Training Project UFLEX LIMITED

7/30/2019 Training Project UFLEX LIMITED

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WHAT IS PACKAGING?

Packaging is the science, art, and technology of enclosing or protecting

products for distribution, storage, sale, and use. Packaging also refers to the

process of design, evaluation, and production of packages. Package

labelling (BrE) orlabeling (AmE) is any written, electronic, or graphic

communications on the packaging or on a separate but associated label

Packaging is heavily integrated into our daily lives, we see it all around us,

on everyday items such as chocolate bars and potato chip (crisp) packets- As

explained below, the main use for packaging is protection of the goods

inside, but packaging also provides us with a recognisable logo, or

packaging, we instantly know what the goods are inside

The purposes of packaging and package

labelsPackaging and package labelling have several objectives:

Physical Protection - The objects enclosed in the package may

require protection from, among other things, shock, vibration,

compression, temperature, etc.

Barrier Protection - A barrier from oxygen, water vapor, dust, etc., isoften required. Package permeability is a critical factor in design.

Some packages contain desiccants orOxygen absorbers to help extend

shelf life. Modified atmospheres or controlled atmospheres are also

maintained in some food packages. Keeping the contents clean, fresh,

and safe for the intended shelf life is a primary function.
http://en.wikipedia.org/wiki/Shock_(mechanics)http://en.wikipedia.org/wiki/Vibrationhttp://en.wikipedia.org/wiki/Oxygen_absorberhttp://en.wikipedia.org/wiki/Modified_atmospherehttp://en.wikipedia.org/wiki/Shelf_lifehttp://en.wikipedia.org/wiki/Shock_(mechanics)http://en.wikipedia.org/wiki/Vibrationhttp://en.wikipedia.org/wiki/Oxygen_absorberhttp://en.wikipedia.org/wiki/Modified_atmospherehttp://en.wikipedia.org/wiki/Shelf_life


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Containment or Agglomeration - Small objects are typically

grouped together in one package for reasons of efficiency. For

example, a single box of 1000 pencils requires less physical handling

than 1000 single pencils. Liquids, powders, and flowables need

containment.

Information transmission - Information on how to use, transport,

recycle, or dispose of the package or product is often contained on the

package or label. With pharmaceutical, food, medical, and chemical

products, some types of information are required by governments.

Marketing - The packaging and labels can be used by marketers to

encourage potential buyers to purchase the product. Package design

has been an important and constantly evolving phenomenon for

dozens of years. Marketing communications and graphic design are

applied to the surface of the package and (in many cases) thepoint ofsale display.

Security - Packaging can play an important role in reducing the

security risks of shipment. Packages can be made with improved

tamper resistance to deter tampering and also can have tamper-evident

features to help indicate tampering. Packages can be engineered to

help reduce the risks ofpackage pilferage: Some packageconstructions are more resistant to pilferage and some have pilfer

indicating seals. Packages may include authentication seals to help

indicate that the package and contents are not counterfeit. Packages

also can include anti-theft devices, such as dye-packs, RFID tags, or

electronic article surveillance tags, that can be activated or detected by
http://en.wikipedia.org/wiki/Mandatory_labellinghttp://en.wikipedia.org/wiki/Marketinghttp://en.wikipedia.org/wiki/Marketing_communicationshttp://en.wikipedia.org/wiki/Graphic_designhttp://en.wikipedia.org/wiki/Point_of_sale_displayhttp://en.wikipedia.org/wiki/Point_of_sale_displayhttp://en.wikipedia.org/wiki/Point_of_sale_displayhttp://en.wikipedia.org/wiki/Tamper_resistancehttp://en.wikipedia.org/wiki/Tamper-evidenthttp://en.wikipedia.org/wiki/Package_pilferagehttp://en.wikipedia.org/wiki/Authenticationhttp://en.wikipedia.org/wiki/Counterfeithttp://en.wikipedia.org/wiki/RFIDhttp://en.wikipedia.org/wiki/Electronic_article_surveillancehttp://en.wikipedia.org/wiki/Mandatory_labellinghttp://en.wikipedia.org/wiki/Marketinghttp://en.wikipedia.org/wiki/Marketing_communicationshttp://en.wikipedia.org/wiki/Graphic_designhttp://en.wikipedia.org/wiki/Point_of_sale_displayhttp://en.wikipedia.org/wiki/Point_of_sale_displayhttp://en.wikipedia.org/wiki/Tamper_resistancehttp://en.wikipedia.org/wiki/Tamper-evidenthttp://en.wikipedia.org/wiki/Package_pilferagehttp://en.wikipedia.org/wiki/Authenticationhttp://en.wikipedia.org/wiki/Counterfeithttp://en.wikipedia.org/wiki/RFIDhttp://en.wikipedia.org/wiki/Electronic_article_surveillance


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devices at exit points and require specialized tools to deactivate.

