Final

Packaging 432 with Clarke at Michigan State University

About this deck

By: Emily Wiggins
Created: 2010-12-17
Size: 98 flashcards
Views: 167

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Michigan Brewing Co

- 27 semis

- Texas to Weberville

Baccardi

- video

- shipped in upside down

delivery of containers > BULK

· Palletized

· Jumbled in boxes

o Dumped into unscramble

delivery of containers > RESHIPPERS

· Actual distribution cases

· Neck down transport to filling operation after neck up

· Indsutries moving away, still common in consumer products

o Emptied by hand

o Emptied by machine (Case Unloader)

§ Glass/plastic containers

§ Upright/inverted

case unloader machine

· opens box flaps (often unsealed)

· removes containers from cases

· puts containers on conveyor to cleaner/filler

· sends boxes to case loader for reloading

CASE UNLOADER – GENERAL APPROACHES > inverted containers in case - process

o Case lifts off conveyor

o weight of container opens inner flaps

o Carton inverted to another conveyor

o Bottles to unscramble, washer, filler

CASE UNLOADER – GENERAL APPROACHES > upright containers in case - proces

o Box moves on conveyor

o box flaps opened

o Gripper head lifts containers

o sets containers on belt to filler

uncaser issues (7)

· Method of delivery

· container size and style

· Speed of operation

· Reliability

· Machine size

· Cost

· Utility Requirements

Bottle cleaning: bottles from reshippers, from pallets, plastic bottles

Bottles from reshippers

· Paper fibers from boxes

Bottles on pallets

· Micro

· Dirt

Plastic bottles

· Dirt

CLEANING TECHNIQUES (7)

· Pressurized air (Simple blast)

· Ionized air (eliminates static cling)

· Water rinse

· Hot water rinse

· Detergent (wash/water rinse)

· Caustic wash (inside or out / rinse)

· Sterilization (5)

cleaning technique > hot water rinse

· Hot water rinse

o Especially for bottles that need to be hot filled

o Serves as heat up container

sterilization (5)

o Heat

o Steam

o Chemical

o – peroxide (H2O2): foods > toxic residual in food

o – ethylene oxide (ETO): pharma

o Radiation

o Clarke student worker in steam tunnels under campus

types of cleaning equipment

· EX: upright air blast / vacuum

· inverted air blast / vacuum

o Vacuum system only for rigid containers

· invert and rinse or wash / rinse

o Multi-station, multi-pass, steam injection nozzles

cleaning residues

· Water droplets from water/steam

· Cleaning agent

o Compatible with product or must be eliminated

o Typically FDA regulated

o Fresh fruits and meats by the FDA

liquid characteristics

LIQUID: flow by force of gravity

· Still

· Carbonated

· Foaming

semi liquid characteristics

SEMI-LIQUIDS: requires extra force to flow

· liquid soaps

· peanut butter

filler approach - volumetric (5)

· Volumetric

o Piston

o Diaphragm

o Timed flow

o Metering valve

o Start/stop pump

Various filler approaches (4)

volumetric filling

net weight filling

constant level filling

level sensing filling

filler approach - constant level (5)

· Constant level filling

o Pure gravity

o Pressure gravity

o Pure vacuum

o Gravity vacuum

o Pure pressure

liquid definition (4)

· Liquid: any fluid that will flow through a round pipe or tube at reasonable rate of flow, using gravity as the force causing the fluid to flow.

viscosity: UNITS and numbers for different states of matter

· Viscosity defined in POISE (or centipoises)

o Liquid 1-100 centipoises (cP)

o Semi-liquid 100-10,000 cP

o Pastes 10,000+ cP

· Increased viscosity > Slower flow

· Decreased viscosity > Faster flow

liquid filling types (4)

1. Bag in Box

2. Aseptic

3. Carbonated

4. Still (Non-carbonated)

Bag in box - filling

Filling:

· Manual, semi-auto, continuous (fully-auto)

· Can adapt it to various processes procedures

o EX: Cold, ambient, high-temp and aseptic

bag in box - basic design

Basic design:

· Flow meter (know how much to fill)

· Filling head or heads

· Uncap – draw vacuum – fill – recap sequence

o Why is a vacuum needed? Eliminates air bubbles in liquid pouch, adding vacuum fill head gets rid of problem

o EX: salsa bag in box would need a fill head good for chunky shit

- DISCHARGE

bag in box - advanced equipment features (4)

