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DipBrew Mod 3 > 3.1 Packaging Materials > Flashcards

3.1 Packaging Materials Flashcards

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1
Q

What are the three categories of packaging?

A

Primary
Secondary
Tertiary

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2
Q

What constitutes primary packaging?

A

they contain the product and meet legislative standards.
the product can’t be sold without these
EG: cans, bottles, crowns, kegs, spears, labels

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3
Q

What constitutes secondary packaging?

A

materials that collate the primary package in some form

EG: wraps, cartons, crates, trays

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4
Q

What constitutes tertiary packaging?

A

materials that aid in protecting and transporting the product safely
EG layer boards, pallets, shrink wrap

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5
Q

what are the two major functions of packaging?

A

technical and marketing functions

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6
Q

what are the 6 criteria that must be met under technical functions of packaging?

A

Containment – Holds product without leaking
Protection – Product doesn’t hurt consumer
Preservation – Keeps in good condition for shelf life
Measurement – Holds legally declared volume
Dispensing – Dispenses easily
Storage – Will travel and store successfully

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7
Q

What are the 6 criteria that must be met under marketing function of packaging?

A

Communications – product name and any additional info
Display – looks good on shelf
Information – contents, ABV, BB, batch #, legal info
Promotion – Peelable labels etc.
Selling – final packaging will help sell product.

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8
Q

materials purchased must allow final ______ to _______ as perceived.
To help control specs they can be divided into 3 parts, what are they?

A

package
function

Overall Policy Statement
General Component Specification
Specific Component Specification

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9
Q

what does the Overall Policy Statement entail?

A

relates to restrictions of treatments used in production that may effect product quality or dictate % of production materials that must be recycled.

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10
Q

What does General Component Specification entail?

A

Covers all components that come under a common heading (EG: bottles, cans, cartons etc.). Includes general descriptions, technical requirements, quality and environment.

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11
Q

What does the specific component specification entail?

A

Provides dimensions, type of material, barcodes, artwork.

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12
Q

what are the key legislation required on packaging?

A 
Product identification
Declaration of contents
ABV
BB 
Name and address of manufacturer and source
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13
Q

what are the 4 R’s of packaging and the environment?

A

Reduce
Reuse
Recycle
Recover

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14
Q

what are the essential requirements packaging must meet to see market in the UK?

A

Packaging must meet minimal safety and hygiene acceptance.
Noxious/hazardous substances in packaging must be minimized.
Packaging must be recoverable through:
-material recycling
-incineration with energy recovery
-compositing or biodegradation
Packaging may be reusable

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15
Q

Why is packaging and the environment so important?

A

because there is a lot of legislation to reduce packaging waste that must be adhered to so that your product can make it to the market. you must be aware of these when choosing packaging materials

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16
Q

define Glass?

A

Glass is an inorganic substance fused at high temp and cooled so it solidifies in a vitreous, non-crystalline condition.

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17
Q

what are the main constituents of glass and the percentage of a mix they make up?

A

Typical mix of materials to produce glass is

  • Silica. 70%
  • Soda Ash. 15%
  • Limestone. 9%
  • Refining agents. }
  • Colourants. } 6%
  • De-colourisers. }
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18
Q

what is cullet?

A

the industrial name for broken glass

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19
Q

why is cullet added to a furnace and at what rate?

A

it is added to the furnace to reduce melt temps required it is often added in the range of 30-75%

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20
Q

how is glass batched up and added to the furnace? what bed depth is maintained in the furnace?

A

glass is batched up by weight and mixed before being added continuously to the furnace to maintain a bed depth of 1.5-2m

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21
Q

what colourants are used to create amber glass?

A

Iron, Sulphur, Carbon

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22
Q

what colourants are used to create green glass?

A

chromium oxides

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23
Q

what colourants are used to create blue glass?

A

Cobalt oxides

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24
Q

what decolourisers are used to produce flint glass?

