How to determine the specification & maximum stacking allowed for your box ?

The main point of this articles is how to calculate maximum BCT ( Box Compression Test ) value of Box that we must develop and determine maximum stacking allowed for the Box. What is BCT ? BCT is a value that indicating maximum load allowed through the box that can not causing damage for the box. If we fail to calculate it, you will found that any damage happen to your box and any cost will be spent out to solve this problem. By the way, in this articles. we solve it !

Just for information, commonly substance used to packed product like Food & Beverages, Pharmacy, Soap product, Candle product, Tools, etc today is :

Type of single wall :

150K/125M/150K in fact, giving BCT value around 200 kgf

150K/150M/150K

200K/125M/200K

200K/150M/200K in fact, giving BCT value around 220 kgf

Type of double wall :

150K/125Mx3/150K in fact, giving BCT value around 280 kgf

150K/150Mx3/150K

200K/125Mx3/200K

200K/150Mx3/200K in fact, giving BCT value around 330 kgf

and using safety factor like this :

Grade Persentage

More save 50%

Save 45%

Enough save 40%

Risk 30%

High Risk 20% and below

Note : Recommended to use safety factor more than 40% to minimize risk from damage.

What is the main factor that we must prepare to develop Box ?

1. Maximum BCT allowed must be calculated
2. Maximum height of stacking on pallet :

• Depend on the stability of pallet during handling the box
• Maximum height and weight of racking. Commonly max height = 1200 - 1300 mm. Commonly max weight per rack = 1000 kgs / racks for 6 racks in height.

3. Maximum stacking on container, Maximum 2370 mm for either 20 and 40 feets.

Type of joint, commonly used is either gluing, stitching, or combination both of them, giving the similar performance of BCT value. ( Rarely, type of joint from glue stitching increasing the value not more than 25% rather than previous joint like glue or stitching ). The difficulty is to ensure consistency of gluing performance during process making. If You not sure about it, recommended to use type of joint from stitching or glue-stitching ( combination both of them ).

TIPS for YOU !

1. Create a different dimension specially for length and width of your box, so you can LOCK the configuration of your box on pallet that you can maintain your box stable ( not moving ) when handling your product on pallet.
2. Never use type of joint from stitching for packed product like liquid ( Oil, Shampoo, Detergent liquid, etc ). Leakage of the product packed will be happen when metal of stitching opened ( must be closed in normal condition ). Survey said, more than 70 % leakage problem from liquid product happen when we use type of joint from stitching and the metal stitch can not perform in right condition.

For an example : We already develop a new soaps 100g/pcs for packed 100 pcs/box. The inner dimension is 350 x 250 x 150 mm. How to determine the specification of your box ? How to determine the maximum stacking allowed for your box ?

OK,...follow this steps to solve it !

Steps.1 Calculate the weight of product for 100 pcs packed in single box. Note : In this calculation, the weight of packaging box not more significantly rather than weight of product. In this calculation, we assume weight of packaging box below 1000 g, commonly 200 - 400 g/Box. If said, in this case we choose 300 g/Box, then the total weight of box and product is [ (100 x 100 ) + 300 ] = 10,300 g = 10.3 kgs.

Steps.2 If the max height of container 20 & 40 feets is 2370 mm, for this box ( we assume the total height for double wall is height of inner dimension + 13 mm = 150 + 13 = 163 mm ) we can place them up to 14 boxes in height. ( Devide 2370 mm with 163 mm, result is 14.5 .. )

Steps.3 Calculate total weight accumulated for the first layer box.

[ ( 14-1 ) x Total weight of Box and product ]

[ 13 x 10.3 ] = 133.9 kgs.

For safety factor, we choose Grade " Save " 45%, then max bursting strength allowed is total weight accumulated for the first layer box / ( 100% - safety factor )

= 133.9 / ( 100% - 45 % ) = 243.45 = 245 kgf

Steps.4 So, in this case, we choose the specification of box that giving BCT value more than 245 kgf is : 150K/125Mx3/150K ( min 280 kgf ). We can not choose the spect of box from 150K/125M/150K because the value of BCT is around 200 kgf, below 245 kgf.

Steps.5 Maxmum stacking of box on pallet. Commonly, the distance of racking in range 1200 - 1300 mm. If we said for 1200 mm, assume the thickness of pallet = 110 mm, 6 Box maximum with the total height = ( 6 x 163 ) + 110 = 1088 <>

So, the specification of the box for this product is :

Inner dimension : 350 x 250 x 150 mm

Substance : 150K/125Mx3/150K

Gramature : 778.7 gsm ( will be explained more detail on next articles )

Type of joint : Stitching ( Not for Liquid Product )

Flute : BC ( Commonly )

BCT : min 245 kgf.

