Food safety of Protact® Compliance with current and future ... · Figure 1: Steps in the Protact...

Food safety of Protact® Compliance with current and future food contact legislation

• Generally Regarded as Safe (GRAS)• CFR175.300 – regulating polymer packaging materials.

Protact undergoes compliance testing as required by the FDA. In FDA regulations, food composition defines the extraction liquid. Heat processing of the extraction liquid is based on heat processing of the canned food product. This approach to testing focuses on the dominant part in the pickup of substances from packaging materials.

Independent compliance testingProtact compliance testing is undertaken by TNO Triskelion, an independent and respected European research institute. The institute evaluates and certifies compliance to the relevant European and American food contact legislation (see figure 1).

Figure 1: Steps in the Protact food safety certification process executed by independent institute, TNO Triskelion.

Food contact legislation is designed to protect consumer health and ensure product quality.

Protact is a fully compliant packaging materialCurrent food contact legislation is designed to:• safeguard human health• protect packaged foodstuffs from unacceptable changes in

composition and quality.Protact laminated steel is fully compliant with all relevant European and USA food contact legislation. Furthermore, well-controlled purity levels of all chemical substances used in Protact enable compliance to upcoming legislation on non-intentionally added substances (NIAS).

Using a packaging steel substrate laminated with a three-layer polymer coating system on each side, the chemical substances used in Protact are specifically formulated without bisphenol A diglycidyl ether (BADGE), novolac glycidyl ether (NOGE), Bisphenol A (BPA) or bisphenol F diglycidyl ether (BFDGE). Protact complies with food contact legislation as set out in:• the Plastic Implementation Measure (PIM) under European Commission

(EC) legislation• the Code of Federal Regulation (CFR) under the USA’s Food and Drug

Administration legislation.

European Union (EU) and USA food contact regulationsIn the manufacture of Protact, Tata Steel maintains strict compliance to the EU and USA food contact regulatory systems and their requirements. Adherence to all relevant legislated procedures ensures that Protact is certified compliant with food safety legislation.

In the EU, substances and practices are scientifically evaluated by the independent European Food Safety Authority (EFSA) and formulated into practical legislation by the European Commission. The EC regulates food contact materials through:• Frame Work Regulation (EC 1935/2004) – defining general principles• GMP Regulation (EC 2023/2006) – defining general principles• Plastic Implementation Measure (PIM, EU 10/2011) and amendments

– defining requirements specific to polymers and polymer coatings.

Protact undergoes the required EC compliance testing which is based on composition, processing and storage conditions. Composition of the packed food product is used to select the appropriate stimulant. Heat processing, storage time and temperatures during the test are based on actual conditions during can processing. In the USA, the Food and Drug Administration (FDA) has a central role in scientific evaluation of new substances, formulation of legislation and enforcement of regulations. Food safety is regulated through:• the Code of Federal Regulation (CFR)• a specific Food Contact Notification (FCN)

Polymer composition from supplier to TNO on confidential basis

Demonstrate compliance with positive list

Coated steel sheets to TNO

Migration and extraction tests

Following EU route Following US route

Overallmigration

Extractionlimits

Specificmigration

Residualcontent

TNO Triskelion uses migration cells to establish substance migration and extraction from packaging materials (see figure 2). By testing product stimulants and the packaging material in secure migration cells, inert test conditions are ensured. A fixed volume and surface area of packaging material is tested. This rigorous testing is in line with food contact legislation.

Figure 2: Use of migrations cells (open on left, closed on right) ensures the legislatively prescribed conditions for migration and extraction testing are securely met.

TNO Triskelion certification for Protact contains the following statements on Protact compliance:• regarding compliance with FDA legislation – Protact “can be used for

packaging, transporting, or holding food”• regarding compliance with EC legislation – “overall migrations, relevant

specific migrations and residual contents meet the limits of the ‘Regulations’”.

Compliance with future NIAS legislationEuropean and American legislation increasingly requires food safety evaluation of direct food contact materials with regard to non-intentionally added substances (NIAS). The objective is to prevent introduction into foodstuffs of: • by-products• impurities• other non-intentionally added substances.

The scientific and regulatory debate on non-intentionally added substances is ongoing. Protact offers a safeguard against any tightening of NIAS regulation. Purity levels and processing conditions of the chemical substances used in Protact manufacture are well-controlled.

600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200

1.20

1.00

0.80

0.60

0.40

0.20

0.00

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Minutes

Graph A: Protact (PET)Shows the results of Protact coating screening undertaken by TNO Triskelion. Infrequent and less prominent ‘peaks’ are shown – confirming that Protact introduces very few non-intentionally added substances into packaged foodstuffs.

600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200

1.20

1.00

0.80

0.60

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Minutes

Graph B: Liquid coating (epoxy)Shows the ‘forest of peaks’ found in a typical epoxyphenolic lacquer. These prominent and more frequent peaks represent a large number of non-intentionally added substances that could potentially transfer into foodstuffs.

