--- title: 'specialized>S8>U8.2>part1' separator: verticalSeparator: theme: moon revealOptions: transition: 'convex' backgroundTransition: 'fade' viewDistance: 5 center: false overview: true touch: true progress: true controls: true controlsTutorial: true controlsLayout: 'bottom-right' help: true mouseWheel: true slideNumber: 'c/t' autoSlide: 15000 width: '102%' height: '102%' margin: 0 minScale: 1.000000e-01 maxScale: 3 display: 'block' transitionSpeed: 'default' --- ___ ## 8 Mechanical Processes 8.2 Forming processes 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting - N.B. Only the forming processes that can be directly integrated into a packaging line are considered in this lecture. ### undefined author ___ version: production (0.331) date: January 03, 2021 content: 36 slides class: specialized>S8>U8.2>part1 title: 8 Mechanical Processes 8.2 Forming processes 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting - N.B. Only the forming processes that can be directly integrated into a packaging line are considered in this lecture. source: Specialized_Unit_8_2_Forming_Processes_Langowski.pptx hash: 658814980b6244cbbaee601038af35af contact: olivier.vitrac@agroparistech.fr note: ##### [16:14:22 - 03/01/2021]olivi@LX-Olivier2020> pptx2reveal_v2 with the following parameters: | **parameter** | **value** | | --------------: | -------- | | `wwwroot`: | ` /home/olivi/Bulk/fitness2020/sandbox/www20201221` | | `wwwrel`: | ` lectures/html/specialized/S8/U8.2` | | `wwwlib`: | ` lectures/src` | | `pptxfolder`: | ` /home/olivi/Bulk/fitness2020/download20201123/fItNeSs _ sPeCiAlIzEd tRaInInG MoDuLeS/SeSsIoN 8 _ FoRmInG, fIlLiNg aNd sEaLiNg pRoCeSsEs/uNiT 8.2 Forming Processes` | | `pptx`: | ` Specialized_Unit_8_2_Forming_Processes_Langowski.pptx` | | `imfolder`: | ` src_part1` | | `imsourcefolder`: | ` ` | | `impat`: | ` Slide*.jpg` | | `svgpat`: | ` Slide*.svg` | | `author`: | ` undefined author` | | `contact`: | ` olivier.vitrac@agroparistech.fr` | | `YAMLtitle`: | ` specialized>S8>U8.2>part1` | | `title`: | ` 8 Mechanical Processes 8.2 Forming processes 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting - N.B. Only the forming processes that can be directly integrated into a packaging line are considered in this lecture.` | | `vrsn`: | ` 0.331` | | `mdfile`: | ` part1.md` | | `projectname`: | ` part1` | | `theme`: | ` moon` | | `resize`: | ` 1200x900` | | `initialscale`: | ` 0.8` | | `maximumscale`: | ` 2` | | `userscalable`: | ` yes` | | `headingshift`: | ` ` | | `headingshiftnotes`: | ` ##` | | `fontsize`: | ` 0.7` | | `hash`: | ` 658814980b6244cbbaee601038af35af` | | `maxtitle`: | ` 120` | | `maxcontentslide`: | ` 12` | | `favicon`: | ` ~/Bulk/fitness2019/template/favicon/favicon.ico` | | `mainindex`: | ` lectures/html/index.html` | | `dependencymain`: | ` index.html` | | `imformatpreferred`: | ` svg` | | `svgmaxsize`: | ` 1200 KB` | | `pdf`: | ` Specialized_Unit_8_2_Forming_Processes_Langowski.pdf` | ___ > this lecture ___ # Fitness lecture - $2020/12/21$ (v0.33) ## Specialized modules ### 8. Forming, filling and sealing processes #### 8.2 Forming processes * part 1/1 ___ > previous lecture ___ #### 8.1 Introduction to mechanical processes > * [part 1/1](./../../../../../lectures/html/specialized/S8/U8.1/part1.html) ___ > next lecture ___ #### 8.3 Filling processes > * [part 1/1](./../../../../../lectures/html/specialized/S8/U8.3/part1.html) ___ --- #### [go back to the main menu (all lectures)](./../../../../../lectures/html/index.html) --- --- # CONTENT --- * [1/36] [Slide 01/36](#/1) * [2/36] [8](#/2) * [3/36] [Forming: overview of process variants according to degree of pre-processing](#/3) * [4/36] [Mechanical processes](#/4) * [5/36] [Pre-stages for thermoforming](#/5) * [6/36] [Principle of injection moulding](#/6) * [7/36] [Production of preforms by injection moulding](#/7) * [8/36] [Production of tubes by extrusion](#/8) * [9/36] [Delivery of preforms (external producers)](#/9) * [10/36] [Stretch blow molding](#/10) * [11/36] [Mould carriers](#/11) * [12/36] [Example of - krones contiform (integrated stretch blow- moulding, filling and closing machine)](#/12) --- #### [go back to the main menu (all lectures)](./../../../../../lectures/html/index.html) --- --- # CONTENT (Cont'ed) --- * [13/36] [Conversion of flat semi-finished products - principle of thermoforming](#/13) * [14/36] [Positive forming](#/14) * [15/36] [Negative forming](#/15) * [16/36] [The following basic thermoforming methods are available](#/16) * [17/36] [Overpressure (compressed air) moulding with mechanical pre-stretching without additional material slip into the mould](#/17) * [18/36] [The positive moulds are located directly below the film. in contrast to negative forming, packaging with a thick base and [...]](#/18) * [19/36] [Combination of vacuum negative and positive forming with mechanical pre-stretching](#/19) * [20/36] [Commonly