F Date: 07-02-2017 £7 arrectter AAs Sieeret £ Indian Institute of Packagin: ‘ete a fm tn rh etn tn ann na Introduction to Plastic Processing Dr. Badal Dewangan Joint Director (T & E Division) IIP-Mumbai aol modling equoet. TST br ieling mctne Ming ye. Visiou pos potete sd thinly onthe uae ted procs. shooting injection mauling ‘+ Fxarsion~Contraconal ature of seed equipments, own Sct fmt mile i, Bil ‘ened fs Eason of hes pes box seppngand monclamet ‘Beraion coating ation ‘Apes tobe cowed a oulny equipment plat yt, proces pane and tha ton the gay the ‘raed padic and woublesoning 4+ ow moulding - Consul ature efbow moung pest Maer bw mocng Caifeatoncruon thw naldng nection tow mouling & Sch bow ‘meng ejection eran), Compara oh shone ces Tele shiny mb eahong, + Galeri nena calender construction Konfguton, Poe pie detract ‘podliechoding teen + Teeomotorming-Msemold omg female mu fring. ig fring hcptinana ming Bnet “Tiaming deve ta edges io = + Rotaonal moulding -Mateals wed Pcie of bi des &maug pln ing of expandable pyrene mel. Prepartonef panda bers Pepantion sabaleaton & muldg sage essed in FP. Poets thea ly spy ph fant winding chalet + Contig: prince ofhcquer ormulaonprcraing end running Tips de egypt vecnione 5 Lamination ehnique: Dry ex Wau: Casitcton Tesing ow,‘ fr oem, wt ging Manuf nd eng of we reat 2/5/2019Packaging Materials e Paper ° Board ¢ Plastics _© Metal ¢ Glass Packaging market globally stands at 700 Billion USD (FY 15) Indian Packaging market stands at 32 billion USD (FY15) Plastics constitute about 42% in various forms in packaging 2/s/2ci9"fian Prospective — Packaging Sector Packaging Sector Composition Market Share 2/5/20192/5/2019, acKaging Market Packaging Market (packaging units, Market Share of Flexible Packaging billions) in 2015 Materials in 2015 exible Packaging | ‘* Flexible Packaging is defined as “a package or container made of either, flexible or easily yielding materials, that filled or closed, can be readily changed in shape”. * The construction of flexible packaging may be of paper, plastic film, aluminium foil or any combination of these materials, The Flexible packaging conforms to the product it is holding and can withstand “handling abuse by being stretchable and puncture resistant.antages & Limitation: Low Cost: exible Packaging utes 75 ls plastic than hee sighd counterparts + Light Weight: Packaging weights reduced by 0% which means lower shipping ots + Space: Empty Pouches occupy upto os ess space. + Dursbityand corrosion resistance + Peintabitty + Forminga flexible package i frtandexsy + Brcallent diy Because most lesb packages are printed asroll-tock Nighcalny el stetages oe toon? al + Themsjorlimitaionsof Nexble are thatthe have traditionally been moredi snd ick Sect men sitet ned forthe customer thelackoffecoecabilty + The lack of ighiy ofthe filled package canbe solved by wings. lack of rigidity package by: owes suchas a bag-in-box construction. Newer, Stand-Up pouches ‘Sand ona shelfwithoutadaiional support +The recloseabuity issue has been addressed in recent years with the use of zipper losures _and recloseable spouts, albeit ata higher cost. Types of Flexible Packaging Flexible Packaging is dominated by low-density polyethylene. It includes checkout bags, sacks, wrapping film (including shrink-wrap and stretch types) and laminated and co-extruded film. __ Examples of Flexible Packaging E Film ___ Sachets © Bubblewrap Shrink-wrap © Stretch wrap ‘Twist wrap. Bags Flat pouches © Stand-Up pouch Retort Pouches * Foams Tubes 2/5/2019Lowest material usage = lowest weight = lowest cost Glass Bottle Rigid Plastic Plastic Laminate LESS Packaging Weight Rigid Plastic it Plastic: Bottle Lee Laminate 45.4 gm 33% 61% 93% LESS LESS LESS Packaging Packaging Packaging Weight ‘Weight Weight 2/5/2019QCan maintain its shape while holding a product. Oils capable of multiple reclosures, with an attached or unattached lid or cap. O Includes Drums, Bottles, Jars & Pails. Variety of polymers are uséd viz. . UPrimary Polymers - HMHDPE; HDPE, PP, PS, PVC, PET Barrier Polymers - Polyamide, Ethylene-Vinyl Alcohol copolymer & Thermoplastic Epoxies as additional layer Ospectrum of manufacturing processes viz. Blow moulding, Stretch blow moulding, Injection moulding, Extrusion and co-extrusion; Thermoforming, Roto moulding 2/5/20192/5/2019 ° Plastic Processing * Goal: To convert raw plastics to useful final products with desirable properties * Plastics + Polymers « (Plastics = Polymer + Additives) Case Example Polyethylene Polyethylene is the most popular plastic in the word. ‘This is the polymer that makes grocery bags, shampoo bottles, children's toys, and even bullet proof vests2/5/2019 Major Processes * Extrusion * Injection Molding * Blow Molding * Calendering * Thermoforming ¢ Rotomolding ‘CALENDERING ‘THERMOFORMINGOTHERS 6% OWDER 2% INJECTION s2% COMPRESSION COATING 5%, EXTRUSION 36% ICALENDERING 6x, BLOWING