Pet Packaging Technology (Sheffield Packaging Technology)

Contents......Page 10
1.1.1 History......Page 16
1.1.2 IP—patents......Page 18
1.2 Market growth and the development of materials......Page 19
1.2.1 PET fibre and film......Page 22
1.2.2 Barrier materials......Page 23
1.2.3 Competitive materials: PVC, AN/S (Lopac) and AN/MA (Barex)......Page 26
1.3 Technology......Page 28
1.3.2 Two-stage ISBM......Page 29
1.3.4 Heat setting......Page 30
1.4.1 Bottles in the early years......Page 31
1.4.2 PET cans......Page 33
1.4.3 Refillable bottles......Page 37
1.4.4 Preform design, neck design—BPF, vent slots......Page 38
1.4.5 Beer spheres......Page 39
References......Page 40
2.1 Introduction......Page 41
2.2 Container technologies......Page 43
2.3 Product processing and filling requirements......Page 44
2.4 Packer/filler shelf-life requirements......Page 45
2.5.1 Material pricing......Page 46
2.5.2 In-house manufacture of PET containers for packer/fillers......Page 47
2.6 Recycling issues......Page 48
References......Page 49
3.1 Introduction......Page 51
3.2 Polymerisation and manufacturing processes......Page 52
3.2.1 Manufacturing plants......Page 55
3.3.1 Structures......Page 59
3.3.2 Morphology......Page 60
3.3.3 Orientation......Page 63
3.3.4 Creep......Page 74
3.4 Properties......Page 75
3.4.1 Molecular weight and intrinsic viscosity......Page 76
3.4.2 End group......Page 79
3.4.3 Thermal properties......Page 80
3.5.1 Melt viscosity......Page 85
3.5.2 Melt flow......Page 87
3.5.3 Moulding shrinkage......Page 90
3.6.1 Moisture level......Page 91
3.6.2 Polymer drying......Page 92
3.7.1 Thermal and thermal oxidative degradation......Page 95
3.8 Reheat characteristics......Page 96
3.9 Gas barrier properties......Page 98
3.10 Amorphous polyesters......Page 102
3.10.1 Homopolymers......Page 103
3.10.2 Low copolymers......Page 104
3.10.3 Medium copolymers......Page 106
3.11 Crystalline polymers......Page 107
3.13 Applications......Page 108
3.15 Global......Page 109
References......Page 110
4.2 Polyesters......Page 113
4.2.1 PEN......Page 114
4.2.2 Amorphous polyesters......Page 115
4.2.3 Other polyesters......Page 116
4.3.1 EVOH......Page 117
4.3.3 Polyamides (nylon)......Page 119
4.3.4 Liquid crystal polymers (LCP)......Page 120
4.4 Barrier technology......Page 121
4.4.2 Inorganic coatings......Page 122
4.4.3 Scavengers......Page 124
4.5 Oxygen barrier......Page 126
4.5.2 Packaging oxygen-sensitive foods and beverages......Page 128
4.6 Carbon dioxide barrier......Page 129
Acknowledgement......Page 130
5.1 Introduction......Page 131
5.2.1 Polymer preparation and handling......Page 132
5.2.2 Extrusion and casting......Page 133
5.2.3 Drawing......Page 136
5.2.4 Heat setting......Page 145
5.2.5 Slitting and winding......Page 148
5.3.1 Polymer......Page 152
5.3.3 Properties......Page 153
5.4.1 Film properties......Page 154
5.4.2 Coating......Page 157
5.4.3 Co-extrusion......Page 158
5.4.4 Fillers......Page 160
5.4.6 Combination of effects......Page 161
5.5.1 Extrusion of PET sheet......Page 164
5.5.2 Thermoforming of PET sheet......Page 166
5.5.4 Materials......Page 168
5.5.5 New developments......Page 169
References......Page 170
6.1 Multilayer characteristics......Page 173
6.2.2 Economics- or legislative-driven applications......Page 176
6.3 Closure vs bottle permeation......Page 177
6.4.1 Barrier properties......Page 179
6.4.2 Oxygen barrier......Page 180
6.4.3 Carbon dioxide barrier......Page 181
6.4.4 Scavenger property......Page 182
6.5 Wall structure......Page 183
6.6 Preform and bottle design......Page 184
6.6.1 Permeation through finish, sidewall and base......Page 186
6.6.2 Controlled fill......Page 187
6.8 Oxygen desorption from PET......Page 189
6.9 Beer containers......Page 191
6.11 Small CSD containers......Page 193
6.12 Core layer volumes......Page 194