used materials for thermoforming are](#/20) * [21/36] [Materials and special problems: heating to 60 °c](#/21) * [22/36] [Achievable degree of deep drawing (drawing ratio)](#/22) * [23/36] [Stretching of the material: wall thickness distribution](#/23) * [24/36] [Comparison of wall thickness distribution in vacuum and overpressure processes without mechanical pre-stretching](#/24) --- #### [go back to the main menu (all lectures)](./../../../../../lectures/html/index.html) --- --- # CONTENT (Cont'ed) --- * [25/36] [Packaging production, filling and sealing in one system](#/25) * [26/36] [Continued in section “forming, filling and sealing machines”](#/26) * [27/36] [Mechanical processes](#/27) * [28/36] [Initial materials](#/28) * [29/36] [In the case of thin foils, the maximum elongation is 3 - 4 %, as the grains are arranged in single layers.](#/29) * [30/36] [Requirements for the plastics used](#/30) * [31/36] [Definitions](#/31) * [32/36] [A: pure aluminium foil 15 µm, soft](#/32) * [33/36] [Mechanical processes](#/33) * [34/36] [3.3. erecting](#/34) * [35/36] [8.2 forming - conclusions](#/35) * [36/36] [Slide 36/36](#/36) --- #### [go back to the main menu (all lectures)](./../../../../../lectures/html/index.html) --- # slide 01/36 ![Slide1.svg](./src_part1/Slide1.svg "slide 1 of 36") note: --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 01/36 | 121398 | 0 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | 160104_TUM_Praesentation_p_v1 | Vide | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # 8 ![Slide2.svg](./src_part1/Slide2.svg "slide 2 of 36") note: ### 8 Mechanical Processes 8.2 Forming processes 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting N.B. Only the forming processes that can be directly integrated into a packaging line are considered in this lecture. --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 02/36 | 121401 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | 160104_TUM_Praesentation_p_v1 | Start | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Forming: Overview of process variants according to degree of pre-processing ![Slide3.svg](./src_part1/Slide3.svg "slide 3 of 36") note: ### Forming: Overview of process variants according to degree of pre-processing Assigning single steps to the packaging process Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr’s GmbH, Hamburg, 2nd Edition, (2014), p. 192 P: package forming filling closing basic forming converting forming filling closing converting filling closing filling closing filling closing wrapping (forming, filling, closing) converting erecting (forming) basic forming basic forming converting packaging processes outside of packaging processes P P P P P P basic forming granules powder granules powder fibres moulded part film, sheet blank article / product --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 03/36 | 121405 | 4 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Mechanical Processes ![Slide4.svg](./src_part1/Slide4.svg "slide 4 of 36") note: ### Mechanical Processes 8.2 Forming Processes 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 04/36 | 121456 | 1 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | 160104_TUM_Praesentation_p_v1 | Start | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Pre-stages for thermoforming ![Slide5.svg](./src_part1/Slide5.svg "slide 5 of 36") note: ### Pre-stages for thermoforming: Extrusion or injection moulding (see also basic lecture: packaging technology - systems) Common feature: Melting of plastic with extrusion screw Injection moulding : Melt flow is injected into cold or tempered moulds and produces preforms . Preforms are further formed into containers by thermoforming in the course of injection blow moulding or stretch blow moulding . Extrusion: T he molten plastic leaves the extruder via a slit die or a ring die and is turned into a film or into a tube (see lecture - Packaging Technology - Systems). The still hot tube is blown into containers via blow moulding . Films are used as semi-finished products for deep drawing of trays, cups etc. 8.2.1 Thermoforming --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 05/36 | 121459 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Principle of injection moulding ![Slide6.svg](./src_part1/Slide6.svg "slide 6 of 36") note: ### Principle of injection moulding 1 screw 2 hopper 3 plastic granules 4 barrel 5 heater bands 6 mould 1 Filling of plastifying unit 2 Plastification 3 Injection Steps after injection: 4 Cooling the melt 5 Opening the mould 6 Ejection of the moulded part Source: Cdang, Brendan Rockey, Unij;kgtjversity of - Alberta Industrial Design - Eigenes Werk, from http://en.wikipedia.org/wiki/File:Injection_molding.png, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=11478077 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 06/36 | 121463 | 7 