· Cooling tunnel: hot bags get agitated and cooled by water jets

· Specialized valve: allow filling of liquids with large particulates

· Steam sterilization: for aseptic filling

· Sterile air chambers: for aseptic filling

Aseptic packaging - filling

· Product > HTST processing > cooling > filling

· Retort = heating process

· Traditional sterilization: after filling and sealing containers

· Aseptic sterilization: product sterilized before introduced to pkg, pkg sterilized during sealing and filling operations

HTST

HTST = high temperature, short time

aseptic packaging process definiton

Process definition: a sterilized product is filled into a sterilized container which is then hermetically sealed inside a commercially sterile environment

carbonated liquids

Contains dissolved gases, carbonated liquids > hard to fill

EX: beer, soda, champagne, sparkling wine/water, etc.

· Require special handling on filling machines because of carbonation

· EX: MillerCoors “Vortex” bottle, not enough headspace when filling for liquid and foam, had to reduce line speed to 60% max speed

carbonated liquids - filling

· Accomplished under pressure and used the container as part of the control of net contents

· Must be filled in way that prevents excess foaming

· CO2 dissolves more readily in cold water than warm.

o to keep foaming down & speeds up, beer/soft drinks run as close to 32F as possible

Blackneck

black residue from spillage in filling operation, sugar in salsa or ketchup

Still/non carbonated - filling

· Sealed container system (filling device seals positively against the container). air cannot get in or out

· Unsealed container system (container is left open to the atmosphere during fill)

HFFS process

· Form tube out of web roll

· Web pulled forward from tension of wheels/rolls

· Wheels also seal film into a tube through heat/pressure

· Results in fin seal, lays flat once end seals added

· Care must be taken with amount of heat/pressure with wheels

· Determine if gussets are needed

- end sealing

HFFS - gussets

o Used to tuck material out of the way

o Pouches can be with/without

o With on pouches > 1 inch thick

o Omitted on high-speed runs because extra mechanical process

HFFS - opening pouch problems

o Problem: pouch carried static charge, film difficult to separate, needed different operations for opening

o Solution: air jet splitter and clamp

§ vacuum opener

§ duck bill opener (powder application)

§ wire blade opener

Three Sided Pouches

Made from single web

Three sides = seals

Bottom = folded

Made on horiz F-F-S due to ease of top filling

Intermittent AND continuous motion

VERTICAL FFS - package styles (5)

1. Pillow style (small individual serve cookies)

2. Gusseted bag with tucks on both sides

3. 3 or 4 sided seal

4. A stand up bag (flat bottomed, gable top)

5. Special designs

Chub package

(sausage, cookie dough, “log shape”; crimped end tubes

VFFS - materials - thermoplastics

o Low protection

o Low materials cost

o PE: porosity, not ideal for hermetic-seal applications where shelf life, freshness are imp; bad gas barrier; good for frozen foods, chemicals, fertilizers

VFFS - materials - heat sealable

o EX: paper, cellulose, some co-ex and laminations

o Don’t melt at sealing temps, so require a heat seal layer

o EX: Coffee: Polymer turns porous at 190F, water goes in coffee, material turns porous, allows water through; quality check for making sure temp for brewing grounds is at 190, not on market

o Sealant layer can be on both sides of web, depending on pkg configuration

FIN SEALS

o FIN SEAL

§ Sealing props on one side, seals to itself

§ Interior to interior sealing

§ Effective for powder products, eliminates sifting

§ Effective if hermetic seal integrity is imp, (gas-flush pkg)

LAP SEAL

o LAP SEAL

§ Less material, sealing props on both sides

§ Interior to exterior sealing

BAG FILLING FACTORS

Limiting line speed factor = product being packaged

Bag filling factors - Product char affecting machines:

· Dust

· Fines

· Stickiness

bag filling factors - piston effect

· Created by some products when dropped into bag-forming tube

· Problem: air gets trapped in the bottom of bag, with no easy way to escape

· Solution: circumvent via inner fill tubes to release air pressure

rule of thumb on VFFS system:

shortest distance between two points

· Filler is best mounted directly above vertical bag making tube

Carded PKG

Marrying plastic materials to paperboard to produce visual, self-vending images

· Merchandises function for self-serving retail

· Protects products

· Provides sales appeal, visibility, directions for use

Totally automatic blister-sealing lines used for ______________________. For example, ____________________.