Figure 3: Migration of can coating into food content. Graphs A and B comparing the level of non-intentionally added substances in thermoset lacquers and Protact polymer laminated steel.

Independent screening confirms very few and less prominent ‘peaks’ when compared with the ‘forest of peaks’ in thermoset lacquer (see figure 3). Fewer and less prominent peaks indicate very few NIAS substances, proving that Protact has excellent levels of food safety.

One innovative regulatory methodology to assess the food safety of packaging materials is the screening of Non Intentionally Added Substances (NIAS). Following recommendation from the International Life Sciences Institute (ILSI) a NIAS screening was carried out for Protact. In typical food contact compliance tests the focus is on starting substances, however, NIAS screenings also measure impurities and reaction by-products in coatings. With this method endocrynic (hormonal) and carcinogenic activity is evaluated by a standardised method. After a thorough and detailed chemical analysis of all substances, samples of Protact were screened by Bluescreen® and other bioassays. The results of the NIAS screening showed no activity, demonstrating that Protact is indeed a very clean coated material, providing further evidence of the food safety of the product.

While care has been taken to ensure that the information contained in this publication is accurate, neither Tata Steel Europe Limited, nor its subsidiaries, accept responsibility or liability for errors or for information which is found to be misleading.

Tata Steel Europe Limited is registered in England under number 05957565 with registered office at 30 Millbank, London SW1P 4WY, United Kingdom.

Copyright 2019Tata Steel Europe Limited

Tata SteelPackaging PO Box 10.0001970 CA IJmuidenThe NetherlandsT: +31 (0)251 498217E: [email protected]

@TataSteelPackagwww.tatasteeleurope.com/packaging

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www.tatasteeleurope.com

System change for efficiency in 2-piece D&I food cans Protact® laminated steel - a safe and sustainable material solution

Efficiency to meet market needsTata Steel developed Protact laminated steel for two reasons. First, it meets market needs for more sustainable, reliable and safe packaging material. Second, it offers canmakers an opportunity to increase yield and be more competitive by removing cost-intensive unit operations in both greenfield and brownfield canmaking. Already technically proven in beer and bever age packaging and used commercially for various food applications such as deep drawn cans, Protact is a fully approved and controlled food-safe product. It is BPA-free and comprises a steel substrate and a coating of thin layers of Polyethylene Terephthalate (PET) or Polypropylene (PP) to meet a variety of performance requirements (see figure 3). Using Protact for 2-piece D&I canmaking eliminates the need for operations related to lacquering (see figures 1 and 2). This enables a reduction in associated manning and maintenance. It also eliminates emission of VOCs in the canmaking process and significantly reduces energy consumption. Use of Protact can also reduce water consumption. To deliver further gains, Tata Steel has developed Protact laminated steel to full D&I width for optimised can line output.

Food safetyPET is acknowledged as one of the safest food contact materials in use. The PET coating in Protact comprises polyester types proven in PET bottles. These contain few chemical components. Purity levels and processing conditions of the chemical substances used in Protact manufacture are well-controlled. Independent screening of Protact confirms very few and less prominent substance-related ‘peaks’ when compared with the ‘forest of peaks’ in thermoset lacquer. Fewer and less prominent peaks indicate very few non-intentionally added substances, proving that Protact has excellent levels of food safety.Protact’s inert polymer coating has excellent organoleptic properties. This ensures that the original taste of packaged food is not affected by the

BackgroundCanmakers, to compete, must comply with stringent legislation for materials in contact with food. Bisphenol A (BPA) is an organic synthetic compound used to make certain plastics and epoxy resins such as lacquers traditionally used to coat food cans. BPA in lacquers has come under intense scrutiny. Lacquers remain susceptible to possible future food safety issues. In addition, environmental legislation has led to strict allowances for volatile organic compound (VOC) emissions associated with the use of lacquers on metal packaging. Growing demands for sustainability mean many canmakers are seeking to limit the use of raw materials and energy in their processes. Brand owners and retailers are also seeking fully recyclable products.Against this legislative and regulatory background, canmakers are under pressure to become increasingly more efficient and innovative in the highly competitive food packaging market.

Surface layerOptimised for forming performance or content release

SubstratePackaging steel substrate

Adhesion layerOptimised for sterilisation

Main layerOptimised for blushing performance or coating colour

Figure 3: Food-safe and fully recyclable, Protact offers significant benefits for 2-piece D&I food can production. The three layer polymer coating system on each side of the substrate has been optimised specifically for the production of food-safe cans.

Figure 2: Canmaking with laminated steel.

