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PACKAGING
COS TA LES
LE CHA GO
CRUZ
PA S CUAL
E S CA LANTE
T E ODORO
INTRODUCTION
LECHAGO, HARVEY
Polymer Chemistry
CRUZ, ANTHONY
TYPES OF PLASTIC
Thermoplastics
Thermosetting Plastic
Thermoplastic
is a plastic material, polymer, that becomes pliable or moldable above a specific temperature and
solidifies upon cooling
associate through intermolecular forces, which weaken rapidly with increased temperature, yielding a
viscous liquid
Thermoplastic
2 classifications by structure:
Crystalline Polymers
Amorphous Polymers
Thermoplastic
Crystalline Polymers:
Have a relatively sharp melting point.
Have an ordered arrangement of molecule chains.
Generally require higher temperatures to flow well when compared to Amorphous.
Thermoplastic
Amorphous Polymers:
Thermosetting Plastic
Also known as thermoset
Is a prepolymer material that cures irreversibly
made up of lines of molecules which are heavily cross-linked.
Curing:
Heat (above 200 C)
Chemical reaction
Suitable radiation
Thermosetting Plastic
Curing process:
transforms the resin into a plastic or rubber by a cross-linking process.
Energy and/or catalysts are added that cause the molecular chains to react at
chemically active sites
Thermosetting Plastic
Properties:
Generally stronger than thermoplastic
Suited to high temperature applications
Good chemical resistance
More brittle
Not recyclable
Classifications of Plastics
PVC
Polyethylene Terephthalate
(PET)
The most common thermoplastic polymer
Polyethylene Terephthalate
(PET)
Softdrink, water, mouthwash
bottles
Peanut butter containers
Salad dressing and vegetable oil
container
Polyethylene Terephthalate
(PET)
Condensation Polymerization: esterification
Polyethylene Terephthalate
(PET)
Properties:
Stiffness and strength
Resilient to deformation
Naturally colourless
Lightweight
Fair moisture barrier
Polyethylene
is a thermoplastic polymer consisting of long hydrocarbon chains.
Simplest polymer
Addition polymerization of ethylene CH2= CH2
Variation:
Found in:
Squeezable bottles
Bread, frozen food, dry cleaning
and shopping bags
Polyvinyl Chloride
Third most used kind of plastic
Vinyl Chloride monomer is produced by combining ethylene with Chlorine
Addition polymerization of monomers to PVC
Amorphous structure
Polyvinyl Chloride
Found in:
Polyvinyl Chloride
Properties:
Fire retarding properties
Ignition temperature of 455C
Chemically stable
Resistant to oxidation (durable)
Chemical resistant to almost all chemicals except
for aromatics
Flexible physical properties depending on
additives
Not safe with food use
Polypropylene
Addition polymerization of propylene
One of the most versatile thermoplastic available
commercially
Polypropylene
Found in:
Yogurt containers
Syrup bottles
Ketchup bottles
Caps
Straws
Medicine bottles
Polypropylene
Properties:
Stronger
Stiffer
Harder
High melting point (170C)
Prone to oxidation
Polystyrene
Polystyrene
Found in:
Polystyrene
Properties:
Solid PS is transparent
Hard and brittle
High gas permeability and good water vapor transmission
Chemical resistant to acid and bases
Good insulator
PLASTICS
MANUFACTURING
PASCUAL, JOHN RYAN
TEODORO, AREEYA KYRA
RAW MATERIALS
Resins
Natural Resins
Synthetic Resins
Additives
Plasticizers
Fillers
Stabilizers
Pigments and Dyes
Blowing Agents
Catalysts
Accelerators
Fire-retardants
Anti-oxidants
Resins
-are group of sticky, liquid, organic substances that usually hardens into brittle, amorphous, solid
substances upon exposure to air
-Three classifications:
- Hard Resins
- Oleoresins
- Gum Resins
Resins
Hard Resins
-hard, brittle, odorless, and tasteless resins that exhibit a glasslike fracture
-Ex. Amber, copals, sandarac
Oleoresins
-obtained by distillation of oleoresin turpentine, which is a stick, amorphous semisolids that
contain essential oils.
-Ex. Balsam, Dragons Blood, Copaiba.
Gum Resins
-Mixtures of both true gums and resins
Resins
Petrochemical Resins (synthetic)
Naphtha Cracking
Additives
-are ingredients added to the resin to produce a more stable plastic
Plasticizer
-Plasticizer is the most important additive.
-It is an organic liquid chosen to increase flexibility of the plastic.
Additives
Filler
-Fillers or extenders are added usually to thermosetting plastics to make them less brittle and to
reinforce mechanical strength.
Pigments and Dyes
-Pigments and dyes are added to give color to the plastic.
Additives
Stabilizers
Additives
Fire-retardants
POLYMER SYNTHESIS
Polymerization
-is the process of building up continuous molecular chains from individual identical monomer
units
Addition Polymerization
-Occurs when an unsaturated monomer molecule opens a double/triple bond to free a valence
Condensation Polymerization
-is the process linking up monomer molecules of different compounds that
can result with the loss of some simple molecules like water or HCl
Calendering
Rotational Molding
Film Blowing
Compression Molding
Injection Molding
Casting
Blow molding
Thermoforming
Extrusion
Plastic material as granules, pellets, or powder, is first loaded into a hopper and then fed into a
long heated chamber .
The plastic is melted by the mechanical work of the screw and the heat from the extruder wall.
At the end of the heated chamber, the molten plastic is forced out through a small opening
called a die to form the shape of the finished product.
