Food Closures - what are the trends? Classic ends Full aperture easyopen. FAEOE (SR to DR) Safety easy-open ends Peel-off ends

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1 Steel Innovations and End Technology David Jones Manager Product & Market Development Corus Packaging Plus IMDA 2004 Annual Convention - Willowbrook, IL

2 Food Closures - what are the trends? Classic ends Full aperture easyopen ends FAEOE (SR to DR) Safety easy-open ends Peel-off ends

3 Easy-open End Developments

4 Easy-open Ends What are the trends? Over the last decade, there has been major market penetration of easy-open ends in Europe with about 60 to 70% penetration. This has been built on the back of easier to open ends which in turn is the result of new steels that have been specifically developed for the application In 2003, it is estimated that about 20 billion ends were produced in Europe although some of these ends are old style or nonround end designs using softer temper steels Corus Packaging Plus is one of the leading suppliers to this market based on its range of high strength ductile steels. Market expected to continue to grow but at a slower rate with a gradual conversion to higher tempers for lightweighting and to improve opening performance

5 Growth of Easy-open Ends in Europe , ,4 6,9 7,5 8,2 8,8 9, ,9 0 16, billion units

6 Steels for Easy-open Ends The different performance criteria and functionality of an easyopen end presents a major challenge for the steel quality. On one hand, a high strength steel is required to meet the pressure resistance and PNR performance whereas rivet formation and the introduction of triple fold end designs require a more ductile steel. Combined with ease of opening and safety considerations, this was certainly a difficult task particularly with the need to lightweight. Nevertheless both SR & DR steels that have been developed which fulfil all the performance expectations required by the end-maker. There has been a progressive move from the softer SR steels to the higher strength TH465(T67CA) grade and more recently to the DR versions and principally the TH550 (DR550N) grade

7 Range of Properties: Various Packaging Steels 800 Tensile Strength (MPa) Ductility (%) 40 High Low Formability

8 Range of Properties: Various Packaging Steels 800 Tensile Strength (MPa) Ductility (%) SR (WELDING, ENDS) 40 High Low Formability

9 Range of Properties: Various Packaging Steels Tensile Strength (MPa) DR (WELDING, ENDS) 20 Ductility (%) 40 High Low Formability

10 Work Hardening Effect Note,there is also a bake hardening and secondary ageing effect with the easy-open end steels 800 Tensile Strength (MPa) Ductility (%) 40 High Low Formability

11 Steels for Easy-open Ends Currently the major volumes are in the T67CA (TH465) and DR550N(TH550) tempers - both of which are produced using Corus s nitrogenised steel grade. These products are manufactured using clean steel casting practices (to avoid rivet splits) with a high surface quality. They are produced on a CAPL using a special annealing cycle. These steels were specifically developed to meet the required end-making and performance criteria Typically the SR product has a strength level of 440 MPa with a minimum elongation of 15%. It is a bake hardening grade and there is also a secondary ageing effect after end formation The DR product is given a low secondary reduction (i.e. normally less than 10%). As a result, there is sufficient retained ductility for rivet formation, whereas the extra strength provides the potential for lightweighting. Higher strength grades are under development

12 Steels for Easy-open Ends - Mechanical properties 600 DR550N T67CA T65CA T61CA stress (MPa) strain (%)

13 Easy-open Ends - Functional performance Key influences Tab accessibility Safety Opening behaviour End/ tab geometry Score geometry Type of steel used

14 Easy-open Ends - FEA aided design FEA simulation of pop, tear and opening forces Computer simulations: EOE opening Opening force [N] Pop Tear Opening Tab displacement [mm]

15 Influence of Steel on Opening Behaviour Laboratory experiments - flat panel - score residual 80 micron Tear force decrease local: small plastic zone global: increased crack propagation force [N] T61CA Tear force T57BA T65CA T67CA Pop force tensile strength [MPa]