Lubricator

Cupper

Bodymaker

Trimmer

Beader / Flanger

Light tester

Lacquer tank

Lacquer tank Water tap

Lubricator

Cupper

Bodymaker

Trimmer

Canwasher / Wash coat

Drier

Beader / Flanger

Internal spray

Curing oven

Light tester

Incinerator

Figure 1: Conventional canmaking.

packaging material. The packaging material does not scalp or taint food flavour. The food safety status of Protact is rigorously controlled by the respected European independent food institute, TNO Triskelion. Protact complies fully with European Food Safety Authority and US Food and Drug Administration food safety regulations. See Tata Steel’s Food safety of Protact® data sheet for additional information.

Sustainable packagingProtact’s polymer coating and steel substrate are infinitely recyclable. Steel is the most recycled packaging material in Europe – with recycling levels at 76% in 2014. The polymer coating of thin PET layers is burned off during the conversion of recycled Protact cans at around 1550°C in the steel making process. This produces thermal energy and high quality steel scrap.

Sustainable processProtact enables improved environmental performance in the canmaking process. Removal of lacquer-related operations – washcoat, spraying and curing – reduces energy consumption and CO2 emissions from gas-fired ovens. It also means that VOC emission is eliminated from the canmaking process, along with the need for equipment dedicated to VOC removal. In Europe, VOC emission continues to be a focus for attention in potential updates to the Best Available Techniques Reference Document (BREF). Use of Protact offers a safeguard against further tightening of VOC-related legislation and the costs that this could entail.

Using Protact, 2-piece D&I food cans can be made in a wet or dry canmaking process. In a dry process there is no requirement for an emulsion or for subsequent can washing. In addition to reducing water consumption, it enables canmakers to dispense with water treatment facilities. Tata Steel continually conducts company-wide life cycle analysis against competitor materials and can provide insights on individual request.

Adopting laminated steel for food can productionGreenfield investments can benefit immediately from the adoption of Protact laminated steel. Without washing and lacquering operations, capital investment and manning costs are significantly lower. There is no need to build and maintain technical expertise in lacquering. The simplified canmaking lines are shorter and can be built on a smaller physical footprint. With no need to store inflammable compounds, insurance costs are reduced due to a lower risk of fire or explosion.

Tata Steel’s Customer Technical Service team and Research & Development experts can assist customers in converting or adapting existing canmaking lines. Lines can be readily converted for Protact by making adaptations at the cupper and bodymaker. Tata Steel has developed techniques for cupping and canmaking that are vital to successful line conversion. These techniques ensure that no polymer hairs are made in the forming process. Hair formation would result in clogging or contamination. Hair formation

can be a problem with some laminated steels in 2-piece can formation. But, with Protact, Tata Steel’s techniques ensure that hair-free canmaking is achieved in the final moments of the drawing process. This entails precise control of timing of the blank holder lift-off to prevent pinching of the blank edge. Dry D&I canmaking also requires modifications to the dies and punch to ensure that heat generated in the process is removed.

In the bodymaking process, small adaptations are needed to run Protact through the installation. These comprise modifications to the wall ironing process and the redraw step in the bodymaker. The changes ensure wall ironing reductions of 50 - 55% are possible, as required for food cans.Tata Steel is recognised for the support it gives customers in assisting in the design of tooling and modifications needed to move from a traditional lacquer-based process to one using Protact laminated steel.

ConclusionFood-safe and infinitely recyclable, Protact offers significant benefits for 2-piece D&I food can production. It eliminates up to five unit operations related to lacquering – delivering safer, more sustainable canmaking operations with a reduced environmental footprint. Canmakers can save money through a reduction in manning, energy bills, insurance premiums and investment. In addition to efficiency gains, Protact offers the opportunity to maximise yield because it is available in widths up to 1220mm. Extra width allows an increase of 10 – 15% in cupper output, compared to standard 1000mm wide material.

Elimination of VOC emission – coupled with the fact that Protact is BPA-free – provides a safeguard against potential tightening of environmental and food contact regulation. Canmakers operating in VOC-capped manufacturing environments, such as California, can increase their production volumes whilst eliminating their VOC output completely.

The D&I canmaking line at Tata Steel’s R&D facility is run at commercial speeds. In co-operation with customers, it offers the opportuity for development of the canmaking process for 2-piece D&I food cans using Protact laminated steel.






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Protact® for 3-piece cansOptimised laminated steel for rationalised canmaking

Can making The coating-free zones in Protact for 3-piece cans allow for H-grain welding (see figure 2). The position and width of the zones can be varied to accommodate all standard can and aerosol diameter requirements from 45 mm and up. The consistent width and position of the coating-free zone and close control of tolerances enable stable and efficient welding operations. Side striping can be applied with good adhesion.The choice of substrate ensures the required elongation properties for successful flanging and double seaming. Protact’s optimised polymer coating system is entirely compatible with these operations and its performance levels remain intact. Protact for 3-piece food cans is suitable for beading.

Protact laminated steel from Tata Steel is a fully approved and controlled food-safe product. In addition, Protact is also suited for paint and general line applications. Already a proven material solution in 2-piece canmaking, we have now developed Protact to meet the needs of 3-piece canmakers.

