AGR INTERNATIONAL, INC. LIGHTWEIGHTING OF CONTAINERS

PRESENTERS:

ALEKSANDER BRODA

WILLIAM SLUSSER

REGIONAL DIRECTOR, NCE EUROPE

MANAGER, RESEARCH SERVICES

PACKAGING AND CONVERTING EXECUTIVE FORUM FEBRUARY 2015

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

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 ANALYSIS

• PROACTIVE BOTTLE DESIGN AND LIGHTWEIGHTING

• IMPLEMENTATION OF NEW SOLUTIONS

• SEMINARS AND TRAINING

OPTIMIZING PROCESS EFFICIENCY

& ACHIEVING QUICK RETURN ON INVESTMENT

CUSTOMERS AROUND THE WORLD

• CONTAINER TESTING AND RESEARCH

• PERFORMANCE EVALUATION

• FRACTURE DIAGNOSIS

• STONE IDENTIFICATION

• BOTTLE DESIGN

• TRAINING SEMINARS

• ANALYTICAL SERVICES

• LINE AUDITS

• COATING AND CONTAMINANT ANALYSES

• LITIGATION SERVICES

PRIVATE, INDEPENDENT TESTING AND CONSULTING LABORATORY FOR THE GLASS PACKAGING INDUSTRY.

1. ENVIRONMENTAL BENEFITS

2. POSITIVE IMAGE

3. SIGNFICANT REVENUE INCREASE

REASONS TO LIGHTWEIGHT

REVENUE INCREASE/COST REDUCTION

Standard Weight

Glass Weight 240 grams

Machine Speed 12 cycle (360 bpm)

Tons per/day (US) 137.2

Packing Efficiency 90%

Btls packed/day 466,560

Selling Price €0.10 $0.14/ bottle

Revenue/annual € 16.3 M

$ 22.9 M

Lightweight Bottle

Glass Weight 200 grams

Machine Speed 14 cycle (420 bpm)

Tons per/day (US) 133.2

Packing Efficiency 90%

Btls packed/day 544,320

Selling Price €0.10 $0.14/ bottle

Revenue/annual € 19.0 M

$ 26.7 M

= INCREASE IN REVENUE OR POTENTIAL FOR COST REDUCTION

SPECIFICATIONS:

2.3 (0.090 in) mm

3.2 (0.126 in) mm

2.8 (0.110 in) mm

3.2 (0.125 in) mm

3.1 (0.123 in) mm

5.1

(0.200 in)

mm 4.7

(0.186 in)

mm

mm in

Finish 3.2 0.126

Shoulder Contact 2.3 0.090

Sidewall 2.8 0.110

Heel Contact 3.2 0.125

Lower Most Heel 3.1 0.123

Bearing Surface 4.7 0.186

Center Bottom 5.1 0.200

LocationAverage Thickness

mm

Finish

Shoulder Contact

Sidewall

Heel Contact

Lower Most Heel

Bearing Surface

Center Bottom

Average ThicknessLocation

in

Weight 315g 11.1 oz

Capacity 500 ml 16.9 fl oz

Process NNPB -

Bottle Style Refillable -

Pressure 6.9 Bar 100 psi

Vertical Load 544 kg 1200 lb

Impact TBD TBD

Weight

Capacity

Process

Bottle Style

Pressure

Vertical Load

Impact

THICKNESS DISTRIBUTION:

LIGHTWEIGHTING

CASE STUDY – 500 ML RET BOTTLE

STANDARD FEA

• PERFORM A STANDARD FEA (FINITE ELEMENT

ANALYSIS) USING THE SPECIFIED CRITERIA FOR:

•INTERNAL PRESSURE

•VERTICAL LOAD

•IMPACT

10

FEA RESULTS

MAXIMUM

SHOULDER50.0%

SHOULDER

CONTACT35.3%

MAXIMUM

SIDEWALL49.7%

HEEL

CONTACT2.1%

BEARING

SURFACE43.7%

MAXIMUM

BOTTOM64.4%

CENTER

BOTTOM64.4%

INSIDE

KNUCKLE54.8%

MAXIMUM

SHOULDER

SHOULDER

CONTACT

MAXIMUM

SIDEWALL

HEEL CONTACT

BEARING

SURFACE

MAXIMUM

BOTTOM

CENTER

BOTTOM

INSIDE

KNUCKLE

LOCATION MPa/bar

1.01 10.1

MAXIMUM

SIDEWALL

HEEL

CONTACT

1.42 14.2

0.06 0.6

1.25 12.5

1.84 18.4

18.41.84

2.82 28.2

1.43 14.3

psi/psi

MAXIMUM

SHOULDER43.7%

SHOULDER

CONTACT20.4%

MAXIMUM

HEEL34.9%

HEEL

CONTACT32.0%

MAXIMUM

SHOULDER

SHOULDER

CONTACT

MAXIMUM

HEEL

HEEL CONTACT

INSIDE

LOCATION kPa/kgf

10.6 0.7

MAXIMUM

HEELHEEL CONTACT

18.2 1.2

16.7 1.11.65 16.503.07 30.70

22.8 1.5

psi/lbf

INTERNAL PRESSURE

VERTICAL LOAD

11

CASE STUDY – 500 ML RET BOTTLE

mm in

Finish 3.2 0.126

Shoulder Contact 2.3 0.090

Sidewall 2.8 0.110

Heel Contact 2.8 0.112

Lower Most Heel 3.7 0.145

Bearing Surface 5.3 0.210

Center Bottom 5.6 0.220

LocationAverage Thickness

mm

Finish

Shoulder Contact

Sidewall

Heel Contact

Lower Most Heel

Bearing Surface

Center Bottom

Average ThicknessLocation

in mm in

Finish 3.2 0.126

Shoulder Contact 1.9 0.073

Sidewall 2.3 0.089

Heel Contact 2.1 0.084

Lower Most Heel 3.7 0.145

Bearing Surface 5.3 0.210

Center Bottom 5.6 0.220

LocationAverage Thickness

mm

Finish

Shoulder Contact

Sidewall

Heel Contact

Lower Most Heel

Bearing Surface

Center Bottom

Average ThicknessLocation

in

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

THICKNESS REDUCTION

FEA RESULTS-AFTER LIGHTWEIGHTING

MAXIMUM

SHOULDER65.1%

SHOULDER

CONTACT44.1%

MAXIMUM

SIDEWALL63.7%

HEEL

CONTACT1.7%

BEARING

SURFACE46.5%

MAXIMUM

BOTTOM66.1%

CENTER

BOTTOM66.1%

INSIDE

KNUCKLE54.2%

MAXIMUM

SHOULDER

SHOULDER

CONTACT

MAXIMUM

SIDEWALL

HEEL CONTACT

BEARING

SURFACE

MAXIMUM

BOTTOM

CENTER

BOTTOM

INSIDE

KNUCKLE

LOCATION MPa/bar

1.26 12.6

MAXIMUM

SIDEWALL

HEEL

CONTACT

1.82 18.2

0.05 0.5

1.33 13.3

1.89 18.9

18.91.89

2.79 27.9

1.86 18.6

psi/psi

MAXIMUM

SHOULDER55.3%

SHOULDER

CONTACT23.3%

MAXIMUM

HEEL49.5%

HEEL

CONTACT46.6%

MAXIMUM

SHOULDER

SHOULDER

CONTACT

MAXIMUM

HEEL

HEEL CONTACT

INSIDE

LOCATION kPa/kgf

12.2 0.8

MAXIMUM

HEEL

HEEL

CONTACT

25.8 1.7

24.3 1.61.65 16.503.07 30.70

28.9 1.9

psi/lbf

Heel Impact

MAXIMUM IMPACT VELOCITY: 15 IN/SEC (38 CM/SEC) DUE TO MAXIMUM HINGE STRESS DURING HEEL IMPACT

INSIDE

FLEXURE34.8%

IN-PLANE

HINGE15.8%

MAXIMUM

HINGE79.3%

BEARING

SURFACE26.4%

HEEL

CONTACT

HEIGHT

INSIDE

FLEXURE

IN-PLANE

HINGE

MAXIMUM

HINGE

INSIDE

LOCATION

HEEL CONTACT

HEIGHT15.2 mm 0.598 in STIFFNESS x1000 22 kg/cm 125 lb/in

MPa/cps

0.20 73

1.00 367

2.61 960

psi/ips

BEARING

SURFACE0.33 122

ADJUSTED DIMENSIONS

15

mm in

Bottle Height 257.4 10.134

Body Diameter 69.4 2.732

Sidewall Diameter 34.4 1.354

Bearing Diameter 57.4 2.260

mm

Bottle Height

Body Diameter

Sidewall Diameter

Bearing Diameter

Dimension in

Brimful Capacity 529 ml 17.9 oz

Headspace 5.8% 5.8%

Weight 315 g 11.1 oz

Brimful Capacity

Headspace

Weight

mm in

Bottle Height 247.7 9.750

Body Diameter 68.6 2.700

Sidewall Diameter 33.8 1.330

Bearing Diameter 57.2 2.250

mm

Bottle Height

Body Diameter

Sidewall Diameter

Bearing Diameter

Dimension in

Brimful Capacity 524 ml 17.7 oz

Headspace 4.8% 4.8%

Weight 265 g 9.35 oz

Brimful Capacity

Headspace

Weight

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

TOTAL BLOWMOLDER MANAGEMENT

Powerful combination of thickness measurement, vision inspection and closed-loop control offers a total process

and quality control program for PET containers

Thickness

Management

Defect

Detection

Automated

Blowmolder

Control

PET CONTAINERS

BLOWMOLDING MANAGEMENT PROCESS

1.Measure

2.Analyze

3.Communicate

4.Adjust

MATERIAL DISTRIBUTON

The Importance of Direct Thickness Measurement

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 spacing = 12.7mm apart

Infra-red light absorbtion technology

Compatible with Sidel, Krones, KHS, SIPA

Used on containers of various shapes, sizes, colors

TOOLS TO MANAGE PROCESS AND IMPROVE PRODUCTIVITY

TOOLS TO MANAGE PROCESS AND IMPROVE PRODUCTIVITY

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

optimizes the process

– The Process Pilot® system measures the material distribution and automatically adjusts multiple blowmolder controls simultaneously

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)

CASE STUDY – COCA-COLA 2L

PROCESS PILOT

ON

PROCESS PILOT

OFF

CASE STUDY – COCA-COLA 2L

PROCESS PILOT OFF: Cpk = 1.52 PROCESS PILOT ON: Cpk = 2.68

Cpk Values Increase 76% with Process Pilot ON: Sensor 21 (In the Heel Region)

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

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 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

MANAGE CRYSTALLINITY

MANAGE CRYSTALLINITY

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

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

PROCESS PILOT® - GLOBAL MARKET

LOGOPLASTE

Process Pilot is the choice of industry-leading brand owners and converters throughout the world!

Agr International, Inc.

THANK YOU

for more information see:

www.agrintl.com

www.americanglassresearch.com