Using packaging in this way is a means ofloss prevention.

Convenience - Packages can have features which add convenience in

distribution, handling, display, sale, opening, reclosing, use, and

reuse.

Portion Control - Single serving or single dosage packaging has a

precise amount of contents to control usage. Bulk commodities (such

as salt) can be divided into packages that are a more suitable size for

individual households. It is also aids the control of inventory: selling

sealed one-liter-bottles of milk, rather than having people bring their

own bottles to fill themselves.

PACKAGING TYPES

Various household packaging types for foods

Packaging may be looked at as several different types. For example atransport package ordistribution package is the package form used to

ship, store, and handle the product or inner packages. Some identify a

consumer package as one which is directed toward a consumer or

household.

It is sometimes convenient to categorize packages by layer or function:

"primary", "secondary", etc.
http://en.wikipedia.org/wiki/Loss_preventionhttp://en.wikipedia.org/wiki/Image:Packages.jpghttp://en.wikipedia.org/wiki/Image:Packages.jpghttp://en.wikipedia.org/wiki/Loss_prevention


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Primary packaging is the material that first envelops the product and

holds it. This usually is the smallest unit of distribution or use and is

the package which is in direct contact with the contents.

Secondary packaging is outside the primary packaging perhaps used

to group primary packages together.

Tertiary packaging is used for bulk handling and shipping.

WHAT ARE BOPP FILMS?

BOPP film (Biaxially Oriented Polypropylene)film in recent years has become one of the most

popular, high growth films in the world

market .

BOPP film is available in a wide range of film variations targeting the

packaging, pressure sensitive tape, label, stationery, metallizing and

decorative markets.


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WHY BOPP IS USED IN PACKAGING?

Excellent clarity

High tensile strength

Good dimensional stability and flatness

Low electrostatic charge

Corona treatment on one or both sides

Waterproof

PRODUCING A BOPP FILM BY 3 LAYER CO-

EXTRUSION PROCESS

This invention relates to an improvement of a process for producing a three

layer co-extrusion biaxially polypropylene (hereinafter as BOPP) syntheticpaper a thickness of from 25~250 m.

process for producing a three layer BOPP by means of a three layer co-

extrusion process wherein two different polypropylene (PP) resin

compositions are first separately extruded by one primary single screw

extruder with venting device and two secondary single screw extruders with


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venting device and then are co-flowed by the same T-die to form a three

layer coating sheet, and through cooling biaxial orientation, corona treatment

and winding to form a three layer co-extrusion synthetic paper of thickness

25~250 m.

The three layer structure of said three layer co-extrusion film of thickness

25~250 m can be made into three kinds, such as: paper sheet layer/foamed

intermediate layer/paper sheet layer with double side paper sheet layer,

paper sheet layer/foamed intermediate layer/resin layer with single side

paper sheet layer and resin layer/foamed intermediate layer/resin with

double side high gloss resin layer, to use as a coating substrate for coating

grade synthetic paper.

SEAL INITIATION TEMPERATURE

One of the most important steps in packaging is heatsealing. Thisstep is critical to package integrity and packageperformance. Sealing behavior is also critical in optimizingthe output of high-speed Form- Fill-Seal (FFS) packaginglines.

Physical Model of Sealing

Heat sealing involves the intimate contact of the surfaces of two semi

crystalline films. Heat is typically applied through seal bars thereby causing

the surfaces to melt. The melted surfaces wet and counter diffuse across


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the interface to entangle molecules, thus fusing the two surfaces. Finally,

cooling leads to the re-crystallization across the interface. Generally, this

interface has adequate entanglement to perform like a singular (simply

thicker) structure. This entire process occurs in less than a second, but is

mainly influenced by temperature, time and pressure.

.

