new materials & new markets for isbmrts2009.mines-albi.fr/s5-new_materials_and_new... · new...

New Materials & New New Materials & New

Markets for ISBMMarkets for ISBM

Patrick Etesse

R&D Packaging, Brussels Innovation Centre

3rd Conference on Rotomoulding

Thermoforming Stretch Blow Moulding

Ecole des Mines, Albi, March 13 2009

2

ISBM Packaging ISBM Packaging –– Innovation strategy Innovation strategy

and examplesand examples

1. Procter & Gamble innovation strategy

2. P&G ISBM packaging needs

3. New ISBM Material in Market examples

4. Our ISBM pilot plant facilities

3







4

Over $84 billion in sales in 07/08

300 brands in over 160 countries

#1 or #2 in 80% of our categories

24 billion-dollar brands

Founded in Ohio (USA) in 1837

Procter & GambleProcter & Gamble

6

Innovation strategy

“Our vision is simple. We want P&G to be

known as the company that

collaborates – inside and outside –

better than any other company

in the world.”

A.G. Lafley

President and

Chief Executive Officer

Acquire 50% of our innovations from outside P&G

6

7

DisruptiveTechnologies

Improved

ways to reach

consumers

How to participate

in new channels

Shared

testing

facilities

“Cooked”

Products

&

Packaging

New

business

models

What do we look for?

8

Innovation strategyInnovation strategyCo-developments in the market

Olay VitaminsCrest New TubesTide Stainbrush

Clairol In-Store Shade Selector

Kandoo WipesPantene Sonic Comb

Mr. Clean Magic Eraser

Glad Press N Seal

Charmin Fresh Mates

Swiffer Duster

Mr. Clean Autodry

Olay Daily Facial Pillows Old Spice

Shave GelVisia Beauty Imaging

Olay Regenerist

Olay White Radiance Facial

Mask

SK-II Facial MaskSK-II Airtouch

Foundation

Prilosec OTC

Crest Scratch N Sniff Pkg.

Crest Liquid Dentifrice

PuR / Whirlpool

Refrigerator Filters

PuR Furnace Filters

OTC Drug Registration

s

Metamucil Capsules

Pringles Dips

Pantene Hair Styling

Products

9







10

500350150100Index

3000 -

7000

2500 –

3500500 – 2500500 - 1500

Flexural modulus

(Mpa)

ISBM

PET

ISBM

PP

EBM

PP

EBM

HDPE

Why ISBM ?Why ISBM ?

* Provides access to higher flexural modulus w/o stress cracking

* Significantly increases material flexural modulus

11

Expected benefitsExpected benefits

Small sizes (200-500ml) 15% lighter

Large sizes (1L & up) 30% lighterMore sustainable

Close coupling when needed

Create scale in preform (from 80 to 12-15 P&G necks)

Design for one machine platform

Win on cost

Shine, Clarity when needed

Speed to market: fast color/size change overWin on shelf

ISBM benefits vs. EBM

12

Packaging innovation needsPackaging innovation needs

Convert 80% of today’s bottle business to ISBM

80%

19%1%

HDPE

PET

PP

13

-

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

15-250 250-600 600-1500 1500-2500 2500-9000 unknown

MM units

Weight

Size range distributionSize range distribution

14

ISBM for P&GISBM for P&G

Challenges

• PET is not always the best material for household products

• Wide aspect ratio (up to 4)

• Size range extends up to 9L

Solutions

• Extend processing capabilities to other materials

• Preferential heating

• Ergonomic handle for large sizes

15

Example: ISBM PPExample: ISBM PP

1) The opportunity

2) The blow process

3) The injection process

4) Small Size Proof of Principle – Iris 400 ml

16

Defining the opportunity - Materials selection charts

Lines if equivalency for different requirements

17

Initial topload modelling – data from standard InstronequipmentPET - topload PP -

topload

322

208

162

210

199

290

Using these results we can generate lines of equivalency for a material selection chart

18

Accuracy of input data is critical

- New Instron Advanced Video Extensometer

- P&G has installed a video extensometer at BRTC

Performed at Instron UK (High Wycombe)

19

Materials selection charts – comparing 1903 & PET

Only for Mars shape can 1903 outperform PET

20

Materials selection charts – comparing 1685 & PET

1685 outperforms PET for all shapes

21

-0.4%-5.2%-9.8%Stretchene 1685

+11.2%+4.4%-2.0%Stretchene 1903

ShrekMagnetMarsMaterial

Predicted weight change for PP resins to achieve equal topload performance to PET.

Including the neck weight difference at the indicated bottle weights

-4.9%-9.8%-11.9%Stretchene 1685

+6.7%-0.2%-4.1%Stretchene 1903

Shrek (45g)Magnet (45g)Mars (27g)Material

22

Conclusions

• A weight saving of 0-10% can be gained by using PP instead of PET if:

a) A specialist material is used

b) A wall thickness distribution and variation equal to PET is achieved

• If the above conditions are not met, PP will require higher weights than PET

23

KEY POINT –the wall thickness distribution need to be correct.

For magnet; IF 10% of the material is moved from 1 side to another, toploaddrops by 7%

24

The blow process

25

Strain hardening with sequential stretch ratios

Performed at the University of Bradford

26

Conclusions

• Current process and preform design do not result in optimal material properties

• To achieve these properties very significant changes would be needed to be made to preform design which would have detrimental cycle time effects

• Strain hardening can be seen in PP but this effect is less critical than temperature variation

27

The injection cycle

28

Conclusions

• Total cycle time for PP is not defined by injection time

• Injection can be quicker than PET for opaque bottles

• Cooling is much slower than PET resulting in overall higher cycle time (4 to 5 s additional)

29

Small size proof of principleSmall size proof of principle

• Achieved ISBM PP bottles 15% lighter than EBM HDPE and up to 40% stronger.