high volume items

EX: razor blades, batteries, pens, toy cars, mascara and universal remotes

carded pkg components (4)

· Preformed plastic blister

· Heat-seal coating

· Printing ink

· Paperboard card

preformed plastic container > NEEDS (3)

· Property type

· Grade

· Thickness

Preformed plastic container > considerations

· Height and weight of product

· Sharp/pointed edges

· Impact resistance

· Aging

· Migration

· Cost

· Compatibility with product **

· Heat sealing properties

· Ease of cutting and trimming

Heat seal coatings

· Provide a bond between the plastic blister and printed card

· Proper coating weight applied for optimum heat-sealing results

· Compatible with paperboard and blister (EX: PE)

heat seal coatings - problems

· Bonding so good > consumer complaints

o Easy opening innovations: blister guard, perforations in back panel

printing inks must resist (5)

· high heat-sealing temps

· abrasion

· bending

· fading

· safe for use with intended product

paperboard

Provides main structural component of pkg

Heavier the product, heavier weight of board to support

Picked according to size, shape, weight, style of product

indirect vs direct sealing

· Direct sealing: heating through film (conventional)

· Indirect sealing: heating through paper, ink, then film, takes longer

Heat sealing machinery should provide Necessary production rate and should be able to be Adjusted to Maintain constant conditions of:

· dwell time

· temperature

· pressure

Heat sealing machines usually employ HEATED DIES, electric current passed through heating element in die.

Some heat sealing machines use

· impulse

· electronic

· high-frequency (ultrasonic) heating

crap wrap

full blister package

skin packaging - definition

Product itself is the mold, heated plastic film drawn by vacuum and heat-sealed to paperboard card

· Product is “laminated” between paperboard card and film

skin packaging process

· Product on board

· Moved to machine with air passages connected to vacuum system

· Film heated, vacuum applied

· Residual heat in film activates heat seal, fusing and forming a fiber-tearing bond

four main types of capping

1. Continuous thread (CT)

2. Vacuum

3. Roll-on

4. Press-on

cappers for CT CLOSURES (4)

a) Hand cappers and tighteners

b) Single-spindle (single-heat) intermittent motion cappers

c) Straight-line continuous motion cappers

d) Rotary continuous motion cappers

Torque control - pneumatic vs mechanical

· Handled through chucks (spinning wheels/rollers)

· Pneumatic or mechanical

o Pneumatic: round flexible ring with hole in center, cap enters hole

o Air pressure is applied, ring COMPRESSES AND GRIPS cap while its removed and screwed on

o Controlled by a pneumatic clutch (EX: tires)

CT - a) Hand cappers / cap tighteners: char, cpm

· Low production levels, hand cramps

· Unusual caps

· 20 cpm

· Hand capper: hand-held chuck

· Cap tighteners: useful for pump trigger-cap application, or retorque after induction sealing

CT - b) single spindle intermittent motion capper

· Either pneumatic or mechanical

· Reduces productivity

· 60 cpm

· Short production runs

· Versatility limited

· Intermittent motion > spillage in wide mouth containers

CT - c) straight-line continuous-motion cappers

· Torque-control clutches are built into multiple spindles (heads) that turn rollers (disks) to apply caps

· Continuous

· 60-300 cpm, limited by conveyor, using multiple spindles can increase rate

· Advantage over rotary: no change parts required, sizes changed with little downtime.

CT - d) Rotary continuous-motion capper

· many heads in combination, rotary arrangement

· Can use different sized caps, don’t need to change internal chucks

· 40-700 cpm

· Higher speeds = more heads (EX: 700 requires 24 heads)

VACUUM closure cappers (3)

pry-off side seal

lug

press-on, twist-off (POTO)

VACUUM - a) Pry-off side seal

· Earliest type, no longer used in US

· Uses rubber gasket

VACUUM - b) lug: # turns, char, EX, cpm

· 4-6 lugs that grip threads

· Requires half a turn to come off

· Flowed in plasticol liner (gasket), polymer coated inside seals closure/bottle of the pkg

· Rarely perfectly level finish, why liner is needed

· EX: Mrs. Butterworth’s holiday outfits?