The material’s coating-free zones are tailored to enable welding of the required can diameter and height. It removes the need for cost-intensive lacquering on the internal side of the can material and if present the external side. This frees up capacity and simplifies 3-piece canmaking operations.

Protact for 3-piece cans offers good side stripe adhesion performance. It is suitable for all 3-piece canmaking operations including welding, flanging, beading and double seaming.

Product featuresProtact for 3-piece cans comprises:■ a tinplate substrate – delivering the required elongation properties

for successful welding, flanging, beading and seaming■ a three-layer polymer coating system- can be applied on each side

of the substrate or on one side only. The coating system is optimised for food, aerosol, beer and beverage, and general line product applications

■ polymer coating-free zones – customised to can diameter requirements for H-grain welding, resulting in a coating that does not shrink or delaminate during welding, side strip curing and can be sterilised.

Polymer coating system and food safetyProtact’s multi-layered polymer coating system can be tailored to meet a variety of needs (see Figure 1). The coating comprises PolyEthylene Terephthalate (PET). Internal polymer layers have proven product contact performance for the products contained within Protact packaging. Protact is available with a total coating thickness ranging from 15 to 30 μm. Protact is fully compliant with all relevant European Food Safety Authority and US Food and Drug Administration food contact regulations. Compliance is certified by the independent and respected European research institute, TNO Triskelion. Current food safety focus for cans is on Bisphenol A (BPA) in lacquers. Protact is BPA-free. The chemical substances used in Protact are also specifically formulated without Bisphenol A diglycidyl ether (BADGE), novolac glycidyl ether (NOGE) or Bisphenol F diglycidyl ether (BFDGE). Kosher certification is available with Protact.

Surface layerOptimised interface properties

SubstrateTinplate substrate

Adhesion layerOptimised adhesion to steel for all product applications

Main layerGeneral functional

Figure 1. The independently optimised layers of Protact’s coating system offer unique advantages. These include improved welding efficiency and enhanced product aesthetics for market differentiation.

Corrosion protection

Protact’s optimised layer system ensures a low level of porosity. Compared with lacquered cans, this delivers superior corrosion protection for corrosive and hard-to-hold substances such as solvents used in aerosols and other general line applications. The product area affected by the heat of welding and side stripe curing has shown a good corrosion performance. The product can also be applied for food applications. This also applies to the overlapping area of the side stripe and the laminate (see figure 3). However we advise our customers to verify the corrosion performance with the fill goods to be used.

DimensionsProtact for 3-piece cans is available in a range of widths up to 1058 mm and in a thickness range of 0.15 mm to 0.60 mm. Welding margins can be created to produce cans from a diameter 45 mm and upwards. Obviously the layout is determined by your requirements. Ongoing product development is extending the choice of dimensions. Please contact us to discuss your needs.






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blank length

Bare edge

Needed coating free zone

blank height

coil width

Polymer coated sheet layout Welded product

Powder coating

Tinplate substrate

Polymer coating

Weld

Side stripe

Figure 3

Figure 2Coating free zone

e.g. 5 +/- 0.5mm

Product supportOur material experts and customer technical support are available to support the deployment of our products in your individual can format and product application. This includes support for adoption of H-grain welding to realise the benefits offered by Protact for 3-piece cans.

For more information:E: [email protected]

Protact® Optimised, efficient and sustainable laminated steel for packaging

Each layer In Protact’s polymer coating system is independently optimised to meet can performance requirements and ensure efficient processing during canmaking (see figure 2).

Formability and canmakingBoth the internal and external three-layer coating systems enable high wall ironing ratios, so Protact does not crack or perforate during the D&I process in 2-piece can production. The coating, in conjunction with small modifications to the canmaking line, ensures wall ironing reductions of 50 - 55% are possible, as required for food cans. This has been proven in commercial production for D&I aerosol and beer and beverage cans where the coating remains robust and reliable after formation. Protact’s containment performance is not compromised during forming. The unique build-up of Protact’s coating layers delivers a non-abrasive material – minimising tool wear during canmaking.

SustainabilityProtact is a permanent available material that is infinitely recyclable with no loss of quality. It is a chlorine-free, fully integrated polymer coated laminated solution for packaging. Recycling and reuse of Protact material does not require complex separation techniques or special treatments.

Use of Protact in the canmaking process removes up to five unit operations related to lacquering. It eliminates emission of VOCs and significantly reduces energy consumption and related CO2 emission – for an improved environmental footprint. Used in a dry canmaking process, water consumption is reduced. Tata Steel continually conducts company-wide life cycle analysis (LCA) against competitor materials and can provide insights on individual request.