Principles That Apply to All PolyolefinsThis model is applicable to a wide variety of polymers,including: linear polyethylenes such as LLDPE and HDPE, mLLDPEand Plastomer;


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as well as long-chain branched polymers like LDPE andEVA,EMA, acrylic-acid copolymers; and it can also be applied to polypropylene

Film structures can be blown, cast, extrusion-coated orlaminated


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Sealing and Seal-Initiation Temperature

The sealing curve is described with relatively common terms.

The Seal-Initiation Temperature (SIT) is the minimumsealing temperature required to form a seal of significantstrength. It is generally a peel-able or low strength seal.

The level of strength that must be reached to be deemed

significant varies with the application. Most of the time theSIT is definedat 0.5N/15mm seal force but other definitions, such as SIT at5 N/15 mm seal force or at 50% of the seal force plateau, arealso used.

Plateau Seal Strength (SSp) represents the fact that athigher temperatures the sealing curve levels off. Theultimate strength that can be obtained is often referred to asPlateau Seal Strength.

Plateau Initiation Temperature (Tpi) is the temperaturewhere tearing failure is observed. This is an importantsealing control parameter in packaging industry.


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Seal Failure

Seals typically fail in one of three modes:

1) Peeling generally results from a lack of diffusion duringthe seal formation across the seal surface. This may becaused by inadequate heating (set points are too low orcontrol problems), by incompatibility of blend components in

a sealant layer, or by cross-linking at the surface beforesealing(due to treating or irradiation or oxidation in extrusioncoating, etc.).

2) Tear-failure or edge-break: this is the most common,and desiredfailure mode. The rupture of the film is adjacent to the seal,which suggests maximum seal strength. It is by definitionequal to the tensile strength of the film itself. In this failure

mode the two sealant layers are typically fully fused or inter-diffused to form essentially a single ply.

3) Delamination can occur between layers of a co-extrudedstructure or between a PE film and a laminated substrate.


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Important Sealing Control Parameters

Time

Dwell time in the order of 0.5 s is adequate to achieve interfacial

temperature close to 95% of the set temperature.

Temperature

The temperature should be set according to the sealingcurve. It is common in the packaging industry to set sealbars to 5-10C (10-20F) above the Plateau Initiation

Temperature. This margin accommodates variability in

control and thus ensures consistent package integrity.

Pressure

Sealing pressure is less critical than time and temperature for hermetic seals.

Too low pressures, however, can result in seal peeling, while too high

pressures can result in seal thinning. A pressure of 0.5MPa is often a good compromise.


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Seal Strength - ASTM F88

The force required to separate a one inch wide heat seal. Seal strength is a

measure of the ability of a package seal to resist separation. Seal strength

data can be useful for setting sealing parameters.

One-inch wide test specimens are cut from a sealed package and placed in a

tensile test machine. The specimen is pulled in tension and the force required

to separate the specimen is recorded.


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Seal Strength Test

Aim of experiment: To study the effect of various variables such aspressure, temperature, time and thickness on seal strength of BOPP films.

Effect of temp and time on seal strength when thickness and pressure

are constant

18micron,1.8bar at dif values of time

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

115 120 130 140 150

temperature

se

alstrength 1

2

3

4


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Conclusion:

It is seen that the most consistent readings are obtained at 120deg.

The readings for different values of time were almost the same.

Effect of pressure and time on seal strength when thicknes and

temperature is constant

18 micron, 120 deg

0

0.1

0.2

0.3

0.4

0.5

0.6

1.5 1.8 2 4 6

pressure

sealstrengt 1

2

3

4


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Conclusion:

It is seen that the most consistent readings are obtained at 1.8bar.

The readings for different values of time were almost the same.

Effect of thickness and time on seal strength when pressure and

temperature are constant.

1.8 bar, 120 deg

0

0.2

0.4

0.6

0.8

1

18 25 35 40

thickness

sealstrengt 1

2

3

4

Conclusion:


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It is seen that the seal strength increases with thickness.