· Usually done by straight-line machinery that incorporates two belts moving at different speeds

· max speed 700 cpm

VACUUM - c) press-on, twist-off: char, application, cpm, liner, construction

· Not snap-fit closure system

· Application: baby food, hot fill products

· Vacuum: pops when released – quality control feature, tamper evident

· > 1000 cpm

· Requires no turn at all

· Plasticol liner MOLDED for high precision

· Straight skirt, no lugs

o Seal formed when plasticol softens and conforms to bottle threads

CAPPERS FOR ROLL ON CLOSURES

No threads before applied

Straight sided shell placed over bottle top, rollers in a chuck form the threads

max speed: 700 cpm

Can use with or without TE perforated band

Application: Wine, some cans

CAPPERS FOR PRESS-ON CLOSURES (4)

crown

snap-fit

dispensing

overcaps

Press on closures > overcaps

· Can be applied by chucks or rollers

· First roller slightly higher than following one, pressing cap on little at a time

· Container has lip around finish area – cap snaps on holding system together

· Max speed: > 1000 cpm

· EX: free trial pack on top of Folger’s Coffee

objective of capping operation

proper tightness

· Loose caps > spoiling/contamination

· Too tight > consumer complaints, breakage

cap tightness

· Measured by torque

o Plastic cap & bottle – one will deform

o Metal on glass – neither will deform

· Application torque > machine adjustment

· Removal torque > temp changes, liners, corrosion, vibration

· Retorque before casing bc they get loose on conveyor

plug insertion - types (3)

plastic plugs

corks

fitments

plug > plastic plugs

wine, champagne

plug > cork

o Expensive wines and champagnes

o From tree bark

o Cork affects 10% wine

o Best cork in world from Portugal

o Must be compressed for insertion, so can expand once inside

o – shrink band

o – foil wrap

o – wire reinforcement

fitments

o Push pull syrup

o Pumps hand soap

o Sprayers windex

o Shakers grated parmasean

LABEL PURPOSES

· identify company > loyalty

· Sales messages

· pictures and decorations: 0.4s, #1 = Kids

· consumer information: nutrients, requirements by regulating bodies

· Tax stamps on controlled items (alc, cigs) - Utah story

· Security issues, Avoiding counterfeit

LABEL TYPES - classified by

· Package location (Neck label)

· Wrap around labels (cans)

· Pressure sensitive labels (MI Brewing Co)

· heat sensitive labels

· Shrink sleeve (on any style jar/can)

LABEL - pkg location

· spot labels (promotional, $5 fine for wrong price)

· cut labels

· roll labels

LABEL - wrap around

· edges glued

· EX cans

LABEL - pressure sensitive

· supplied on roll w/quick release backing

· several application techniques

· a lot of scrap without a lot of rejects

LABEL - heat sensitive

· glue gets sticky when melted, sets when cooled

· EX pharma (clean system)

IML

in mold label

mural instead of hung picture

BARCODES

37 years old

UPC - universal product code

Checkweighing - in or off line?

IN LINE

checkweighing function

· Do 100% of weight inspections of prod in production process in pkg line

· Perform without interrupting product flow

· No operator

checkweighing categorized as

· Weight-regulation compliance

· process control

· production reporting

checkweighing components (4)

· Weighing element

· Setup controls and indicators

· Product transport mechanism

· Reject device

checkweighing reject devices

o Air blasts (light)

o Air pushers (med-heavy)

o Swing gates (med-heavy)

o Drop-through (light-med)

o Center gate rejectors

o parallel gate rejectors

o slider conveyors

two ways to weigh product

static (intermittent) - accurate, but slower

dynamic (continuous) - less accurate

checkweighing applications

1, monitor weight of pkg

2. compliance with gov regulations

3. classify product into weight categories (chickens)

4. verify counts (cans in case, golf balls in sleeve)

5. pricing (meats)

checkweighing Spacing (3)

1. dual belt infeed (one belt accelerates faster than the other)

2. timing screws (grab one bottle at a time, space apart)

3. rotary timer (screw for boxes)

checkweighing application considerations

· pack length

· pack weight

· line speed required

· pack content

· motor technology

· stabilization time of weight transducer

· airflow causing readings in error

· vibrations from machinery caused by unnecessary objects

· sensitivity to temp

About this deck

By: Emily Wiggins
Created: 2010-12-17
Size: 98 flashcards
Views: 167

About StudyBlue

“I have been getting MUCH better grades on all my tests for school. Flash cards, notes, and quizzes are great on here. Thanks!”
Kathy