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Production of preforms by injection moulding ![Slide7.svg](./src_part1/Slide7.svg "slide 7 of 36") note: ### Production of preforms by injection moulding Hot preform is inflated with gas and stretched into the mould Rapid cooling Injection blow moulding : conversion of preforms into containers directly after injection moulding close injection mould preform injection moulding eject close blow mould blow moulding bottle eject Basic forming - Injection moulding Conversion – Blow moulding Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr‘s GmbH, Hamburg, 2nd Edition, (2014), p. 471 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 07/36 | 121473 | 5 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Production of tubes by extrusion ![Slide8.svg](./src_part1/Slide8.svg "slide 8 of 36") note: ### Production of tubes by extrusion Hot tube is squeezed, inflated with gas and stretched into the forming tool Rapid cooling Blow moulding : Conversion of extruded tubes (here: in combination with filling  blow-fill-seal process) plastic tube from extruder blowing unit product filling unit head jaws filled and sealed bottle closing blow mould forming closure of the bottle filling product forming of the bottles opening blow mold Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr‘s GmbH, Hamburg, 2nd Edition, (2014), p. 68 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 08/36 | 121491 | 14 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Delivery of preforms (external producers) ![Slide9.svg](./src_part1/Slide9.svg "slide 9 of 36") note: ### Delivery of preforms (external producers) Heated (well below melting point) preform is inflated with gas and stretched into the mould Rapid cooling Stronger orientation due to the stretching process than via injection blow moulding Higher strength Improved barrier properties Large variety of shapes - Stretch blow molding : conversion of externally produced preforms --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 09/36 | 121508 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Stretch blow molding ![Slide10.svg](./src_part1/Slide10.svg "slide 10 of 36") note: ### Stretch blow molding Mechanical pre-stretching Delayed blowing Cool down - Venting Eject Source: KHS Gruppe --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 10/36 | 121512 | 5 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Mould carriers ![Slide11.svg](./src_part1/Slide11.svg "slide 11 of 36") note: ### Mould carriers --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 11/36 | 121523 | 1 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Example of - Krones Contiform (integrated stretch blow- moulding, filling and closing machine) ![Slide12.svg](./src_part1/Slide12.svg "slide 12 of 36") note: ### Example of - Krones Contiform (integrated stretch blow- moulding, filling and closing machine) --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 12/36 | 121529 | 1 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Conversion of flat semi-finished products - Principle of thermoforming ![Slide13.svg](./src_part1/Slide13.svg "slide 13 of 36") note: ### Conversion of flat semi-finished products Principle of thermoforming - The film is heated to forming temperature (below melting temperature). The film is heated by contact heating and/or radiant heat. Cooling takes place at the wall of the die. Demolding / ejecting is only possible after the temperature has fallen below the freezing temperature and is supported by the shrinkage of the product. --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 13/36 | 121535 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Positive forming ![Slide14.svg](./src_part1/Slide14.svg "slide 14 of 36") note: ### Positive forming - hot forming with mechanical preforming and final forming with vacuum Conversion of flat semi-finished products supply heated film / sheet close mould film / sheet forming via vacuum opening mould lifting plug mechanical pre-stretching of film conveying converted film Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr‘s GmbH, Hamburg, 2nd Edition, (2014), p. 385 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 14/36 | 121539 | 11 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Negative forming ![Slide15.svg](./src_part1/Slide15.svg "slide 15 of 36") note: ### Negative forming - hot forming with mechanical preforming and final forming via vacuum supply heated film / sheet closing mould film forming via vacuum opening mould mechanical pre-stretching of film conveying converted film Tell me the difference between positive and negative forming! Conversion of flat semi-finished products Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr’s GmbH, Hamburg, 2nd Edition, (2014), p. 330 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 15/36 | 121554 | 11 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # The following basic thermoforming methods are available ![Slide16.svg](./src_part1/Slide16.svg "slide 16 of 36") note: ### The following basic thermoforming methods are available: vacuum forming overpressure forming combination of vacuum and overpressure forming punch forming (mechanical pre-stretching) Positive or negative moulds can be used with all methods, whereby negative moulds are mainly used for mass production. These four moulding methods have an influence on the results: Wall thickness distribution Edge sharpness Degree of deep drawing - Thermoforming methods --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 16/36 | 121568 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Overpressure (compressed air) moulding with mechanical pre-stretching without additional material slip into the mould ![Slide17.svg](./src_part1/Slide17.svg "slide 17 of 36") note: ### Overpressure (compressed air) moulding with mechanical pre-stretching without additional material slip into the mould Negative overpressure forming without and with controlled film slip in the mould overpressure - Overpressure (compressed air) forming with mechanical pre-stretching and additional controlled film slip into the mould Source: Weisser, H., Karlsruhe, personal archive --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 17/36 | 121572 | 5 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # The positive moulds are located directly below the film. In contrast to negative forming, packaging with a thick base and [...] ![Slide18.svg](./src_part1/Slide18.svg "slide 18 of 36") note: ### The positive moulds are located directly below the film. In contrast to negative forming, packaging with a thick base and thin edge is more likely to be produced here. Positive forming without mechanical pre-stretching is mainly used for skin packaging, where the product to be packaged is used as the positive form. skin-pack-process: skin pack: Positive forming without mechanical pre-stretching heating forming and sealing vacuum separating Film roll permeable base base film product Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr’s GmbH, Hamburg, 2nd Edition, (2014), pp. 462, 463 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 18/36 | 121580 | 3 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Combination of vacuum negative and positive forming with mechanical pre-stretching ![Slide19.svg](./src_part1/Slide19.svg "slide 19 of 36") note: ### Combination of vacuum negative and positive forming with mechanical pre-stretching Vacuum Source: Weisser, H., Karlsruhe, personal archive --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 19/36 | 121598 | 3 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Commonly used materials for thermoforming are ![Slide20.svg](./src_part1/Slide20.svg "slide 20 of 36") note: ### Commonly used materials for thermoforming are: PS (films) PP (films) PET (increasing, for preforms and films) PVC (decreasing, for preforms and films) PLA (still rare, but increasing, for preforms and films) PEN (rare, for preforms) Special problems: PP Melting range around 150 - 170 °C, but: good temperature resistance, as glass temperature is far below 0 °C PET Melting range well above 200 °C, but: Poor temperature resistance, as glass temperature is about 60 °C Materials --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 20/36 | 121604 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Materials and special problems: Heating to 60 °C ![Slide21.svg](./src_part1/Slide21.svg "slide 21 of 36") note: ### Materials and special problems: Heating to 60 °C PP: remains unchanged PET: right image before, left image after heating --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 21/36 | 121608 | 3 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Achievable degree of deep drawing (drawing ratio) ![Slide22.svg](./src_part1/Slide22.svg "slide 22 of 36") note: ### Achievable degree of deep drawing (drawing ratio) H: D = Height: Diameter S: B = Surface area: Base (initial) area depends on the thermoforming temperature at the corresponding heating time interval and the thermoforming process for a given film material and film thickness. Edge sharpness The edge sharpness is influenced by the flowability of the plastic, the moulding temperature and the moulding process. Wall thickness distribution depending on initial film thickness deep-drawing processes - Characterization of conversion --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 22/36 | 121616 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Stretching of the material: wall thickness distribution ![Slide23.svg](./src_part1/Slide23.svg "slide 23 of 36") note: ### Stretching of the material: wall thickness distribution The more even the stretching, the more stable and impact-resistant is the packaging. The stretching can be made visible by distorting a grid printed on the