tox — fama EXTRUSION INJECTION [5 BLOWING (7 CALENDERING EEE COATING (a COMPRESSION (== POWDER (am OTHERS rusion - Products 2/5/2039 10EXTRUSION Continuous Process . In principle, the plastic raw material is plasticated by means of a ‘screw plastication unit and the molten material is continuously pumped out through a standard orifice (die) in order to take the shape and then the ‘shape is set by cooling/sizing system. . Example: Film, Pipe, Tube, Profile, Monofilament, Box Strapping ete. 2/5/2019Screw Geometry 2/5/2019 9)Screw Pump Hopper Barrel Hopper Throat Drive System Compression Zone Metering zone 2/5/2019 Combination of Screw & Barrel Funnel like device, mounted on Hopper throat. Holds a constant reserve of material. Cylindrical housing In which the screw rotates,” Circular opening at the feed end through which the material enters the screw pump. AC/DC drives Speed reduction gear box ‘Transmission system ‘Transport the material from hopper to compression zone. Compacts, eliminates air gap Transport the material from compression to ‘metering zone. Softens the material Melts, Mixes, pressurizes the molten material and pumps the melt. 132/5/2019 - SERA Ye 3 cy ATE Ags 1 WEEE WLLL LDL. KGa 142/5/2019 Is the ratio between the channel depth in the feed zone to that of the metering zone. - Usually from 4.5 to 4:1 UD ratio : Lenath to nominal dia of screw - usually 20 to 22:1 ‘Compression Ratio ‘Important Specification = Nominal dia of screw » ‘Output(kgs/hr) Extruder Screws. > General purpose screw > PVC screw > Nylon screw General purpose screw 1sPerforated circular metallic disc of about. 4-5 mm thick. Functions E + Support for’Screen pack = Converts the Spiral flow of melt in to stream lined laminar tlow = Holds back contamination and unmelted particles. Screen Pack - Wire mesh 40,60,80 - Arrests the unmelted particles and contamination - Helps In developing back pressure 2/5/2013 16igh grade steel cylinders ‘+ Has to withstand up to 400 atm. Iron Based Alloy Complex non-ferrous alloys More hard & less corrosion less hard & more corrosion resistant resistant ‘These expensive materials are used as liners in steel barrels, Barrels of Nitrided steel are also used. ‘They are Cheap, hard, less resistant to corrosion. ‘Screw material * Low carbon alloy steel * Flight tips are hardened by flame hardening to Prevent wear or nitriding the entire screw. Chrome plated screws for vinyl polymers ‘© special nickel alloy steel for processing of saran. Types © Single Screw Extruder Twin Screw Extruder 2/5/2019 72/5/2019 « Drag Nese postive Medium/wide Low/narcow (useful for ‘eacion) Reduces output Siight/moderste effect on output High (ucefl fr stable Low (usefal for VO. Poor/medkam Good (useful for compounding) ah Cony be ale Low ey endectng ‘High (output limited by Medium Gimits output) melting, stability, ee) High Low (imnits pressure) Robust simple ‘Complicated Moderate High ‘Two screws rotating inside a barrel. Intermeshing type are more popular. Different models/design available 18Co-totating Counter-rotating With corotating screw both screw have either right handed or left handed thread. In counter rotating screws, one screw has left and other has right handed thread. Polymer flow in a shape of 8 in totally intermeshing screws. This develops the regions of high & low pressure. 2/5/2019 19)OFiginal riner ‘Well distributed Poorly dispersed Poorly dispersed al Pooriv distributed Well dispersed Wall distributed Poorly distributed * High-speed, corotating twin screw extruders are used for ‘compounding resin with additives (colorants, fillers, flame retardants, reinforcements, stabilizers), devolatilization to remove solvents, and reactive extrusion (chemical reactions done in situ in the extruder). * Low-speed corotating and counterrotating extruders are used to produce profiles and pipe. Counterrotating twin screws are used for compounding PVC and other resin system. * Nonintermeshing, counterrotating extruders are principally used for devolatilization and chemical reactions, i.e. grafting, polycondensation, addition, controlled cross-linking, and functionalization. 20| Mosty for compounding of TP Positive pumping Less power consumption than single screw Less than coating Less shear compared to co-rotating | ‘Less power consumption than Single screw, More lketinood of material stagnation | | 21fins, BOF. Melee! Used. PRIPVC, LDPE, HOPE, PET, Nylon ets. 2, Pipertube Materlat, HDPE, LDPE, LLDPE, PVC ete. 3. Sheet: Motorist HOPE, ABS, HIPS, PC ete. 4, Monofilament ‘Material: PP, Nylon etc. ‘5. Extrusion Coatina/Lamination ‘Coated Playing Cards, Wrapping ard LOPE: laminated Woven sacks Matera LO,PRHOPE Box Stranpina Materiat PP, HOPE etc. 7. Tape(Woven Sack Materia PP, HOPE ‘8. Wire Coating/Covering Primary/Secondary insulation Material: LOPE, PVC (Primary insulation) Nylon (secondary insulation) ‘8, Profiles (Door and window) Material: PVC 22