INNOVATIONS IN RIGID PACKAGING IPI SEMINAR , MUMBAI , JANUARY 11, 2006 VINAY AGARWAL CREATIVE PLASTICS 185 Zaveri Bazar, Bank of India Bldg., 3 rd Floor, Mumbai 400 002 Tel: +91-22-2344 3354/23443207 Fax: +91-22-23412922 Email: vagarwal@vsnl.com
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: � Personal Care Pharmaceuticals/Health 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 Implementation Market Share Capability Launch Feasibility Growth Process IDEAS Idea Phase Operations Corporate Technology
SOME EXAMPLES 3 PIECE SATCHET UPGRADATION INNOVATIVE RIGID PACKS CLOSURE MULTI COMPONENT LIGHTWEIGHTING OF BOTTLES REPLACEMENT WITH SINGLE BOTTLE
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 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
CONVENTIONAL SCREW Melt Profile in a 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
BARRIER SCREW Melt Profile in a 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
BARRIER SCREW The Key Advantages of a Barrier Screw Design are: • Better mixing and homogeneity (more uniform melt) • Greater output (at same RPM) • Reduced weight variation • Higher quality parison (for bottle formation)
DIE HEAD AND DESIGN Die Head controls parison quality Die Head directs melt flow from horizontal to vertical
TYPES OF DIE HEADS Die head for side entry, with Die head with mandrel supported mandrel extended to the top of by torpedo and spider the die body for support. (Here arrangement allowing top the parison programmer can be concentric entry. connected.)
TYPES OF DIE ORIFICE
Parison Wall Thickness Control 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.
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 120 100 QUALITY QUALITY EFFICIENCY 80 QUALITY EFFICIENCY CONSISTENCY EFFICIENCY CONSISTENCY 60 COST CONSISTENCY COST 40 COST 20 0 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 Show Video
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 Shampoos/Detergents Flavored/Vitamin Waters Ready to Drink Teas Baby Bottles Still Water
INJECTION MOLDING STACK MOLDING A method of molding parts on multiple mold faces • Single face mold • Two face stack mold • Four face stack mold
STACK 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.
DOUBLE STACK/ FOUR FACE STACK MOLD
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