Bubble Wrap Manufacturing Process

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Group 6:Anjali shrikant Basuki Nath dubey Debasish Padhy Kushal roy Mona kumari Richa daruka Sonam keshari Sumit khandelwal Introduction to bubble wrap packaging Raw material used Manufacturing Process Poka yoke mechanism managing by product/ waste Use of single minute exchange of die mechanism Future improvementsName Bubble wrap is registered by Sealed Air Corporation of Saddle Brook, New Jersey It is a packing material consisting of two plastic sheets laminated together in a way that traps air bubbles in small, uniform pockets Its Flexible cushion helps in protecting fragile objects during storage or shippingPlastic resinPolyethylene and polypropylene as they perform well and are relatively inexpensive Can be cast into strong, flexible films, which have the ability to hold air without leaking These are thermoplastic materials Other additives Polypropylene or polyethylene films are formed with a variety of additives mixed with the base polymers in order to modify their properties and to facilitate processing Lubricants and plasticizers which control the flexibility of the resin blend Coupling agents and strength modifiers which improve the bond between the polymer and the filler Antistatic agents are added to reduce buildup of static electricity Biocides may be included to inhibit microbial growth.As the molten resin is squeezed through the die, it is shaped into a sheet which is then processed further. After being extruded, the sheet passes through a series of stainless steel rollers, known as a three roll finisher or a three roll stack.Polyethylene resin is heated and mixed with the additives Mixture is then melted and formed into small pellets 0.125 in (0.3175 cm) in diameter These pellets are introduced into a molding machine, known as an extruder At one end of the extruder is a hopper into which the pellets are dumped Hopper feeds the pellets into a long heated barrel Barrel is equipped with a screw mechanism, which pushes the plastic forward The resin melts as it moves along the heated barrel, and by the time it reaches the end, it can be easily forced out through the opening in the die After being extruded the sheet passes through a series of stainless steel rollers, known as a three roll finisher or a three roll stack. These rollers are 10-16 in (25.441 cm) in diameter and are internally cooled with waterLamination is the process used to seal the two sheets together in such a way that traps air bubbles.Resin and additives must be added carefully to ensure the formula components are blended in the proper ratios Finished resin may be analyzed to ensure its chemical and physical properties meet specifications before sheet extrusion operations begin Start of the extrusion process a small amount may be flushed through the barrel of the extruder. This purging process cleans out the barrel and reveals any problems with the molding systems. It is critical that the resin is kept at the proper temperature In certain methods of manufacturing it is important that top and bottom plastic sheets respond to heat differently so that during the lamination process one sheet distorts but the other does not. For this type of operation, it is critical that the heat distortion of the two sheets differ by at least 77 F (25 C) or problems will occur during laminationThe major waste product from cushioning laminate manufacturing is the plastic resin. Resin that is contaminated, overheated, or otherwise ruined Sheets that fail quality checks for reasons related to physical molding problems can be reworked This recycling process is known as regrinding and shredding the sheets, re melting them, and re-extruding them as new sheets. To ensure the plastic meets physical specifications, regrind may be mixed with virgin resin. This can be done without loss of quality because of the thermoplastic nature of polypropyleneSingle minute Exchange of Die is one of the many lean production methods for reducing waste in manufacturing processImproved plastic compounds that are easier to process, provide better cushioning ability, and are biodegradableThis process creates bubbles without the use of a forming surface. It remains to be seen if this, or other new manufacturing methods, will be embraced by the industry in the future.