6.14 Comparison of co-injection technologies......Page 195
6.15 Co-injection molding equipment......Page 197
6.16 The future......Page 198
7.1 Introduction......Page 199
7.2.1 One-stage machine construction......Page 204
7.3.1 Injection mould and hot runner......Page 207
7.3.2 Conditioning station......Page 210
7.3.3 Blowing station......Page 211
7.4 'Integrated two-stage' machines......Page 212
7.5 Drying system......Page 213
7.5.1 Requirements for a reliable drying system......Page 214
7.6 Preform design......Page 215
7.6.1 Neck finish......Page 216
7.6.3 Cycle time and preform wall thickness......Page 217
7.6.4 Stretch ratios......Page 218
7.6.5 Injection mould design and manufacture......Page 220
7.6.8 Differences between one- and two-stage preform designs......Page 221
7.7 Container design......Page 222
7.9 Quality control procedures......Page 223
7.10.1 Appearance and shape......Page 224
7.10.4 Preform eccentricity......Page 225
7.10.6 Intrinsic viscosity (IV)......Page 226
7.11.2 Dimensions......Page 227
7.11.3 Capacity......Page 228
7.11.4 Container wall thickness and material distribution......Page 229
7.11.7 Leakage of liquid (seal integrity)......Page 230
7.11.9 Acetaldehyde (AA)......Page 231
7.11.13 Container weight......Page 232
7.12.3 Carbonation retention......Page 233
7.13 Additional tests for hot-fill containers......Page 234
Appendix: one-stage and integrated PET machine manufacturers......Page 235
8.1.1 The principles of the two-stage process......Page 238
8.1.2 Technological basics of PET as a stretch blow moulding material......Page 242
8.1.3 Production concepts and target markets......Page 248
8.2 Preform injection moulding......Page 253
8.2.1 Injection machine concepts......Page 254
8.2.2 Mould design......Page 259
8.2.3 Productivity parameters......Page 262
8.3.1 Principles of the two-stage stretch blow moulding process......Page 266
8.3.2 Machinery concepts......Page 279
8.3.3 Mould technology......Page 283
8.4.1 Container design......Page 285
8.4.2 Preform design......Page 289
Abbreviations......Page 293
9.1 Basic principles......Page 295
9.2 History......Page 296
9.3 Process identification......Page 297
9.4.1 Rotary table machines: Jomar, Uniloy and similar......Page 298
9.5 Tooling......Page 299
9.7 Materials......Page 301
9.9 Machine and process capabilities......Page 302
10.1 The hot-fill process......Page 307
10.2 The heat-set process......Page 308
10.3 The pasteurization process......Page 322
10.4 The retort process......Page 325
10.5 Concluding remarks......Page 328
References......Page 329
11.1 Introduction......Page 330
11.3 EU Packaging and Packaging Waste Directive......Page 331
11.3.1 Compliance with the Directive's targets......Page 333
11.3.2 Material identification......Page 334
11.3.4 CEN 'umbrella standard' (pren 13427)......Page 335
11.3.5 Implementation of the Directive in the member countries......Page 337
11.4 Collection and recovery procedures......Page 338
11.4.3 Reverse vending machines......Page 339
11.5 Plastics packaging waste......Page 340
11.6 Recycling of PET......Page 343
11.6.1 Principal methods of PET recovery......Page 344
11.6.3 Recycling of PET by mechanical methods......Page 345
11.6.4 R-PET and food-contact quality......Page 349
11.6.5 Recycling of PET by chemical methods—'solvolysis'......Page 351
11.7 Environmental benefits of recycling......Page 357
11.7.1 General principles of recycling......Page 358
11.7.2 Application of the general principles to the recovery and recycling of PET bottles......Page 361
11.8 Economic factors affecting PET bottle recycling......Page 370
11.9 Markets for recovered PET......Page 372
11.10 PET recycling—the future......Page 374
References......Page 377
B......Page 380
C......Page 381
E......Page 382
H......Page 383
I......Page 384
M......Page 385
P......Page 386
S......Page 388
T......Page 389
Z......Page 390