• Requires very good process control

30

Iris 400 PP Topload

234

309

353343

247

369

100

125

150

175

200

225

250

275

300

325

350

375

400

425

SBO 2/3: 1903 SBO 2/3: 1685 SBO 1/2: 1903

(24h)

SBO 1/2: 1685

(24h)

SBO 1/2: 1903 SBO 1/2: 1685

Machine: Resin

To

plo

ad

(N

)

Max

Min

Mean

Min Spec = 200N

HDPE = 244N

Note:

SBO 2/3: n=12

SBO 1/2 (24 h): n=6

SBO 1/2: n=20

Test 1: SBO 2/3 Test 2: SBO 1/2

31







32

Market examplesMarket examplesBeauty Care

Samson

33

Market examplesHome Care

34

Market examplesMarket examplesAriel Bleach & Laundry Additive

35

Market examplesMarket examplesAriel Bleach & Laundry Additive – the innovation

ISBM / PP bottle:• Transparency & soft touch• Excellent ESCR• O2 Permeability for bleach• Low WVTR for shelf life• 15% light weight

ISBM PET doser:• Transparency• ¼ turn opening & seal

Bottle/grip design:• Easy-to-hold grip• 2L handling requirement

36

Market examplesMarket examplesAriel Bleach & Laundry Additive – the cooperation

37

Market examplesMarket examplesVicks Throat Drops

38

Market examplesVicks Throat Drops – the innovations

Optimized cap:• Improved seal integrity• 30% light weighted

ISBM PP jar:• High transparency• Higher moisture barrier• 20% light weighted

Time to market:• 10 months from concept

Vicks PP throat drop jars are the largest & lightest clear Polypropylene jars with an injection molded neck to be commercially manufactured till dateDr. S. Agarwal (Board of directors SPE)

39

Market examplesMarket examplesVicks Throat Drops – the cooperation

40







41

P&G Pilot PlantP&G Pilot Plant

Rotary pilot unit (Cincinnati):

SBO 2/10 as of April 2009

Prototyping of sizes below 2.5L

New Materials testing

Validation of ISBM modeling tools

Linear Pilot Unit (Switzerland):

• Compact 2XL linear as of May 2009

• Focus on > 2.5L Sizes but small size capable

• Handled Bottle Development

• Partner with machine manufacturers & non competitors

42

Chosen PlatformsChosen Platforms

Hopper + rail + guideHopper + rail + guidePreform Feeding System

pneumaticvariable angle stretching camStretch Rod Speed

< $10M per format change< $10M per format changeCost to size change Machine

129Heating Zones per Module (unit)

510Heating Modules (unit)

6050Pitch (in mm)

PET and PPPET and PPProcess Capabilities

430340Max Bottle Height under neck ring

(mm)

10L2.5LMax Bottle Volume (liters)

200115 shell (up to 140 GUPM)Max Bottle Diameter (in mm)

3535Max Neck Height (mm)

development+/- 10° (+/- 3° in mold)Neck Orientation

5548.5Max neck ring Ø (mm)

developmentYesPreferential Heating

1200 per cavity•1400 per cavity inc. preferential heating•1100 per cavity with +/- 3° neck orientation)

Max Production Rate (bph)

1 or 21 or 2Max. Number of Cavities

Lab Machine > 2.5L @ BICSidel SBO 2XL

Lab Machine < 2.5L @ BRTCSidel SBO 2/10 Lab Universal

Machine Characteristics

43

Modeling & Simulation VisionModeling & Simulation Vision

Model that supports our development processes• Bottle/preform design process

• Reheat blowing process

Thick preforms, oval bottles & new materials

Goal

Thicknessdistribution

Mat. propertydistribution

Bottle3D

Processingparameters

ISBMM&S

VPS(topload, squeeze,

drop, conveying…)

Preformdesign

Material

Optimization

Bottleperformance

Bottledesign

Goal

Thicknessdistribution

Mat. propertydistribution

Bottle3D

Processingparameters

ISBMM&S

VPS(topload, squeeze,

drop, conveying…)

Preformdesign

Material

Optimization

Bottleperformance

Bottledesign

44

Tools Tools -- approaches of current solutionsapproaches of current solutions

1st Principles• Tailored to Sidel• Pref. heating• Range of PET mats• PP reheat

Proprietary• Cylindrical validated• Cyl mapped to 3D• Range of PET mats• No PP today

Reheat

Stretch-Blow

1st Principles• Flexible oven setup• No pref. heating• Range of materials• PP reheat?

FEM• Elasto-viscoplastic• Any 3D shape• Range of PET mats• No PP today

1st Principles• By Phillips / Fr

FEM• Elasto-viscoplastic• Any 3D shape• Few PET mats• No PP today

• Via internet• Non-expert interface• Output: Abaqus input

System

Virtual PrototypingBy PTI

BlowSimBy NRC Canada

APT Research ProjectBy Univ Belfast & et.

• Software license• Non-expert interface• Output: FEM input• Also does EBM

• Abaqus or internet• Dual interface• Output = input

45

Our Needs & PartnershipOur Needs & Partnership

Our Needs

• Reheat model for (indirect) preferential heating

• FEA model for stretch-blow molding of bottles

• Effective constitutive models incl. tests

Partnership

• Validation center w/ SIDEL machines

• Provide IT support

46

Patrick Etesse

Temselaan 100

B-1853 Strombeek-BeverTel. +32-2-456-4249

Email [email protected]

Thank You!

new materials & new markets for isbmrts2009.mines-albi.fr/s5-new_materials_and_new... · new...

Documents