Food safetyProtact is fully compliant with all relevant European Food Safety Authority and US Food and Drug Administration food contact regulations. Compliance is certified by the independent and respected European research institute, TNO Triskelion. Current food safety focus for cans is on Bisphenol A (BPA) in lacquers. Protact is BPA-free. The chemical substances used in Protact are also specifically formulated without bisphenol A diglycidyl ether (BADGE), novolac glycidyl ether (NOGE) or bisphenol F diglycidyl ether (BFDGE). Kosher certification is available with Protact.

Protact laminated steel from Tata Steel is a fully approved and controlled food-safe product. It is a proven material solution across a number of high performance canmaking applications and formats. Protact removes the need for complex, cost-intensive operations associated with the use of lacquer.

For example, using Protact to manufacture 2-piece drawn and wall ironed (D&I) food cans removes up to five unit operations. It also means the canmaking process consumes less energy and can be water-free. With Protact, there are no volatile organic compound (VOC) emissions during canmaking.

Product featuresProtact comprises:• packaging steel substrate• a three-layer polymer coating system on each side of the substrate

which has been optimised for food, aerosol and general line product applications.

Coating systemProtact’s multi-layered polymer coating system can be tailored to meet a variety of needs. Depending on the application, the coating comprises polyethylene terephthalate (PET) or polypropylene (PP). Internal polymer layers have proven product contact performance for the products contained within Protact packaging. Protact is available with a total coating thickness ranging from 12 to 40 µm.

The three layers of coating on each side of the substrate comprise an adhesion layer, a main layer and a surface layer (see figure 1).

Surface layerOptimised interface properties


Adhesion layerOptimised adhesion to steel for all product applications

Main layerGeneral functional

Figure 1. The independently optimised layers of Protact’s coating system offer unique advantages. These include improved canmaking efficiency and enhanced product aesthetics for market differentiation.

Corrosion protectionProtact’s optimised layer system ensures a low level of porosity. Compared with lacquered cans, this delivers superior corrosion protection for corrosive and hard-to-hold substances such as solvents used in aerosols and other general line applications.

Print and colourProtact is compatible with varnishes, UV and thermo-cured inks. It provides a good base layer for optimised print and improved branding performance. Protact is available in a range of base colours:• white• clear• black• gold

DimensionsProtact comes in a range of widths and dimensions (see figure 3). Availability of some dimensions depends on the packaging steel substrate and relevant polymer coating for the product application. Please contact us to discuss your needs.

Product supportOur material experts and customer technical support are there to support the deployment of our products in your individual can format and product application.

For more information:E: [email protected]






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1058

1220

650

0.13

0.60

thickness (mm)

wid

th (m

m)

Figure 3. Protact dimensional capability.

■ Existing capability■ Future capability

Application Adhesion layer Main layer Surface layer

Food Optimised for sterilisation

Optimised for non-blushing performance or coating colour

Optimised for forming performance or content release

Aerosol Optimised for heat resistance

Optimised for barrier performance or coating colour

Optimised for print

General Line (Paint)

Optimised for chemical resistance

Optimised for barrier properties or coating colour

Beer and beverage

Optimised for adhesion

Optimised for barrier performance, deformation stresses and coating colour

Optimised for forming performance and print

Figure 2. Protact can be customised to meet specific applications and canmaking needs.



Copyright 2017 Tata Steel Europe Limited

Tata Steel PackagingPO Box 100001970 CA IJmuidenThe Netherlands

T: +31 (0)251 49 82 17E: [email protected]

@TataSteelPackag

www.tatasteeleurope.com/packaging

PA0317:1000:EN:0317


Protact® is a registered trademark of Tata Steel. Packaging

Steel for packaging applicationsProduct range and technical specificationsGeneral specification window for packaging applications

Thickness Thickness

mm inches

0,40 0.0157

0,38 0.0150

0,36 0.0142

0,34 0.0134

0,32 0.0126

0,30 0.0118

0,28 0.0110

0,26 0.0102

0,24 0.0094

0,22 0.0087

0,20 0.0079

0,18 0.0071

0,16 0.0063

0,14 0.0055

0,13 0.0050

Grade TS230 TS245 TS260 TS275 TS290 TH415 TH435 TH520 TH550 TH580 TH620

T1 T2 T2.5 T3 T4 T5 DR7.5 DR8 DR8.5 DR9

* Beer and beverage cans

Specifications shown here are typical values. For all enquiries, including outside of these specifications, please contact us.

Aerosol tops

Aerosol bodies

Drawn cans

Pails and paint can bodies D&I food

D&

I B&

B*

Aer

osol

bot

tom

s

Food

can

end

s

Food

can

bod

ies

Dra

wn

bake

war

e

Expandedbodies

Easy-openends

Twist-offcaps

Tata Steel’s range of products includes; tinplate, tin-free steels (ECCS), blackplate, and our market leading Protact®laminated steel. This includes; clean steels for D&I, high strength formable steels for easy-open-ends and coated steels ideally suited to coil-fed canmaking operations.