original film. The distortion also indicates the differences in wall thickness. For example, a pre-stretch punch results in a more even stretch than without. Shaped parts with previously applied marking grid - Evaluation parameters Source: Weisser, H., Karlsruhe, personal archive Source: Fraunhofer IVV, Dresden --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 23/36 | 121620 | 4 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Comparison of wall thickness distribution in vacuum and overpressure processes without mechanical pre-stretching ![Slide24.svg](./src_part1/Slide24.svg "slide 24 of 36") note: ### Comparison of wall thickness distribution in vacuum and overpressure processes without mechanical pre-stretching Comparison of wall thickness distributions Unplasticized PVC d = 250 µm F: initial film thickness M, R, B: different measuring points - Wall thickness / µm Source: Weisser, H., Karlsruhe, personal archive --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 24/36 | 121628 | 4 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Packaging production, filling and sealing in one system ![Slide25.svg](./src_part1/Slide25.svg "slide 25 of 36") note: ### Packaging production, filling and sealing in one system Requirements for this system: As few changes as possible in product and volume. High machine output (mass production) Intermittent film take-off from the roll Lid material: Sealable films plastic laminates Aluminium foil provided with heat-sealing lacquer Option: snap-on lid (not sealing) Advantages: Low personnel requirements Particularly suitable for small portion packaging Better hygiene - Integration of thermoforming into forming, filling and sealing (FFS) systems --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 25/36 | 121639 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Continued in section “Forming, filling and sealing machines” ![Slide26.svg](./src_part1/Slide26.svg "slide 26 of 36") note: ### Continued in section “Forming, filling and sealing machines” Special aspects of thermoforming in guest lecture FFS system, principle, example blister pack Blister pack process: Example of push-through packaging filling forming heating vacuum roll with deep-draw film sealing separating roll with lidding film give off Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr’s GmbH, Hamburg, 2nd Edition, (2014), p. 69 --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 26/36 | 121643 | 13 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Mechanical Processes ![Slide27.svg](./src_part1/Slide27.svg "slide 27 of 36") note: ### Mechanical Processes 8.2 Forming 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 27/36 | 121659 | 1 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | 160104_TUM_Praesentation_p_v1 | Start | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Initial materials ![Slide28.svg](./src_part1/Slide28.svg "slide 28 of 36") note: ### Initial materials: strips / foils from aluminium and steel 3.2. Cold forming https://pixabay.com/de/photos/kaffee-kapsel-kaffeekapsel-3841386/ --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 28/36 | 121662 | 3 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # In the case of thin foils, the maximum elongation is 3 - 4 %, as the grains are arranged in single layers. ![Slide29.svg](./src_part1/Slide29.svg "slide 29 of 36") note: ### In the case of thin foils, the maximum elongation is 3 - 4 %, as the grains are arranged in single layers. In the case of strips, the grains flow along their sliding lines - the stretchability increases. The elongation can be further increased (25-30 %) by bonding the grains to plastic films on one or both sides. Higher elongation can lead to the formation of pores. Al thin strips with a thickness of 220 to 280 µm are used for the manufacture of semi-rigid containers. Influence of laminating on the stretchability of aluminium foils aluminium foil 0.015 mm, annealed as above, stretched, rupture at 3,5 % elongation aluminium foil 0.100 mm, annealed as above, stretched by 20 %, elongation of the grains, no rupture Al-aluminium foil 0.015 mm KL-- laminating adhesive KU- plastic film 0.020 mm as above, stretched by 25 %, elongation of the grains, still poreless (no rupture) Source: modified from Weisser, H., Karlsruhe, personal archive --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 29/36 | 121668 | 9 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Requirements for the plastics used ![Slide30.svg](./src_part1/Slide30.svg "slide 30 of 36") note: ### Requirements for the plastics used: high tensile strength (> 100 N/mm 2), small elongation at break (20-100 %) and heat sealability (applies to the inner layer) Primarily BOPET, BOPP (for the outside) and PE-HD / PE-LD (for the inside) are used. Requirements for lamination plastics for cold forming --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 