AGR INTERNATIONAL, INC. LIGHTWEIGHTING OF CONTAINERS

Size: px

Start display at page:

Download "AGR INTERNATIONAL, INC. LIGHTWEIGHTING OF CONTAINERS"

Rodney McCarthy
6 years ago
Views:

1 PACKAGING AND CONVERTING EXECUTIVE FORUM FEBRUARY 2015 AGR INTERNATIONAL, INC. LIGHTWEIGHTING OF CONTAINERS PRESENTERS: ALEKSANDER BRODA WILLIAM SLUSSER REGIONAL DIRECTOR, NCE EUROPE MANAGER, RESEARCH SERVICES

2 ABOUT AGR INTERNATIONAL HIGHLIGHTS: HEADQUARTERS- BUTLER, PENNSYLVANIA, USA 175 EMPLOYEES, GLOBAL PRESENCE SERVING THE PACKAGING INDUSTRY FOR OVER 85 YEARS QUALITY CONTROL, CONSULTING AND PROCESS MANAGEMENT SOLUTIONS FOR BOTTLES AND JARS OVER 40 PATENTS AND 20 TRADEMARKS

3 MARKETS SERVED GLASS CONTAINER FACTORIES PLASTIC PACKAGING PRODUCERS (PET BOTTLES AND PREFORMS) FILLERS / BEVERAGE PRODUCERS SOFT DRINKS, MINERAL WATER BEER, WINE, SPIRITS FOOD PHARMACEUTICAL, CHEMICAL AND OTHERS

Complete solution provider EQUIPMENT ON-LINE, SAMPLING, LABORATORY TECHNICAL SERVICE TRAINING AND MAINTENANCE (TOTAL CARE) AMERICAN GLASS RESEARCH ROOT CAUSE PROBLEM

4 Complete solution provider EQUIPMENT ON-LINE, SAMPLING, LABORATORY TECHNICAL SERVICE TRAINING AND MAINTENANCE (TOTAL CARE) AMERICAN GLASS RESEARCH ROOT CAUSE PROBLEM ANALYSIS PROACTIVE BOTTLE DESIGN AND LIGHTWEIGHTING IMPLEMENTATION OF NEW SOLUTIONS SEMINARS AND TRAINING OPTIMIZING PROCESS EFFICIENCY & ACHIEVING QUICK RETURN ON INVESTMENT

5 CUSTOMERS AROUND THE WORLD

6 PRIVATE, INDEPENDENT TESTING AND CONSULTING LABORATORY FOR THE GLASS PACKAGING INDUSTRY. CONTAINER TESTING AND RESEARCH PERFORMANCE EVALUATION FRACTURE DIAGNOSIS STONE IDENTIFICATION BOTTLE DESIGN TRAINING SEMINARS ANALYTICAL SERVICES LINE AUDITS COATING AND CONTAMINANT ANALYSES LITIGATION SERVICES

7 REASONS TO LIGHTWEIGHT 1. ENVIRONMENTAL BENEFITS 2. POSITIVE IMAGE 3. SIGNFICANT REVENUE INCREASE

REVENUE INCREASE/COST REDUCTION Glass Weight Machine Speed Standard Weight 240 grams Tons per/day (US) 137.

8 REVENUE INCREASE/COST REDUCTION Glass Weight Machine Speed Standard Weight 240 grams Tons per/day (US) Packing Efficiency 90% Btls packed/day 466,560 Selling Price Revenue/annual 12 cycle (360 bpm) 0.10 $0.14/ bottle 16.3 M $ 22.9 M Glass Weight Lightweight Bottle Machine Speed 200 grams Tons per/day (US) Packing Efficiency 90% Btls packed/day 544,320 Selling Price Revenue/annual 14 cycle (420 bpm) 0.10 $0.14/ bottle 19.0 M $ 26.7 M = INCREASE IN REVENUE OR POTENTIAL FOR COST REDUCTION

LIGHTWEIGHTING 3.2 mm (0.126 in) CASE STUDY 500 ML RET BOTTLE SPECIFICATIONS: THICKNESS DISTRIBUTION: Weight Weight 315g 11.1 oz Capacity Capacity 500 ml 16.

9 Bar 100 psi Vertical Load Load 544 kg 1200 lb Impact Impact TBD TBD Location Location Average Thickness mm in Finish Finish 3.2 0.126 Shoulder Contact 2.3 0.