Our manufacturing base produces reliable high performance steel grades. We process our steel in lengths and widths to match the specific needs of canmakers. We have the flexibility and expertise to customize products to meet specific end-application requirements. Our partners value our on-site support to optimize the process efficiency of canmaking.

We have the technical expertise of a dedicated packaging steel manufacturer. Wide experience and advanced capabilities including canmaking on commercial presses and Electrochemical Impedance Spectroscopy, have helped our partners create even more efficient designs for their products and improve pack performance. Our product testing facility helps to bring packaging solutions to market faster.

A comprehensive product portfolio for demanding canmaking operations

HIGH PERFORMANCE STEEL FOR PACKAGING

Downgauging is an important trend in the metal packaging industry for both efficiency and sustainability. We collaborate with canmakers on a dedicated project-by-project basis for mutual benefit.

We encourage sustainability by focusing on manufacturing efficiency and waste reduction. Working with national industry associations, we champion how steel is truly recyclable and

100 per cent sustainable. Steel is the most recycled packaging material. Only steel has a recycling rate of over 70 per cent - the highest of all. Steel can be used and recycled infinitely with no loss of quality.

For more detailed product information or to find out how partnership with us can optimize your business, please contact us at [email protected]

Protact®

Protact laminated steel from Tata Steel is a fully approved and controlled food-safe product. It is a proven material solution across a number of high-performance canmaking applications and formats. Protact removes the need for complex, cost-intensive operations associated with the use of lacquer. For further information visit tatasteeleurope.com/packaging.

Standard grades

Temper EN AISI/ASTM

Yield/proof

strength (MPa)

Yield/proof

strength (KSI)

Tensile strength

(MPa)

Tensile strength

(KSI) Range (MPa) Range (KSI)

TS200 - - 200 29 320 46 +/- 50 +/- 7

TS230 TS230 T1 230 33 325 47 +/- 50 +/- 7

TS245 TS245 T2 245 35 340 49 +/- 50 +/- 7

TS260 TS260 - 260 38 360 52 +/- 50 +/- 7

TS275 TS275 T3 275 40 375 54 +/- 50 +/- 7

TS290 TS290 - 290 42 390 56 +/- 50 +/- 7

TS310 (*) - - 310 45 395 57 +/- 50 +/- 7

TS345 - - 345 50 400 58 +/- 50 +/- 7

TS355 - - 355 51 415 60 +/- 50 +/- 7

TS370 - - 370 54 425 62 +/- 50 +/- 7

TS385 - - 385 56 435 63 +/- 50 +/- 7

TS480 - - 480 70 505 73 +/- 50 +/- 7

TS520 - DR7.5 520 75 545 79 +/- 50 +/- 7

TS550 TS550 DR8 550 80 575 83 +/- 50 +/- 7

TH415 TH415 T4 415 60 435 63 +/- 50 +/- 7

TH435 TH435 T5 435 63 460 68 +/- 50 +/- 7

TH460 - - 460 67 480 70 +/- 50 +/- 7

TH480 - - 480 70 500 73 +/- 50 +/- 7

TH520 TH520 DR7.5 520 75 540 78 +/- 50 +/- 7

TH550 TH550 DR8 550 80 570 83 +/- 50 +/- 7

TH580 TH580 DR8.5 580 84 590 86 +/- 50 +/- 7

TH600 (*) - - 600 87 610 88 +/- 50 +/- 7

TH620 TH620 DR9 620 90 625 90 +/- 50 +/- 7

(*) = Under development

D&I grades (food and beverage)

Tinplate for Drawn and Wall Ironed (D&I) applications has specific properties including low earing performance. Tata Steel offers alloyed extra low carbon, continuous annealed products to ensure excellent formability and highly efficient processing. Through our continuous improvement approach we focus on developing stronger, more ductile and formable steel grades to further increase the efficiency of canmaking. These steel grades combine the formability requirements of canmaking with the strength required of the final pack in beer and beverage and food applications.

D&I AISI/ASTM

Yield/proof

strength (MPa)

Yield/proof

strength (KSI)

Tensile strength

(MPa)

Tensile strength


TH340 T3 340 49 360 52 +/- 40 +/- 6

TH360 T3.5 360 52 380 55 +/- 40 +/- 6

TH380 T3.5 380 55 400 58 +/- 40 +/- 6

TH415 T4 415 60 415 60 +/- 40 +/- 6

Easy-open-end grades

Steel for easy-open ends requires high strength to withstand the retorting process, yet still enabling the ends to be easy to open. The steel is also ductile enough for seaming and rivet forming operations.

