QUESTION 1 Discuss the corrosion that occurred in plain tin plate. QUESTION 1 Discuss the corrosion occurred: a.

In plain tin plate

Plain tinplate cans are used for specific food types, including tomatoes and other tomatobased products, white fruits and some vegetables. They are used, in preference to lacquered cans. In plain tin plate, there are some interaction between the can and its contents where all food interacts with the internal surface of the can in which they are packed. In plain tinplate containers, this takes the form of etching or pitting corrosion, staining of the surface where this all are occurred. Pitting corrosion is a self nucleating corrodes that started at occluded cells. Pitting also often covers the pits and may form a chimney or structure for venting gas that can contaminate the food in the can. Usually, only the tinplate that has any corrosion resistance to the acids found in foods that were in unlacquered form. By that, even tinplate must be lacquered where particularly aggressive products are packed, such as tomato puree (high acid foods) or where there is a danger of pitting corrosion or surface staining.

Figure 1 - Type of Pitting Corrosion b. Lacquered tinplate

Corrosion can occurred in lacquered tinplate because of the chemical reactions between the metal and the product. Scratch in situations where a small lacquer discontinuity would result in concentrated attack of the base steel (the small area of tin would quickly disappear) and could potentially lead to pin holing and microbial ingress. The presence of lacquer or in other words enamel is a very effectively limits dissolution of tin into the product, and so the use of lacquers is becoming increasingly common, even with those product which were previously packed in plain tinplate cans. There are several different types of lacquer in common use today. As far for nowadays used, Epoxy Phenolic Group are the most common type which are suitable for packing meat, fish, vegetables, and fruit products. These have largely replaced the Oleoresinous group (resin-oil mixture either obtained naturally from plants or produced synthetically), which had a similar wide range of application. Some canners are cans lacquered with the vinyl resins, which have the important quality of being free from any taste and odour, and particularly suitable for dry packs such as biscuits and powders, sometimes also for beverages. White vinyl lacquers have been used where staining of the underlying metal caused by reaction with the product is a problem and by from it also is

used as marketing reasons in order to present a hygienic or clinical appearance and not the aesthetically undesirable corrosion patterns on tinplate. The Organosol (film former contain a dispersion vinyl, resin, plasticizer containing more than 5 percent volatile content and the plastisol to which a solvent has been added) group are also free from any taste or smell behaviour, and have also found applications for beverage cans. In three-piece can, it is often desirable to protect the exposed metal at the side-seam, even if the rest of the inside can body is not to be lacquered and the strips of lacquer sometimes known as the side-stripe. The numbers of the lacquers mentioned above are used for this purpose, but some powdered coatings are also used. Coatings are well screened before release for canned food applications. As part of due to some persistent effort, the coating application and cure conditions have to be strictly support to and full cure regularly confirmed.

QUESTION 2 What factors contributing the corrosion in canned food. Higher concentrations are found in canned foods as a result of dissolution of the tin coating or tin plate. The concentration of tin in canned foods depends on a number of factors, including the type and acidity of the food, time and temperature of storage, and the presence of air in the can headspace. Oxidizing agents such as nitrates and iron and copper salts, certain pigments, and sulphur compounds all accelerate dissolution of tin. Other substances, such as tin salts, sugars, and colloid like gelatin, retard detinning. Lacquering of cans also reduce corrosion and prevent detinning. Tin concentrations in foodstuffs in unlacquered cans frequently exceed 100 g/g, while in lacquered cans, tin levels are generally below 25 g/g. Storing foods in opened unlacquered cans results in substantial increases in the tin concentration of the food. Given all of these factors, it becomes apparent why tin levels found in canned foods are quite variable.

QUESTION 3 Discuss briefly two principal methods of forming the seamless aluminium steel a. Draw & Redraw Process (DRD) DRD is another technique to make two-piece cans. Results in thicker bodies suitable e.g. for retorted foods. In the art container production, it is known to form containers by utilizing a first forming member which performs what is called the draw to preliminary form a blank of metal into a cup-shaped configuration followed by the utilization of a second forming member to perform what is called the redraw operation to reduce the container to its final configuration. Precoated, laminated and printed tinplate or TFS is fed in sheet or coil form in a reciprocating press that may have single or multiple tools. At each tool station the press cycle cuts a circular disc (blank) from the metal and whilst in the same station draws this in to a shallow can (cup).

During the drawing process the metal is reformed from flat metal into a threedimensional can without changing the metal thickness at any point. After this single draw, the can may be already at its finished dimension. However, by passing this cup through a similar process with different tooling, it may be redrawn into a can of smaller diameter and greater height to make a drawredraw can (DRD). This process may be repeated once more to achieve the maximum height can. At each of these steps, the can base and wall thickness remain effectively unchanged from that of the original flat metal. One advantage of twopiece cans is that there is only one can end instead of two, meaning that one major critical control hazard point is eliminated.

Figure 2: Two-piece drawn cans form.

A disk of metal is formed into a shallow cup using the process described above.

The cup is then pushed through several other dies by a series of pistons. Each die and piston set is slightly smaller in diameter than the previous one, so that the sidewalls are stretched out and become thinner.

The top of the can is then trimmed and flanged and shipped to the customer.

The can end is manufactured in a separate stamping process and sent to the customer

In the draw-redraw process, the gauge of the bottom and side wall of the finished container is essentially the same as the starting gauge of the metal sheet. As a consequence, the can is stronger with a maximum ratio of height to diameter ratio of about 2:1 while the maximum for a D&I can is about 1.5:1.

b.

Draw and wall iron process(DWI) The DWI cans are constructed from uncoated tinplate or aluminum. However, DWI cans for processed food are only made from tinplate as thin wall aluminum

cans do not have sufficient strength to withstand the heat process cycles. For this process, the coiled metal, as it is unwound, is covered with a thin film of watersoluble synthetic lubricant before being fed continuously into a cupping press. This machine blanks and draws multiple shallow cups for each stroke, as described under the section entitled Drawn cans above.

The cups are then fed to parallel body-making machines which convert the cups into tall cans. This is the drawing and ironing process where the cups are first redrawn to the final can diameter and then rammed through a series of rings with tungsten carbide internal surfaces which thin (iron) the can walls whilst at the same time increasing the can height. During this process the can body is flooded with the same type of lubricant used in the cupping operation. In addition to assisting the ironing process, the lubricant cools the can body and flushes away any metallic debris. No heat is applied to the can during this process any heat generated being from the cold working of the metal as it is thinned. After the forming of the can body the uneven top edge of the can is trimmed to leave a clean edge and a can of the correct overall height. Trimmed can bodies are passed through chemical washers and then dried. This process removes all traces of lubricant and prepares the metal surfaces for internal and external coating and ultimately external decoration (drink cans only).

Figure 3: Two-piece drawn and wall ironed (DWI) can forming.

DWI is a technique to make two-piece cans which results in light-weight cans e.g. for beverages.

A disk of metal is formed into a shallow cup using the process described above.

The cup is then pushed through several other dies by the piston. Each die is slightly smaller in diameter than the previous one, so that the sidewalls of the cup are stretched out and become thinner. Since the cup is held on the original punch, or one just like it, the inside dimension remains constant during this process.

The top of the can is then trimmed and flanged and shipped to the customer. The can end is manufactured in a separate stamping process and sent to the customer.

The draw and iron process is used almost exclusively to make cans for carbonated beverages. The internal pressure of the carbonated beverage gives the cans rigidity and stacking strength. The walls are too thin to withstand the pressure and vacuum created during the processing of food products.