A

selenium and cobalt oxide

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25
How is a furnace heated?
a furnace is heated using a natural gas burner that fires from one side of the furnace and exhausts at the other
26
what methods are used to save energy in a furnace?
at the exhaust side of the furnace is a regenerator that recovers heat energy being expelled
27
how does a cross fired regenerative burner work?
there is a burner and regenerator at both sides of the furnace that swap over intermittently to make the best use of stored energy
28
how hot does it get in the furnace? where is the heat generated?
1500 degrees C | the heat is generated from the burners and radiation as the glass passes through
29
what is the throat in a furnace?
the throat is a barrier with a gap at the bottom of the furnace at the working end that prevents unmelted glass from getting mixed up with melted glass that is ready for the next stage of processing
30
where does the glass enter once it leaves the furnace? what occurs here?
the forehearth, here the glass is squeezed through an orifice ring with the help of a plunger and is sheared off to form the gob
31
once the gob is formed what does it do?
it is transferred down a trough into the blank side of a forming machine
32
what variables effect gob size?
``` temperature glass composition orifice size length of plunger stroke timing of shears. ```
33
what is a parison?
a partly formed bottle
34
what are the three main methods for manufacturing glass containers?
press and blow blow and blow narrow neck press and blow
35
describe the blow and blow method of bottle manufacture?
bottle drop int a mould and receives two blasts of compressed air from each end to fill the mould. the parison is then transferred into a final mould where it is blow into shape
36
what is a disadvantage of the blow and blow method?
it doesn't always produce uniform internal bottle shapes
37
describe the press and blow method of manufacture? what type of container is this method used to make?
gob is pressed into a mould by a plunger to form the parison, it is then transferred to another mould where it is blow into shape. Jars
38
describe the narrow neck press and blow method for making bottles?
similar to the press and blow method. Gob is pressed into a mould in the shape of a bottle neck. this parison is then transferred to a final mould where it is blow into the final bottle shape.
39
what is one main advantage and disadvantage of the narrow neck press and blow method?
adv: consistent wall thickness 10-20% lighter finished product disadv: tooling is much more expensive, high precision required
40
what are the purposes of surface treatments and annealing?
providing lubricated surface to run smoothly down a packaging line and providing the bottle with internal strength respectively
41
define annealing? why is it necessary?
“Heating metal or glass and allowing it to cool slowly to remove internal stresses and toughen it” When a bottle leaves the forming machine it is 300C and its exterior is hard while the interior remains hot and soft. If cooling occurred naturally interior would contract more and stresses would develop
42
how is annealing carried out?
bottles leave the forming machine and enter a machine called a lehr, this heats the bottle to 550C and then very slowly cools it
43
what are the two different types of surface treatments? what are their different purposes?
cold end treatments and hot end treatments cold end treatments provide lubricant to the bottle exterior. hot end treatments provide a protective layer against abbrasion
44
what materials are typically used in hot end treatments?
metal oxides (typically tin though titanium and zircon are also used)
45
how is tin applied in hot end treatments? what are some dangers of using tin?
it is applied as a stannic chloride vapour that decomposes to an oxide during heating. overuse can promote the rusting of crowns
46
when are cold end treatments typically applied?
as the bottle leaves the lehr
47
what are the two categories of cold end treatments?
soluble and insoluble
48
what are soluble cold end treatments made of? how are they applied?
polyethylene glycols and their esters | Applied in dilute form by spray heads that traverse back and forth at the end of annealing lehr.
49
what are insoluble cold end treatments made of? how are they applied?
Typically oleic acid | Applied as vaporized droplets in special treatment hood.
50
what is a quality issue that can arise from cold end treatments?
if the sprays are not timed correctly it can spray it into the bottle which can cause gushing upon opening
51
what are the three categories of faults in glass bottle production? define them.
Hazardous – Critical • Feature that may lead to glass inside product such as: - fused glass on interior - Birdcages (string of glass across inner body) - High top (ring of glass on sealing surface) Functional – Major • Glass that would fail to pass down filling line. • EG: split rings, some stones Visual – Minor • Container fills, caps and labels well but departs from accepted visual standard.
52
what are the 6 areas of quality inspection glass bottles are subject too?
