Towards a bottle weight reduction - Evaluation in a selected milk plant in the United Kingdom
Författare
Summary, in English
The United Kingdom is one of the biggest milk producers in the world. The dairy
market is a competitive industry where cost is a driving force. Milk is considered a day-to-day product in this country, packaged primarily in HPDE bottles. The need for a cost effective product is driving companies to seek for alternative packaging solutions.
The thesis is focused on the weight reduction of a HDPE bottle in a selected
production milk plant. The achievement of this reduction has a direct implication
on material cost and environmental impact. A study of the different milk bottles on the market is included, evaluating designs and materials.
Five different tests are used for studying the standard and light weight bottle. In addition, the performance of the standard bottle in the milk production plant was assessed, identifying the critical points in the line.
An initial trial was carried out on the blow molding equipment that allowed the
evaluation the bottles properties. The data obtained in this thesis allows
proceeding with a weight reduction trial and provides the necessary information
for comparing with the standard bottle.
Different materials and technologies were investigated as possible alternatives for cost reduction. Results from these investigations provide a frame for further study, where it is necessary to further assess the cost implications and its feasibility.
market is a competitive industry where cost is a driving force. Milk is considered a day-to-day product in this country, packaged primarily in HPDE bottles. The need for a cost effective product is driving companies to seek for alternative packaging solutions.
The thesis is focused on the weight reduction of a HDPE bottle in a selected
production milk plant. The achievement of this reduction has a direct implication
on material cost and environmental impact. A study of the different milk bottles on the market is included, evaluating designs and materials.
Five different tests are used for studying the standard and light weight bottle. In addition, the performance of the standard bottle in the milk production plant was assessed, identifying the critical points in the line.
An initial trial was carried out on the blow molding equipment that allowed the
evaluation the bottles properties. The data obtained in this thesis allows
proceeding with a weight reduction trial and provides the necessary information
for comparing with the standard bottle.
Different materials and technologies were investigated as possible alternatives for cost reduction. Results from these investigations provide a frame for further study, where it is necessary to further assess the cost implications and its feasibility.
Summary, in English
Weight reduction is becoming an essential activity in the dairy industry, due to the rise in polymer prices. In order to reduce the cost, 10% weight reduction was evaluated in HDPE bottles for pasteurized milk.
A trial in the extrusion blow molding process was carried out. However, for understanding the effect of the weight reduction not only the bottle making process must be studied, but also the routes that the bottles do once they are produced until they reach consumers. Different characteristics were evaluated, such as the ability to withstand free-falls when consumers drop the bottles at home or the applied compression forces during transportation. These values are also related to the forces that the bottle must resist in the different stations at the dairy. The results of this study were positive; only thickness values were compromised in the top part of the bottle.
But, what happen with the rest of the bottles on the market?
Although pasteurized milk is a highly consumed product there is a lack of innovation in the market; two designs are mainly used (ECO and Infini). Other bottles present different characteristics depending on the product requirements. In the case of Extended Shelf Life products titanium dioxide, a compound that avoids light oxidation is added. Moreover, for ensuring a complete cleaning, wider designs are available. Clear PET is also used allowing consumers to see the products and for differentiating among competitors.
Polymer’s prices are increasing, so why don’t use another polymer that can reduce the cost?
PET is 22% cheaper than HDPE, however, is not possible to produce a handle with a conventional injection blow molding system. Similar resins have been developed such as PETG or EPET that can create a handle in the design. Also, other alternative technologies to extrusion blow molding such as compression (stretch) blow forming, Liquiform or the use of foam structures, can potentially reduce the cost. Nevertheless, the majority of these technologies are in the early stages of development, so you should not lose track of them!
A trial in the extrusion blow molding process was carried out. However, for understanding the effect of the weight reduction not only the bottle making process must be studied, but also the routes that the bottles do once they are produced until they reach consumers. Different characteristics were evaluated, such as the ability to withstand free-falls when consumers drop the bottles at home or the applied compression forces during transportation. These values are also related to the forces that the bottle must resist in the different stations at the dairy. The results of this study were positive; only thickness values were compromised in the top part of the bottle.
But, what happen with the rest of the bottles on the market?
Although pasteurized milk is a highly consumed product there is a lack of innovation in the market; two designs are mainly used (ECO and Infini). Other bottles present different characteristics depending on the product requirements. In the case of Extended Shelf Life products titanium dioxide, a compound that avoids light oxidation is added. Moreover, for ensuring a complete cleaning, wider designs are available. Clear PET is also used allowing consumers to see the products and for differentiating among competitors.
Polymer’s prices are increasing, so why don’t use another polymer that can reduce the cost?
PET is 22% cheaper than HDPE, however, is not possible to produce a handle with a conventional injection blow molding system. Similar resins have been developed such as PETG or EPET that can create a handle in the design. Also, other alternative technologies to extrusion blow molding such as compression (stretch) blow forming, Liquiform or the use of foam structures, can potentially reduce the cost. Nevertheless, the majority of these technologies are in the early stages of development, so you should not lose track of them!
Avdelning/ar
Publiceringsår
2017
Språk
Engelska
Fulltext
Dokumenttyp
Examensarbete för masterexamen (Två år)
Ämne
- Technology and Engineering
Nyckelord
- pasteurised milk
- milk packaging
- HDPE bottles
- Light weight
- PET bottles
Handledare
- Märit Beckeman
ISBN/ISSN/Övrigt
- ISBN: 978-91-7753-355-9