin, less
material stress) • Quick color change/ Less scrap • Lower Operation Costs (lower
heat/cooling) • Lower tooling Investment per output
volume
Limitations of Compression Molding
• Volumes • Part Design • Thread Profiles • Blemish Marks • Closure size