The Challenges of Designing & Developing Plastic Aerosols ...
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providing packaging solutions through engaged hearts and mindsTM
The Challenges of Designing & Developing Plastic Aerosols for a Global Market
Richard C. Darr VP Global Packaging Development October 2018
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Our Company
• Family owned and managed
• Founded in 1967
• 2017 revenue : $2.7 billion
• Over 40 billion units produced annually
• 6,600 associates worldwide
• Over 40 production sites globally
• 5 + billion bottles recycled annually
• Over 1,500 patents globally
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A Global Business
• 58% of Global Business
• Founded in 1967
North America
• 4% of Global Business
• Entered Market in 1997
South America
• 37% of Global Business
• Entered Market in 2005
Europe & Africa
• 1% of Global Business
• Entered Market in 2015
Asia
Global Revenue 2017 - $2.7 billion
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Why use a PET aerosol container?
Shelf impact
Low carbon
footprint
Lightweight
Different!
Innovative
Versatile / shape
flexibility
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PET Aerosol Containers
Technical challenge Regulatory limitations
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Legislative
Constraints
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Plastic Aerosol Regulation Accuracy or Ambiguity?
• Plastic aerosol containers are in the market today
• Current legislation worldwide allows plastic containers up to 500ml brimful volume (except Europe and parts of Asia)
• Plastic containers up to 1000ml brimful volume became standard in North America, based on British standard
• European Commission asked for harmonisation with global regulations in 2005
• FEA supports plastic cans up to 800ml and increased pressure up to 13.2 bar (with compressed gasses)
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Regional Legislative Overview
• U.S. DOT (Department of Transportation) Outlines the various testing procedures
• NFPA (National Fire Protection Association) 30B:
– Fire & explosion prevention
– Applies to all areas of manufacturing & storage facilities
• No stated legislative requirements within most LATAM countries for Plastic Aerosols
• Requirement to place a safe aerosol on the market
• Major brand owners follow DOT or ADD regulations
• Regulated by the Aerosols & Dispensing Devices Directive (ADD 75/324/EEC and revision in 2008)
• Plastic aerosols treated like glass aerosols
• Size limitations
– ≥50ml, ≤220ml
• Pressure limitations
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PET Aerosols:
Design &
Development
Challenges
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• PET
• Mechanical performance
• Barrier performance
• Thermal characteristics
PET Material
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PET: Polyethylene Terephthalate
A thermoplastic polymer resin of the polyester family
PET
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Packaging material barrier properties
Oxygen p
erm
eabilit
y (
cc/m
².day.b
ar)
Water permeability (gr/m².day)
0.01 0.01 0.1 1 10 100 1000 10000
0.1
1
10
100
1000
10000 LDPE
PP
PET
PEN
HDPE
MxD6
COC
LCP
EVOH
PS PC
PA6
Cellulose
Starch
Film thickness : 100 µm
PET has an excellent gas barrier
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Tg. Glass transition temperature
PET = 70-75°C The glass transition temperature is the temperature below which
the physical properties of amorphous materials vary in a manner
similar to those of a solid phase (glassy state), and above which
amorphous materials behave like liquids (rubbery state).
Tc. Crystallization temperature
PET = 140-160°C The temperature at which a crystalline resin begins to crystallize
upon cooling.
Tm. Melting temperature
PET = 245-255°C The temperature at which a material turns suddenly from solid to
liquid.
Sidel Source
Thermal Characteristics
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• A machine that injects a preform and blows a container within the one machine
• Suitable for small volumes
ISBM Single stage or One-Step Technology
Injection Stretch Blow Moulding (ISBM)
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ISBM 2 step technology
1. Preform injection
2. Container blowing
Manufacturing SprayPET® Plastic Aerosols
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PET Resin Drying
PET Resin Extrusion
PET Resin Injection
Preform Cooling
The injection process
Preform Injection
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Why the need for drying?