30/36 | 121680 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Definitions ![Slide31.svg](./src_part1/Slide31.svg "slide 31 of 36") note: ### Definitions : Stress σ : Applied force F divided by initial perpendicular cross section of the sample A, σ = F / A Strain ε : Elongation ∆ L divided by initial length of the sample L 0 ε = ∆ L / L 0 σ B maximum stress σ R tear stress σ S yield stress ε B strain at maximum stress ε R strain at tear ε S yield strain ∆ σ / ∆ ε tangent at small elongations: Young’s modulus Digression: stress- strain diagrams σ R σ B σ R σ R σ S ∆ σ ε R ε R ε B ε S ε R ∆ ε --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 31/36 | 121684 | 14 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # A: pure aluminium foil 15 µm, soft ![Slide32.svg](./src_part1/Slide32.svg "slide 32 of 36") note: ### Load-Strain-Diagrams: Examples Inhaltsplatzhalter 1 L. longitudinal : Laminated film of aluminium foil 15 µm, laminated with two-component adhesive against biaxially stretched PP film, 20 µm, measured in longitudinal direction L. transverse : as above, measured in transverse direction P. longitudinal P. transverse L. longitudinal L. transverse strain / % Force / dN A: pure aluminium foil 15 µm, soft P. longitudinal (- - - -): biaxially stretched PP film 20 µm measured in longitudinal direction P. transverse (- - - -): biaxially stretched PP film 20 µm measured in transverse direction Source: modified from Weisser, H., Karlsruhe, personal archive --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 32/36 | 121701 | 3 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # Mechanical Processes ![Slide33.svg](./src_part1/Slide33.svg "slide 33 of 36") note: ### Mechanical Processes 8.2 Forming 8.2.1 Thermoforming 8.2.2 Cold forming 8.2.3 Erecting --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 33/36 | 121715 | 1 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | 160104_TUM_Praesentation_p_v1 | Start | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # 3.3. Erecting ![Slide34.svg](./src_part1/Slide34.svg "slide 34 of 36") note: ### 3.3. Erecting S tarting materials: Prefabricated blanks, mostly made of cardboard Folding organ: Example folding flap packaging material folding flap bending angles: 90° Folding box: Examples for consumer packaging made of cardboard Design A10.10.03.03 Design A20.20.01.03 Folding flaps and adhesive closure Offset insert flaps inside flap inside flap insert lid (outside flap) outside flap insert flaps base flap base flap Folding box feeder suction cup erecting finger breaking counter-suction unit magazine Modified from - Bleisch G., Langowski H.-C., Majschak J.-P. (Eds.): Lexikon Verpackungstechnik, Behr’s GmbH, Hamburg, 2nd Edition, (2014), pp. 155 (top left), 158 (top right), 157 (bottom) --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 34/36 | 121718 | 24 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # 8.2 Forming - Conclusions ![Slide35.svg](./src_part1/Slide35.svg "slide 35 of 36") note: ### 8.2 Forming - Conclusions Forming before filling can be done with different starting materials or semi-finished products The container / receptactle can be produced directly by basic forming (primary forming, example: injection moulding from plastic granulate) or by conversion from a semi-finished product Forming can take place at elevated temperatures (injection moulding, blow moulding, stretch blow moulding, thermoforming) or at ambient temperatures (cold forming, erecting) Cold forming processes are more difficult to control Semi-finished products are Plastics: film, sheet, preform - Paper / cardboard: web, sheet, blank Metals: foil, sheet --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 35/36 | 121748 | 2 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Inhalt | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) # slide 36/36 ![Slide36.svg](./src_part1/Slide36.svg "slide 36 of 36") note: --- | **name** | **id** | **number of objects** | **date PPTx (name)** | | :--------------: | :--------: | :-------------------: | :-----------------------------: | | slide 36/36 | 121752 | 0 | December 21, 2020 (Specialized_Unit_8_2_Forming_Processes_Langowski.pptx) | | **slide master** | **layout** | **style** | **date of conversion (engine)** | | Inhalt | Vide | | Dec 21, 2020 (extractTXTfromPPT) | content provided AS IS - [report a problem](mailto:olivier.vitrac@agroparistech.fr) --- # Thank you for your attention. --- ### Use this link to go back to the first slides * > [first slide](#/) * > [logo slide](#/1) * > [content slide](#/0/2) * > [title slide](#/2) --- #### report issues to [Olivier Vitrac](mailto:olivier.vitrac@agroparistech.fr) ___ # [go back to the main menu (all lectures)](./../../../../../lectures/html/index.html) ___ > next lecture ___ #### 8.3 Filling processes > * [part 1/1](./../../../../../lectures/html/specialized/S8/U8.3/part1.html) ___