EOE grades EN AISI/ASTM

Yield/proof

strength (MPa)

Yield/proof

strength (KSI)

Tensile strength

(MPa)

Tensile strength


TH460 - - 460 67 495 72 +/- 50 +/- 7

TH520 TH520 DR7.5 520 75 540 78 +/- 50 +/- 7

TH550 TH550 DR8 550 80 570 83 +/- 50 +/- 7

TH580 TH580 DR8.5 580 84 590 85 +/- 50 +/- 7

TH600 (*) - - 600 87 610 88 +/- 50 +/- 7

TH620 TH620 DR9 620 90 625 90 +/- 50 +/- 7

(*) = Under development

Metallic coating mass for electrolytic tinplate and tin free steel (ECCS)

EN ASTM

Metallic coating Min Max Min Max

Tinplate Total Tin 1 14 g/m2 per side 0.05 0.62 lb/bb per side

Tin free steel (ECCS) Total Chromium 50 140 mg/m2 per side 4.6 13 mg/ft2 per side

Chromium in Oxide 7 35 mg/m2 per side 0.7 3.3 mg/ft2 per side

Surface finish

EN10202 ASTM

Product description Roughness (µm) Finish Roughness (µinch)

Super Bright < 0.25 5B 30 - 50

Bright < 0.35 5C 30 - 60

Fine Stone 0.25 - 0.45 5D (1) >60

Stone 0.35 - 0.60 7B 7 - 15

Heavy Stone 0.60 - 0.80 7C 6 - 25

Silver/Matt (1) 0.80 - 2.50

1) Special roughness range upon request Available in bright and matt

Dimensions

Product Coils/sheets* Sheets

Thickness Width Cut length

Single reduced (SR) 0.17 - 0.49 mm 700 - 1200 mm 457 - 1137 mm (width max. 1018 mm)

Double reduced (DR) 0.13 - 0.26 mm 700 - 1200 mm 457 - 1137 mm (width max. 1018 mm)

Wide D&I - Up to 1219 mm -

Width tolerance Standard trim (- 0.00, + 3.00 mm)

Special trim (- 0.00, + 1.00 mm)

Super trim (- 0.25, + 0.00 mm)

Dimensions

Product Coils/sheets* Sheets

Thickness Width Cut length

Single reduced (SR) 0.007 - 0.019 inch (60# - 169#) 27 - 47 inch 18 - 44.8 inch

Double reduced (DR) 0.005 - 0.010 inch (45# - 89#) 27 - 47 inch 18 - 44.8 inch

Wide D&I - Up to 48 inch -

Width tolerance Standard trim (- 0.00, + 0.118 inch)

Special trim (- 0.00, + 0,039 inch)

Super trim (- 0.01, + 0.00 inch)

* Other dimensions available on request. Scroll cutting also available on request.* Minimum and maximum dimensions are indicated. Restrictions in the combination of thickness and width may be applicable.

System change for efficiency in 2-piece D&I food cans Protact® laminated steel - a safe and sustainable material solution

Efficiency to meet market needsTata Steel developed Protact laminated steel for two reasons. First, it meets market needs for more sustainable, reliable and safe packaging material. Second, it offers canmakers an opportunity to increase yield and be more competitive by removing cost-intensive unit operations in both greenfield and brownfield canmaking. Already technically proven in beer and bever age packaging and used commercially for various food applications such as deep drawn cans, Protact is a fully approved and controlled food-safe product. It is BPA-free and comprises a steel substrate and a coating of thin layers of Polyethylene Terephthalate (PET) or Polypropylene (PP) to meet a variety of performance requirements (see figure 3). Using Protact for 2-piece D&I canmaking eliminates the need for operations related to lacquering (see figures 1 and 2). This enables a reduction in associated manning and maintenance. It also eliminates emission of VOCs in the canmaking process and significantly reduces energy consumption. Use of Protact can also reduce water consumption. To deliver further gains, Tata Steel has developed Protact laminated steel to full D&I width for optimised can line output.

Food safetyPET is acknowledged as one of the safest food contact materials in use. The PET coating in Protact comprises polyester types proven in PET bottles. These contain few chemical components. Purity levels and processing conditions of the chemical substances used in Protact manufacture are well-controlled. Independent screening of Protact confirms very few and less prominent substance-related ‘peaks’ when compared with the ‘forest of peaks’ in thermoset lacquer. Fewer and less prominent peaks indicate very few non-intentionally added substances, proving that Protact has excellent levels of food safety.Protact’s inert polymer coating has excellent organoleptic properties. This ensures that the original taste of packaged food is not affected by the

BackgroundCanmakers, to compete, must comply with stringent legislation for materials in contact with food. Bisphenol A (BPA) is an organic synthetic compound used to make certain plastics and epoxy resins such as lacquers traditionally used to coat food cans. BPA in lacquers has come under intense scrutiny. Lacquers remain susceptible to possible future food safety issues. In addition, environmental legislation has led to strict allowances for volatile organic compound (VOC) emissions associated with the use of lacquers on metal packaging. Growing demands for sustainability mean many canmakers are seeking to limit the use of raw materials and energy in their processes. Brand owners and retailers are also seeking fully recyclable products.Against this legislative and regulatory background, canmakers are under pressure to become increasingly more efficient and innovative in the highly competitive food packaging market.