``` At hot end by operator. Manual inspection at cold end. Lab measurements. Auto inspection equip. Final inspection. Acceptance – positive release. ```
53
what quality parameters are checked during the hot end inspection?
* Go/No Go gauging of body and finish parameters * SPC measurements of key features * Visual checks
54
what quality parameters are checked during the lab checks?
* Glass wall thickness measurement * Capacity * Hot end surface treatment checks
55
what quality parameters are checked during the cold end inspection?
* Go/No Go gauging of body and finish parameters * Surface treatment checks * Internal pressure resistance checks * Automatic inspection equipment checking
56
what quality parameters are checked via automatic inspection equipment?
* Minimum through bore * Finish checks/Splits including high tops * Dannies (cracked shoulders) * Bottom checks/splits * Side wall inspection * Sealing surface * Wall thickness * Out of round (ovality) * Push up (base profile) * On line pressure testing
57
what occurs in the final inspection phase?
* Defects divided into categories * Info fed back to production * Failed batches resorted or culleted
58
What is PET?
Polyethylene Terethphalate
59
What is PEN?
Polyethylene Napthalate
60
what are PET multilayer or blend bottles?
PET bottles in multilayer form using another polymer (eg: Ethylene Vinyl Alcohol EVOH) or single layer bottles using a blend of PET and PEN
61
what other sorts of polymers are used in pet multilayer bottles?
ethylene vinyl alcohol EVOH
62
What does PCR stand for?
Post Consumer Recyclate, waste that has been reprocessed, flaked or pelleted in readiness for re use.
63
What criteria must plastic bottles meet to be acceptable to the brewer?
- Prevents O2 ingress - Prevents Co2 egress - Prevent H2O or alcohol loss - Prevent detectable flavor or aroma loss - Prevent migration of deteactable compounds from bottle wall such as acetaldehyde - Be cost comparative to can or bottle - Be socially accepted
64
What are four methods used to overcome permeability issue with plastic beer bottles?
- Monolayer PEN - Blends of PET and PEN - Barrier coated monolayer PET - Multi layer PET with barrier/scavenger in center wall
65
What are some advantages of PEN over PET
``` Better Vapour transmission rate Better CO2 and O2 permeation rate Stronger Can be pasteurised at higher temp longer shelf life ```
66
What are some disadvantages of PEN over PET
Cost | inferior to multilayer bottles
67
Coated PET bottles EITHER have an ______ OR an ________ coating
internal | external
68
External Coatings of PET bottles is made of what? What is the most common brand
Silicon Oxide | BestPet
69
How is external coatings of PET bottles applied?
deposited on the outside of bottle as it is spun on a mandrel
70
What is a major disadvantage of External coating on PET?
potential damage during transport and processing rendering it non effective
71
What are the two types of internal coatings for PET bottles?
Amorphous Carbon Treatment of Internal Surfaces (ACTIS) Glaskin (a silicon oxide)
72
what is a disadvantage of Amorphous Carbon Treatment of Internal Surfaces?
is leaves a smoky residue making it unsuitable for clear bottles
73
What is the most popular type of plastic bottle?
Multilayer bottles
74
How are multilayer bottles made?
preforms are made with co injection nozzles that distribute the PET and barrier resins at the correct times to create a preform. the preform is then blow to size
75
What are some common barrier products?
``` Bind Ox Amosorb Aegis Ox CPT312 Oxbar ```
76
How are preforms blown to size?
Heated in long linear oven to 110C Placed in a mould Blowing tube inserted in the top and compressed air applied stretching the preform to the size of the mould
77
What are 4 common quality issues to look out for when manufacturing plastic bottles?
Cloudiness Stress Whitening Distorted contours Ovality of Seal Face
78
What are the three most common materials used in crown manufacture?
Stainless Steel Electrolytic Tin Plate Tin Free Steel
79
Which Crown material is the most common?
Tin Free Steel
80
What are the advantages and disadvantages of SS and Electrolytic Tin Plate for manufacturing crowns?
Advantage: Better Corrosion Resistance Disadvantage: Cost and Easy to scratch respectively
81
What are the best methods for preventing crown corrosion?
ensuring the area around and under the crown is sufficiently dried after crowning limiting stannic chloride hot end treatments to 10 CTU's (Coating units)
82
How is the area around the crown dried?
using high volume low pressure air blowers angled up to get under the crown
83
What are the crowns fitted with to help seal the crown to the bottle top?
PVC or PVC free foamed liner
84
Foamed liners are necessary to allow?
good pressure retention pre and post past stackability oxygen barrier O2 scavenging capabilities when blended with scavenging materials
85
what is the advantage of the double lip design on the crown?
the foamed liner has 2 raised lips around its circumference providing 2 sealing surfaces for added security
86
How must twist of crowns be manufactured differently?
tighter tolerance for size variation | profiled to fit sealing surface

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