16 Easy-open Ends - Improved designs for better performance Latest designs have improved opening and performance characteristics combined with significant downgauging. Whilst the opening behaviour is dependent on the type of steel used (a more brittle steel will allow the score to fracture at lower forces and to propagate easier), other factors like the tab geometry,score geometry and consistency of the score residuals play a major part. Peaking performance has been maintained by the use of these higher strength steels and by the introduction of new end profiles. Not only has this given savings in metal usage but it also means that the new generation of easy-open ends are truly easy to open

17 Easier to Open Easy-open ends 80 Earlier designs Tear Force (N) Maximum Acceptable Tear Force (N) 0

18 What are the trends? U.S.A market for Easy-open Ends Easy-open end market in the USA appears to be undergoing massive growth linked to increase in capacity for DWI Food cans. Volumes in 2003 estimated at only 8 billion but expected to exceed 20 billion units by 2006 Initially market slow to adopt easy-open ends because of safety concerns and the higher cost. But recent launches by some of the major fillers have demonstrated that the extra costs are more than compensated by increased sales (e.g Campbells Chunky Soups) Also some of the new end designs are triple fold or safety ends which reduce the risk of cuts from the sheared edge. These ends are sometimes more difficult to form and can have implications on the type of steel to be used. Wider range of end-making technologies than in Europe.

19 Easy-open Ends in the U.S.A - growth & predicted growth Billion Units

20 Polymer-coated Steel for Ends In addition to the steel and design developments, advances in polymer-coated steels has meant that these materials are being increasingly used in this market sector Polymer coated steels are now being supplied for easy peeloff ends, easy-open ends and also for the tabstock. and the market is growing.

21 Polymer coatings - Benefits & drivers Environmental advantages No VOC s (solvent emissions) Easily recycled with no harmful emissions to the atmosphere Food compliant NOGE/BADGE/BPA etc. free Much lower migration levels compared to FDA/EU legislation High quality Protection, toughness, formability, abrasion resistance, aesthetic appearance and convenience Excellent organoleptic properties: Excellent barrier properties of steel Chemical inertness of polymer coatings versus the product packed No flavour scalping Coil coating process No practical thickness limitation, can coat all available packaging gauges Very consistent quality

22 Polymer-coated Steels - Products available from Corus Protact Ferrolite

23 Polymer-coated Steels - Corus Capabilities Product Process Start-up year Capacity Coating thickness Coating material Width Thickness range Duffel Protact Direct Extrusion ton 20 µm PET, PP mm. ~ mm. Trostre Ferrolite & Promica Film coating ton µm PET, PP, a.o mm mm.

24 Polymer-coated Steels for Easy-open ends Polymer-coated easy-open ends now in the marketplace. Starting to grow market share Main drivers are food safety, excellent corrosion resistance inside & out, and an attractive, clean image Technical developments Fully printed ends possible even in the seam area Seaming optimisation for irregular shaped cans

25 Polymer-coated Tabstock One of the spin-offs of the development of new steels for easy-open ends has been the supply of new steels for tabstock and redesign of the tab itself Now that the ends are easier to open, this has enabled the tabs to be downgauged and by the use of these high strength steels this will allow even further lightweighting

26 Polymer-coated Tabstock CPP is now supplying a new range of tabstock products based on these high strength nitrogenised steels in combination with polymer coatings Main drivers are cost advantages versus the EZ lacquered route with improved performance, and downgauging due to the high strength steels. Good corrosion resistance Other benefits include Greater potential for further lightweighting Ability to co-ordinate appearance with the end. Greater flexibility in tab design due to improved formability of polymer coatings New qualification trials ongoing

27 Food ends - Easy peel-off lids Increased market share of polymer coated peel off ends for wet, retortable products. Main drivers are excellent heat sealing characteristics and retort performance. Polymer coating improves the bond between the foil and ring. Benefits include better consumer convenience, enhanced safety & opportunity for brand differentiation Peel-off foil can be printed to enhance the design Steel polymer coated ends now available from a number of end-makers. Easy Peel

28 Thank you for your attention