The readings for different values of time were consistent for different values

of time.( Except 4 seconds and higher)

a)

18micron,1.8bar at dif values of time

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

115 120 130 140 150

temperature

sealstrength 1

2

3

4

b)


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18micron,2bar

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

115 120 130 140 150

temperature

sealstreng

t

1

2

3

4

c)

18micron,4bar

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

115 120 130 140 150

temperature

sealstrengt 1

2

3

4

d)


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18micron,6bar

0

0.1

0.2

0.3

0.4

0.5

0.6

115 120 130 140 150

temperature

sealstrengt 1

2

3

4

Conclusion:

Looking at graphs a,b,c,d it can be observed that the most consistent

readings can be observed at 120 deg.

e)


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18micron, 115deg

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

1.5 1.8 2 4 6

pressure

sealstrengt 1

2

3

4

f)


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18 micron, 120 deg

0

0.1

0.2

0.3

0.4

0.5

0.6

1.5 1.8 2 4 6

pressure

sealstrengt 1

2

3

4

g)

18micron,130 deg

0

0.1

0.2

0.3

0.4

0.5

0.6

1.5 1.8 2 4 6

pressure

sea

lstrengt 1

2

3

4

h)


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18micron,140deg

0

0.1

0.2

0.3

0.4

0.5

0.6

1.5 1.8 2 4 6

pressure

sealstreng

t

1

2

3

4

i)

18micron,150deg

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

1.5 1.8 2 4 6

pressure

sealstrength 1

2

3

4

Conclusion:

Comparing the graphs e, f, g, h, I it can be observed that most concordant

readings can be observed at 1.8 bar.


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j)

40 micron,120 deg

0

0.2

0.4

0.6

0.8

1

1.8 2 4 6

pressure

sealstrengt 1

2

3

4

k)

40 micron,130deg

0

0.2

0.4

0.6

0.8

1

1.8 2 4 6

pressure

sealstrengt 1

2

3

4


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l)

40 micron, 140 deg

0

0.2

0.4

0.6

0.8

1

1.2

1.8 2 4 6

pressure

sealstrengt 1

2

3

4

m)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.8 2 4 6

1

2

3

4

Conclusion:


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Comparing the graphs j, k, l, m it can be seen that the most consistent

readings are obtained at 1.8 bar (except for high temperatures such as 150

deg and higher) for film with thicknesss 40 micron at various temperatures.

n)

40micron,1.8bar

0

0.2

0.4

0.6

0.8

1

1.2

1.4

120 130 140 150

temperature

sealstrengt 1

2

3

4

o)


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40 micron, 2bar

0

0.2

0.4

0.6

0.8

1

1.2

120 130 140 150

temperature

sealstrengt 1

2

3

4

p)

40 micron, 4 bar

0

0.2

0.4

0.6

0.8

1

120 130 140 150

temperature

sealstr

engt 1

2

3

4

q)


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40 micron, 6 bar

0

0.2

0.4

0.6

0.8

1

1.2

120 130 140 150

temperature

sealstrengt 1

2

3

4

Conclusion:

Comparing graphs n,o,p,q it can be observed that the most consistent reading

are obtained at 120 deg even for higher microns such as 40 at various

pressures.

FINAL CONCLUSION OF PROJECT


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A detailed study was performed on the effect of various

variables such as temperature, pressure, time on seal strength

of a BOPP film.

Effect of time:The different time intervals taken were 1sec, 2 sec, 3 sec and 4 sec.

It was seen that the readings were almost consistent for all these

values. Hence there is no effect of time on seal strength.

Effect of pressure:

The different values taken were 1.5 bar, 1.8 bar, 2 bar, 4 bar and 6

bar. The graph indicated the increase in seal strength upto 1.8 bar

after which it was constant and later reduced at higher temp.

Effect of temperature:

The different temperatures taken were 115 deg, 120 C, 130 deg,

140 deg and 150 deg. The most consistent readings were obtained

between 120 deg and 130 deg. After 130 results getting started

eratic and at 150 decrease in seal strength was observed which

with increasing pressure indicating the thinning of seal layer.

Hence the most accurate and economical readings of seal strength

can be obtained at-

Time :1 sec

Pressure :1.8

Temperature :120-130 C


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ACKNOWLEDGEMENT

I would like to thank Mrs. Rekha Agrawal (JEM

- Tech. Services , Flex Industries) for the

guidance and support given to me through out

this project.

I would also like to express my gratitude to

Ms Poonam Fotedar, Mr Ashish Tiwari,

Mr Rahul Verma and all the members of the

film division lab for extending their support.

http://www.exxonmobilchemical.com/Public_Fil

es/OPPFilms/Oriented_PP_Films/NorthAmerica

/Test_Method_Crimp_seal_strength_MST_rang

e.pdf


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Training Project UFLEX LIMITED

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