Designing a bottle through injection moulding system
designing of an injection stretch blow molded (ISBM) bottle made from Ingeo biopolymer for water
packaging. Since there are many factors to consider with preform and bottle design, development,
and manufacturing, an experimental approach may be needed.
The importance of bottle design cannot be overstated. The overall design of the bottle provides
many functions that may include:
• Shape and color for consumer appeal and product differentiation
• Ribs that provide structural support to the package, while keeping the overall bottle weight low
• Vacuum panels for use in hot-fill applications
• CSD bottle designs to minimize creep
Ingeo biopolymer 7001D can be manufactured into ISBM bottles using conventional equipment
made for PET. There are, however, some aspects about Ingeo biopolymer that should be noted
when trying to find the best bottle design.
The first and most important thing to consider is Ingeo biopolymer’s barrier properties. Ingeo
exhibits higher transport rates for water vapor, carbon dioxide, and oxygen by a factor of 8-10 times
than that of PET. A comparison to HDPE is also shown in the table below.
Design Considerations for Packaging Water in Ingeo Bottles
• The water bottle having reinforcing features, such as ribs, to help alleviate paneling of the sidewall
over time
• It is also recommended not to light weight the bottle. Typical weights for a 500ml Ingeo bottle
should be 22-25 grams. Too thin of a sidewall will increase the rate of water loss.
• Dosing with nitrogen may help minimize the impact of altitude changes & internal pressure loss in
the bottle that can then result in sidewall paneling
• Sharp & aggressive corners in the bottle design should be avoided, as Ingeo biopolymer stretches
easier than PET.
• These same issues will need to be address with products containing high water content (e.g. -
soaps, shampoos, other beverage drinks, etc.)
Physical Properties
The bottle design also plays an important role in providing performance in physical properties. In
general, Ingeo biopolymer blown into a bottle designed for PET should perform well in tests such as
top-load and drop impact. In order to get adequate physical properties, one will need to get the right
material distribution in the base and shoulder in order to pass drop impact and top load testing.
Corrugated plastic board
Corrugated plastic sheet has become one of the most sought after products in the industries
worldwide. This is mainly because of the various usage corrugated sheets hold on different
platforms and workplace. From factory sheds to sign boards, street directions to roofing
alternatives, there is a host of alternatives corrugated sheets can address.
Corrugated sheets are very strong due to the combination of two layers held by a ribbon center in
between. This structure makes them known as twinwall plastic. The dynamic value of
corrugated sheets hold significance in its usage because of the property of polypropylene and
polyethylene which are versatile thermoplastics. Polypropylene is resistant to many chemicals at
normal temperatures and can provide extra resistance from UV, harsh weather, static load and
fire. Its propensity to adhere to climatic changes and unforeseen hardships is indeed an
advantage. Many warehousing industries have been using PVC corrugated plastics reinforced
with chopped glass fiber for their storage cabins. ASA, PVC and polycarbonates have become
synonymous with longevity. One can find them commonly being used in the roof construction
also.
USES:
Building architecture: Corrugated sheets give ideal protection against storms and heavy winds
because they can withstand air pressures almost 200 times stronger than glass and they are
easily installable because they are 5 times lighter than plywood.
Dust cover: Newer building constructions are covered to contain dust and fumes emanating
from debris arising from house revamping. Large corrugated boards work as excellent trapdoors
to contain the grits from falling to the neighbor’s premises. They also work as a security fence to
avoid unrestricted entry
Packaging: Corrugated plastic sheets are favorable to make into a perfect packaging
material. Henceforth their strength, durability and soil resistance makes them an easy alternative
to paperboards and wooden package material. Comparatively, they are cheap to afford and
don’t tear off but can be easily cut through a knife. Many grocery stores, book sellers, distillers,
gift sellers use corrugated boxes for packing different materials.
Printing: From sign boards to street advertisements, corrugated material has come a long
way. We can also find attractive printing put on translucent polycarbonate sheets with the photos
of eatables and price list at any fast food joint.
