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: vagarwal@vsnl.com

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

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Imp

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tati

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Lau

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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