9 LIGHTWEIGHTING 3.2 mm (0.126 in) CASE STUDY 500 ML RET BOTTLE SPECIFICATIONS: THICKNESS DISTRIBUTION: Weight Weight 315g 11.1 oz Capacity Capacity 500 ml 16.9 fl oz Process Process NNPB - Bottle Bottle Style Style Refillable - Pressure Pressure 6.9 Bar 100 psi Vertical Load Load 544 kg 1200 lb Impact Impact TBD TBD Location Location Average Thickness mm in Finish Finish Shoulder Contact Sidewall Sidewall Heel Heel Contact Contact Lower Most Heel Bearing Surface Center Bottom mm 4.7 mm (0.200 in) (0.186 in) 2.3 mm (0.090 in) 2.8 mm (0.110 in) 3.2 mm (0.125 in) 3.1 mm (0.123 in)

10 STANDARD FEA PERFORM A STANDARD FEA (FINITE ELEMENT ANALYSIS) USING THE SPECIFIED CRITERIA FOR: INTERNAL PRESSURE VERTICAL LOAD IMPACT 10

FEA RESULTS INTERNAL PRESSURE CASE STUDY 500 ML RET BOTTLE LOCATION MAXIMUM SHOULDER SHOULDER

BOTTOM CENTER BOTTOM INSIDE KNUCKLE MPa/bar 1.43 14.3 50.0% 1.01 10.1 35.3% 1.42 14.2 49.7% 0.

2 VERTICAL LOAD LOCATION MAXIMUM SHOULDER SHOULDER CONTACT MAXIMUM HEEL MAXIMUM HEEL HEEL

11 FEA RESULTS INTERNAL PRESSURE CASE STUDY 500 ML RET BOTTLE LOCATION MAXIMUM SHOULDER SHOULDER CONTACT MAXIMUM SIDEWALL MAXIMUM HEEL HEEL CONTACT SIDEWALL CONTACT BEARING SURFACE MAXIMUM BOTTOM CENTER BOTTOM INSIDE KNUCKLE MPa/bar % % % % % % % 54.8% psi/psi VERTICAL LOAD LOCATION MAXIMUM SHOULDER SHOULDER CONTACT MAXIMUM HEEL MAXIMUM HEEL HEEL CONTACT CONTACT HEEL INSIDE kpa/kgf psi/lbf % % % % 11

12 THICKNESS REDUCTION REDUCING THE THICKNESS 57% reduction for the shoulder 18% reduction for the sidewall regions 25% reduction for the heel contact Note: Inside Knuckle and Bearing Surface untouched due to high neighboring stresses ORIGINAL REDUCED Location Location Average Thickness Average Thickness Location Location mm in mm in Finish Finish Finish Finish Shoulder Contact Shoulder Contact Sidewall Sidewall Sidewall Sidewall Heel Heel Contact Contact Heel Heel Contact Contact Lower Most Heel Lower Most Heel Bearing Surface Bearing Surface Center Bottom Center Bottom

FEA RESULTS-AFTER LIGHTWEIGHTING LOCATION MAXIMUM SHOULDER SHOULDER

BEARING SURFACE MAXIMUM BOTTOM CENTER BOTTOM INSIDE KNUCKLE MPa/bar

5 46.5% 1.33 13.3 66.1% 1.89 18.9 66.1% 1.89 18.9 54.2% 2.79 27.

HEEL HEEL CONTACT CONTACT HEEL INSIDE kpa/kgf psi/lbf 55.3% 28.9 1.

13 FEA RESULTS-AFTER LIGHTWEIGHTING LOCATION MAXIMUM SHOULDER SHOULDER CONTACT MAXIMUM SIDEWALL MAXIMUM HEEL HEEL CONTACT SIDEWALL CONTACT BEARING SURFACE MAXIMUM BOTTOM CENTER BOTTOM INSIDE KNUCKLE MPa/bar psi/psi 65.1% % % % % % % % LOCATION MAXIMUM SHOULDER SHOULDER CONTACT MAXIMUM HEEL MAXIMUM HEEL HEEL CONTACT CONTACT HEEL INSIDE kpa/kgf psi/lbf 55.3% % % %

Heel Impact LOCATION MPa/cps psi/ips INSIDE

598 in STIFFNESS x1000 22 kg/cm 125 lb/in

14 Heel Impact LOCATION MPa/cps psi/ips INSIDE FLEXURE 34.8% IN-PLANE HINGE 15.8% MAXIMUM HINGE 79.3% BEARING 26.4% SURFACE HEEL HEEL CONTACT CONTACT HEIGHT HEIGHT INSIDE SURFACE mm in STIFFNESS x kg/cm 125 lb/in MAXIMUM IMPACT VELOCITY: 15 IN/SEC (38 CM/SEC) DUE TO MAXIMUM HINGE STRESS DURING HEEL IMPACT

ADJUSTED DIMENSIONS Dimension mm in Bottle Bottle Height Height 257.4 10.134 Body Body Diameter 69.4 2.

8% Weight Weight 315 g 11.1 oz Dimension mm in Bottle Bottle Height Height 247.7 9.750 Body Body Diameter 68.6 2.