1. Degradation of PET due to water (hydrolysis – IV drop)
2. Hazy preform due to crystallization
3. 40% of energy to heat the pellets is supplied through the dryer
Residence time
4 – 6 hours
Less 40ppm
160-175oC
Dew point: max -30oC
Dryer
Resin drying is essential for high quality preform moulding
Preform Injection
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Preform Injection
Opening and
Part Removal
Mould
Close Shutter-
In/Clamp-Up
Inject Hold Cool
Dry Cycle
Process Cycle
Cycle Compression (Cycle Time Saving)
SHOOTING POT
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The blowing process
We all have done it!
Container Blowing
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Container Blowing
Preform Heating
Preform Stretching
Preform Blowing
Bottle Cooling
The blowing process
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Start Stretching
End Stretching
8 bar
40 bar
Bottle Temp < 75°c
Stretching Stretching & Pre-Blow
End Stretching & Pre-Blow
Blowing Exhaust
Container Blowing Process
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The Key Technical Challenges
Ability to withstand
high pressures
Material resistance to
extreme temperatures
Ability to withstand
impact from dropping
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Technical Challenge in Context
In Europe Plastipak aerosol containers are rigorously tested to draft FEA standard 647 part 1
Pressurised to c. 2 -3 bar Pressurised to c. 10 bar
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Ability to withstand high pressure
• Dependent on desired burst pressure, specific hydraulic pressure applied and held for 25 seconds
• Pressure then increased until container bursts
• To pass, burst point must be 20% higher than hydraulic pressure
• Must pass burst test without splintering
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SprayPET® Achieves Burst Pressure up to 27bar/390psi
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Resistance to Heat
• FEA proposed testing
• Under test, filled & pressurised aerosols must not burst or leak
– Water bath: 55oC for 10 minutes
– Hot air testing: placed in an oven at 65oC for minimum 5 hours. Deformation is allowed
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Resistance to Heat
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Drop Resistance
• Containers filled with antifreeze or water
• Held at -18oC for 24 hours and 55oC for 6 hours
• Then dropped from height of 1.8m on to concrete floor
• Containers must not burst or leak
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Drop Resistance
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Summary of Plastipak’s extensive testing
Test Result
Hydraulic test Pass @15.0 bar
Burst test Max 27.0 bar/390psi
Drop test (all temperatures)
Pass
Hot air 65°C Pass (5h)
Top load Min 100.0 kgF
Stress cracking Pass with NaOH
Applies to SprayPET
220ml container
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Other
Perceived
Challenges
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Compatibility with propellants
• Compressed gasses
• Non-flammable combinations of liquid propellants
• Hydrocarbons
– PET has a good chemical resistance to butane and propane
• DME not compatible
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Content Compatibility
• PET aerosols compatible with many products – but not everything
• Compatibility testing required for each project
• Reformulation an option with challenging contents
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Decoration
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Sleeving
• Containers can be sleeved without issue
• Sleeve manufacturer tested sleeved containers in 55oC water bath for 10 minute, 1 hour, 2 hour & 3 hour periods:
– No detrimental impact observed
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Printing
• Printing is fully possible on PET containers
• Printing on different shapes is possible – not just straight sided cylinders
• Plastipak offers 4 colour, high-speed silk screen printing
• Used effectively for premium brands
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Direct Object Printing
• Successfully launched in the USA and currently in development in Europe
• Real “no label” look
• Mass customisation
• Reduced waste
• Enhanced customer engagement
• Faster speed to market with inline variable data print
• Instant change over
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Some Initial Different Designs
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• Easy to implement
• Change of blow moulds required
– Preform changes may be required subject to design
– Cost dependent on volumes / blowing machine
• How much value do you put on shelf presence / differentiation?
Complexity of Customised Shape?
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Case study
• Launched in US January 2017
• PET container supported by HDPE base cup
• Sleeve decoration
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Plastic Valves
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Summary
Different legislation
regionally – largely
supportive
Comprehensive
testing regime in
place
Decoration not an
issue
Propellant & product
compatibility OK