Surface layerOptimised for forming performance or content release


Adhesion layerOptimised for sterilisation

Main layerOptimised for blushing performance or coating colour

Figure 3: Food-safe and fully recyclable, Protact offers significant benefits for 2-piece D&I food can production. The three layer polymer coating system on each side of the substrate has been optimised specifically for the production of food-safe cans.

Figure 2: Canmaking with laminated steel.

Lubricator

Cupper

Bodymaker

Trimmer

Beader / Flanger

Light tester

Lacquer tank

Lacquer tank Water tap

Lubricator

Cupper

Bodymaker

Trimmer

Canwasher / Wash coat

Drier

Beader / Flanger

Internal spray

Curing oven

Light tester

Incinerator

Figure 1: Conventional canmaking.

packaging material. The packaging material does not scalp or taint food flavour. The food safety status of Protact is rigorously controlled by the respected European independent food institute, TNO Triskelion. Protact complies fully with European Food Safety Authority and US Food and Drug Administration food safety regulations. See Tata Steel’s Food safety of Protact® data sheet for additional information.

Sustainable packagingProtact’s polymer coating and steel substrate are infinitely recyclable. Steel is the most recycled packaging material in Europe – with recycling levels at 76% in 2014. The polymer coating of thin PET layers is burned off during the conversion of recycled Protact cans at around 1550°C in the steel making process. This produces thermal energy and high quality steel scrap.

Sustainable processProtact enables improved environmental performance in the canmaking process. Removal of lacquer-related operations – washcoat, spraying and curing – reduces energy consumption and CO2 emissions from gas-fired ovens. It also means that VOC emission is eliminated from the canmaking process, along with the need for equipment dedicated to VOC removal. In Europe, VOC emission continues to be a focus for attention in potential updates to the Best Available Techniques Reference Document (BREF). Use of Protact offers a safeguard against further tightening of VOC-related legislation and the costs that this could entail.

Using Protact, 2-piece D&I food cans can be made in a wet or dry canmaking process. In a dry process there is no requirement for an emulsion or for subsequent can washing. In addition to reducing water consumption, it enables canmakers to dispense with water treatment facilities. Tata Steel continually conducts company-wide life cycle analysis against competitor materials and can provide insights on individual request.

Adopting laminated steel for food can productionGreenfield investments can benefit immediately from the adoption of Protact laminated steel. Without washing and lacquering operations, capital investment and manning costs are significantly lower. There is no need to build and maintain technical expertise in lacquering. The simplified canmaking lines are shorter and can be built on a smaller physical footprint. With no need to store inflammable compounds, insurance costs are reduced due to a lower risk of fire or explosion.

Tata Steel’s Customer Technical Service team and Research & Development experts can assist customers in converting or adapting existing canmaking lines. Lines can be readily converted for Protact by making adaptations at the cupper and bodymaker. Tata Steel has developed techniques for cupping and canmaking that are vital to successful line conversion. These techniques ensure that no polymer hairs are made in the forming process. Hair formation would result in clogging or contamination. Hair formation

can be a problem with some laminated steels in 2-piece can formation. But, with Protact, Tata Steel’s techniques ensure that hair-free canmaking is achieved in the final moments of the drawing process. This entails precise control of timing of the blank holder lift-off to prevent pinching of the blank edge. Dry D&I canmaking also requires modifications to the dies and punch to ensure that heat generated in the process is removed.

In the bodymaking process, small adaptations are needed to run Protact through the installation. These comprise modifications to the wall ironing process and the redraw step in the bodymaker. The changes ensure wall ironing reductions of 50 - 55% are possible, as required for food cans.Tata Steel is recognised for the support it gives customers in assisting in the design of tooling and modifications needed to move from a traditional lacquer-based process to one using Protact laminated steel.

ConclusionFood-safe and infinitely recyclable, Protact offers significant benefits for 2-piece D&I food can production. It eliminates up to five unit operations related to lacquering – delivering safer, more sustainable canmaking operations with a reduced environmental footprint. Canmakers can save money through a reduction in manning, energy bills, insurance premiums and investment. In addition to efficiency gains, Protact offers the opportunity to maximise yield because it is available in widths up to 1220mm. Extra width allows an increase of 10 – 15% in cupper output, compared to standard 1000mm wide material.

Elimination of VOC emission – coupled with the fact that Protact is BPA-free – provides a safeguard against potential tightening of environmental and food contact regulation. Canmakers operating in VOC-capped manufacturing environments, such as California, can increase their production volumes whilst eliminating their VOC output completely.

The D&I canmaking line at Tata Steel’s R&D facility is run at commercial speeds. In co-operation with customers, it offers the opportuity for development of the canmaking process for 2-piece D&I food cans using Protact laminated steel.






PA0317:1000:EN:0317


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