15 ADJUSTED DIMENSIONS Dimension mm in Bottle Bottle Height Height Body Body Diameter Sidewall Diameter Bearing Diameter Brimful Capacity 529 ml 17.9 oz Headspace Headspace 5.8% 5.8% Weight Weight 315 g 11.1 oz Dimension mm in Bottle Bottle Height Height Body Body Diameter Sidewall Diameter Bearing Diameter Brimful Capacity 524 ml 17.7 oz Headspace Headspace 4.8% 4.8% Weight Weight 265 g 9.35 oz 15

16 ADVANCED PROCESS CONTROL AGR OMNI-LAB A WELL DESIGNED BOTTLE REQUIRES CONSTANT MONITORING OF PRODUCTION. THIS IS ENSURED BY THE AUTOMATED SAMPLING SYSTEM BY AGR, MEASURING: OUTSIDE BODY DIMENSIONS OUTSIDE FINISH DIMENSIONS INSIDE FINISH PROFILE ANGLES AND RADII LABEL AREA BULGES AND SINKS WALL THICKNESS MEASUREMENT VOLUME (FILL-HEIGHT & BRIMFUL) PRESSURE TESTING

17 TOTAL BLOWMOLDER MANAGEMENT PET CONTAINERS Thickness Management Automated Blowmolder Control Defect Detection Powerful combination of thickness measurement, vision inspection and closed-loop control offers a total process and quality control program for PET containers

18 BLOWMOLDING MANAGEMENT PROCESS 1.Measure 2.Analyze 3.Communicate 4.Adjust

19 MATERIAL DISTRIBUTON The Importance of Direct Thickness Measurement

20 IN-THE-BLOWMOLDER OPERATION

IN-THE-BLOWMOLDER OPERATION Sensors for the Pilot Profiler system mount within the blowmolder Holds up to 32 sensors in fixed positions Sensor

21 IN-THE-BLOWMOLDER OPERATION Sensors for the Pilot Profiler system mount within the blowmolder Holds up to 32 sensors in fixed positions Sensor spacing = 12.7mm apart Infra-red light absorbtion technology Compatible with Sidel, Krones, KHS, SIPA Used on containers of various shapes, sizes, colors

22 TOOLS TO MANAGE PROCESS AND IMPROVE PRODUCTIVITY

23 TOOLS TO MANAGE PROCESS AND IMPROVE PRODUCTIVITY

24 PROCESS PILOT AUTOMATED BLOWMOLDER CONTROL SYSTEM Closing the loop on the reheat stretch blowmolding process

PROCESS PILOT AUTOMATED BLOWMOLDER CONTROL SYSTEM How it works Similar to Autopilot in an aircraft Process Engineer sets up blowmolder controls and

25 PROCESS PILOT AUTOMATED BLOWMOLDER CONTROL SYSTEM How it works Similar to Autopilot in an aircraft Process Engineer sets up blowmolder controls and optimizes the process The Process Pilot system measures the material distribution and automatically adjusts multiple blowmolder controls simultaneously

26 THE PROCESS PILOT SYSTEM OFFERS VALUE Ultimate lightweighting tool Wall thickness can be actively managed to design parameters Material can be reduced to the exact amount required (no need of safety margins)

27 CASE STUDY COCA-COLA 2L PROCESS PILOT ON PROCESS PILOT OFF

28 CASE STUDY COCA-COLA 2L Cpk Values Increase 76% with Process Pilot ON: Sensor 21 (In the Heel Region) PROCESS PILOT OFF: Cpk = 1.52 PROCESS PILOT ON: Cpk = 2.68

surface Surface irregularities Seal surface width

29 PILOT VISION Seal Surface Inspection Advanced defect detection for: Nicks, dents (V notches) Scratches in seal surface Surface irregularities Seal surface width Inner/outer diameter Ovality Blown finish Seal surface integrity Short shots

PCR-related defects Contamination foreign materials Dark spots

30 PILOT VISION Sidewall Inspection Comprehensive inspection for: Neck folds Clarity and consistency issues Areas of crystalinity PCR-related defects Contamination foreign materials Dark spots Holes Color variations Under-blown containers Active base formation and flaws

PILOT VISION Base Inspection Common base defects detected: Holes Random occurring in base Random occurring in foot region In gate Opaque spots Foreign

31 PILOT VISION Base Inspection Common base defects detected: Holes Random occurring in base Random occurring in foot region In gate Opaque spots Foreign particles Un-melted material Under-blown and improperly formed feet and base characteristics Folds in base region Off-center gate Gate size Gate ovality/tears

32 MANAGE CRYSTALLINITY

33 MANAGE CRYSTALLINITY

34 PROCESS PILOT FAMILY Benefits Management of the blowing process leads to: stable production (Cpk increase) improved bottle performance Closed-loop system provides opportunity for further lightweighting Data can be collected and processed for QA analyses Defective containers are immediately rejected

35 PROCESS PILOT FAMILY Benefits System provides operators with: process information (correlated to mold/spindle) immediate feedback on control changes remote access benefits blowmolder troubleshooting help Enables the elimination of section weight measurements Easy to operate, requires very little maintenance

36 PROCESS PILOT - GLOBAL MARKET Process Pilot is the choice of industry-leading brand owners and converters throughout the world! LOGOPLASTE

37 Agr International, Inc. THANK YOU for more information see:

SECTION 1043 FENCE MATERIAL

SECTION 1043 FENCE MATERIAL 1043.1 Scope. This specification covers the material required in the construction of chainlink fence and woven wire fence. 1043.2 Basis of Acceptance. The basis of acceptance