Eco-friendly: Polypropylene boards are impact resistant and they can be recycled. Easy
molding allows them to have great economic value as they can be stapled, stitched and cut to
shape with a knife.
BENEFITS:
Durability: Corrugated material is far more durable than simple plastic or wooden structures
and there is no comparison with paperboards. Plastic roofing of corrugated sheets are used in
the construction industry widely due to their anti-scratch coating and ultraviolet protection as this
ensures longevity to the roofing structure against adverse environmental conditions.
Cost effectiveness: Be it roofing sheets, greenhouse constructs or any other purpose,
corruglated sheets are easily tailormade into any design that user wants. They don’t crack or
leak and the installation process is very simple and affordable. Hard labor is not required at all.
Most property owners prefer this material simply because they are cost worthy.
It is the future as it holds great versatility and quality. Owing to the even newer usage almost
every day, it has become one of the most sought after materials in day to day life use.
Ancillary material
The ancillary materials along with the primary packaging materials
Provide product package compatibility
Product preservation
Protection, containment , identification consumer convenience and consumer protection
Ancillary material required for packaging
1. Adhesive
2. Printing inks
3. tapes
4. Labels
5. Caps and closures
6. Reinforcement materials such as tapes and straps
Adhesives
Adhesive bonding is the process of uniting materials with the aid of an adhesive, a
substance capable of holding such materials together by surface attachment
Polymers are widely used as adhesives because of their versatility
The primary function of adhesives is to join parts together
Adhesives do this by transmitting stress from one member to another in a manner that
distributes the stress much more uniformly than can be achieved with conventional
mechanical fasteners.
Classification of adhesives
Adhesives are broadly classified as
1. Waterborne adhesives
2. Hot-melt adhesives
3. Solvent-borne adhesives
WATERBORNE ADHESIVES
This is the oldest and still by far the largest volume class of adhesive used in packaging
These adhesives share the general advantages of ease and safety of handling enery
efficiency low cost and high strength
Two types
1. Natural waterborne adhesives
Include starch , protein , animal glue casein and natural rubber latex . the largest
class of natural adhesive is based on starch
2. Synthetic waterborne adhesives
Are the most broadly used class of adhesives in general packaging
Almost all are resin emulsions, specifically polyvinyl acetate emulsions- stable
suspensions of polyvinyl acetate particles in water
HOT MELT ADHESIVES
1. Hot melt adhesives have been the fastest growing important class of adhesives in
packaging for the last 25 years
2. Most of the volume goes into high speed large volume case and carton sealing
3. Hot melt can be defined as 100 % solid adhesive based on thermoplastic polymer
that are applied when heated in the molten state and set to form a bond on cooling
and solidification
4. Their chief attraction is the extremely rapit rate of bond formation which can
translate into high production rates on a packaging line
5. The backbone of any hot melt is thermoplastic polymer.
6. Most widely used material is the co-polymer of the ethylene and vinyl acetate ( EVA)
SOLVENT BORNE ADHESIVES
SOLVENT borne adhesives find use in specialized application where waterborne or hot melt
Systems do not meet the technical requirements.
Rubber resin solution are still used as pressure sensitive adhesives for labels and tapes
Printing INKS
Printing inks are coloured liquid or pastes formulated to transfer and reproduce an image
from a printing surface.
They are used mainly to convey a message and provide protection however they also can
give a decoration effect to the substrate to which they are applied
Printing inks are used on a wide range of papers, boards, plastic , glass and textiles surface
in flats and in some instances preformed shapes
Adhesives tapes
An adhesive tape is composed of a backing element in a long strip upon which an adhesive is
applied
Its function is to attach the carrier backing to some secondary surface
The attachement is made by activating the adhesive with solved heat or finger pressure
Tapes are used for holding ,bundling , sealing, protecting, reinforcing, color identification
and box closing
Strapping material
Strapping is generally the last but a key step in the packaging operation
Strapping are normally used for reinforcing, palletiizing, unitising, bundling and tying
It is very useful in brace shipment of goods during transit
Types
1. Metallic
a. Round wire
b. Steel straps
2. Non-metallic
a. Polyster
b. Nylon
c. Polyolefin