As the plastic is extruded from the die, it is fed onto a conveyor belt for cooling or onto rollers
for cooling or by immersion in water for cooling.
Extrusion
Calendering
An extension of film extrusion.
The still warm extrudate is chilled on polished, cold rolls to create sheet.
The thickness is well maintained and surface made smooth by the polished rollers.
Calendering is used for high output and the ability to deal with low melt strength.
Calendering
Film Blowing
This process continuously extrudes vertically a ring of semi-molten polymer in
an upward direction.
A bubble of air is maintained that stretches the plastic axially and radially into
a tube many times the diameter of the ring.
The diameter of the tube depends on the plastic being processed and the
processing conditions.
The tube is cooled by air and is nipped and wound continuously as a flattened
tube.
Film Blowing
Injection Molding
This process can produce intricate three-dimensional parts of high quality and great
reproducibility.
It is predominately used for thermoplastics but some thermosets and elastomers are also
processed by injection molding.
In injection molding plastic material is fed into a hopper, which feeds into an extruder.
An extruder screw pushes the plastic through the heating chamber in which the material is then
melted.
At the end of the extruder the molten plastic is forced at high pressure into a closed cold
mold. The high pressure is needed to be sure the mold is completely filled. Once the plastic
cools to a solid, the mold opens and the finished product is ejected.
Injection Molding
Blow Molding
Blow molding is a simple process where compressed air is introduced underneath a warmed
sheet of thermoplastic material forcing the material into a mold cavity, or allowing it to expand
freely into the shape of a hemisphere.
Blow Molding
The beads contain a blowing agent or gas, usually pentane, dissolved in the plastic.
The closed mold is heated to soften the plastic and the gas expands or blowing agent generates
gas.
The result is fused closed cell structure of foamed plastic that conforms to a shape, such as
expanded polystyrene cups.
Used where the article to be made has a narrow neck, such as a bottle.
The plastic material is first extruded as a tube shape into an open die.
The die is then closed to seal the ends of the tube and air is blown in forcing the plastic tube to
take up the shape of the die cavity.
Rotational Molding
Consists of a mold mounted on a machine capable of rotating on two axes simultaneously.
Solid or liquid resin is placed within the mold and heat is applied.
Rotation distributes the plastic into a uniform coating on the inside of the mold then the mold is
cooled until the plastic part cools and hardens.
This process is used to make hollow configurations.
Rotational Molding
Compression Molding
This process has a prepared volume of plastic placed into a mold cavity
A second mold or plug is applied to squeeze the plastic into the desired shape.
Compression Molding
Casting
This process is the low pressure, often just pouring, addition of liquid resins to a mold.
Casting
Thermoforming
Films of thermoplastic are heated to soften the film
Then the soft film is pulled by vacuum or pushed by pressure to conform to a mold or pressed
with a plug into a mold. Parts are thermoformed either from cut pieces for thick sheet or from
rolls of thin sheet.
The finished parts are cut from the sheet and the scrap sheet material recycled for manufacture
of new sheet.
Thermoforming
Rigid Plastic
Packaging
ESCALANTE, JOHN
PET Bottles
Polyethylene terephthalate is used as a raw material for making packaging materials such as
bottles and containers for packaging a wide range of food products and other consumer goods.
Examples include soft drinks, alcoholic beverages, detergents, cosmetics, pharmaceutical
products and edible oils. PET is one of the most common consumer plastics used.
PET Bottles
Advantages
PET Bottles
Recycling
When the PET bottles are returned to an authorized redemption center,
or to the original seller in some jurisdictions, the deposit is partly or fully
refunded to the redeemer. In both cases the collected post-consumer PET is
taken to recycling centers known as materials recovery facilities (MRF) where it is
sorted and separated from other materials such as metal, objects made out of
other rigid plastics such as PVC, HDPE, polypropylene, flexible plastics such as
those used for bags (generally low density polyethylene), drink cartons, glass,
and anything else which is not made out of PET.
PET Bottles
HDPE Packaging
High density polyethylene (HDPE) was first developed for packaging as a
film before being introduced as a bottle for milk in 1964. Its use for packaging has
increased because of its low cost, flexibility, durability, ability to withstand the
sterilizing process, and resistance to many chemicals.
As a food packaging, HDPE is most commonly associated with milk, oil,
and juice bottles. Non-food packaging uses include supermarket bags, cleaning
product containers, motor oil containers, agricultural films and chemical
containers, paper bag liners, bags, crates, drums, and pails.
HDPE Packaging
Plastic Pallets
These are HDPE plastic molds used mainly for storage
and transportation of goods. Plastic pallets can be made
using virgin or recycled resin.
Plastic Crates/Baskets/Bins
Plastic Crates/Baskets/Bins a container used for storage or
shipping of goods
Hand held plastic crates - are high quality stackable/nestable handheld containers that can be
used in supermarkets or your home.
Flexible Plastic
Packaging
COSTALES, ELIJAH
Thick Polyethylene ;
Good barrier against moisture, air and odours;
Stronger, less flexible and more brittle than LDPE;
It has a higher softening temperature (121C);
It is a strong film that gives a strong heat seal
Ability to withstand puncturing, tearing and stretching;
Use as sacks for rough handling;
However, it is more slippery than jute, paper or other natural
fibres
Poor resistance to sunlight
Active packaging
Intelligent packaging
There is continuing research regarding biodegradable/compostable films and the push to make
them more widely available and utilized.
A recent application of foodgrade flavor molecules added to polymer structure has resulted
in the development of a film that releases odors/aromas on the inside or outside of a package
(Byrne).
THANK YOU
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