Don't drink Pepsi in India or Pakistan

Men buying the material to make a PEPSI from public maket

Men at work - washing the bottles

Men at work washing the bottles fully

Boys placing the bottles in the tray

Boys filling The PEPSI, soo......called

Boys filling the PEPSI and checking the air bubles

Boys filling the gas in the bottles

Boys searching for the right caps

Great man capping the bottles

Quality check and SUCCESS

Please forward this mail & picture to as many people as possible !!!...

Next Articles will be ready ... " How to make a security in your packaging and how to check it ! "

and... Don't try this at home !

How to determine maximum diameter & length of Roll Film with core 3 inch using Tim's Diameter Calculation

Why it will be the important things for an Engineer or Packaging Development people ? When an Engineer and Packaging Development people starts to develop a new packaging, there are not enough information about how length of the packaging roll to be determined and how weight of the packaging roll to be determined. In fact, The Packaging Development must optimize the length of the roll film to reduce down time by changes roll and the otherside, not exceed the specification of the packaging machine like a maximum outer diameter unwind unit and maximum load capasity of unwind unit.

Maximum diameter unwind unit is a maximum diameter unwind unit at certain packaging machine that varies from one another to ensure the packaging roll rotate in normal condition at unwind unit.

Maximum load capasity for unwind unit is a maximum load of the packaging material that can handle by unwind unit to ensure no damage happen causing overweight at unwind unit.

If said, Your packaging machine has a maximum diameter unwind unit is 350 mm max and max load for unwind unit is 25 kgs, for an example the packaging material that you must develop having structure like : BOPP20/ink/adh/CPP40, width of film = 160 mm, core 3 inch, thickness of core is 9 mm. From this information, you can determine how length and how weight the roll must be by following this steps and using my formula named TIM'S DIAMETER CALCULATION below.

Step 1. From the structure of film, you can get some information like :

• Total thickness = 20 + 1 + 1 + 40 = 62 microns
• Density of BOPP film = 0.91 g/cm3
• Density of CPP film = 0.91 g/cm3
• Gsm adhesive = 2 gsm ( commonly )
• Gsm ink = 1 - 2 gsm ( commonly ), 2 gsm for Full Block Design
• Weight of core 3 inch ( thickness 9 mm ) = 195 g/100 mm

Step 2. Using my formula to determine maximum length of Roll film allowed :

TIM'S DIAMETER CALCULATION FOR CORES 3 INCH :

Max length(M)={[max.diameter(mm)exp.2 - 8836 /[thickness(microns)x1.274]}

= [(350)exp.2 - 8836]/[62 x 1.274 ]

= 113664 / 78.988

= 1439 meters tolerances 1% in length

So, The Engineer and Packaging Development must determine the length of packaging roll must below 1439 meters, for an example 1300 or 1250 meters/roll.

Steps 3. The next steps is to ensure that the weight of the packaging roll not exceed the max load capasity of unwind unit. For this case, we choose 1250 meters/roll for an example from previous steps. Then, please using this formula :

For film(Kg)=[length(M)xwidth(M)xthickness(microns)xdensity(g/cm3)]/1000

For Adhesive or Ink(Kg)=[length(M)xwidth(M)xGsm(gsm)]/1000

For Cores(g)=using extrapolation for this data :

Weight of core 3 inch ( thickness 9 mm ) = 195 g tolerances 5 % in weight

For this cases :

• For BOPP Film(Kg)= [1250x0.16x20x0.91]/1000 = 3.64 Kg
• For CPP Film (Kg) = [1250x0.16x40x0.91]/1000 = 7.28 Kg
• For Adhesive (Kg) = [1250x0.16x2]/1000 = 0.4 Kg
• For Ink (Kg) = [1250x0.16x2]/1000 = 0.4 Kg

Width of cores must wider than width of film, for this cases 160 - 0 + 2 mm. We choose 162 mm.

• For core (Kg) = [162/100]x195 = 315.9 g = 0.316 Kg
• Total weight (Kg) = 12.04 Kgs

So, The Packaging material roll for 1250 meters can be applied because the weight of the roll = 12.04 Kgs, not exceed the max load 25 kgs, and the maximum outer diameter roll not exceed the maximum outer diameter unwind unit. Good Luck !!

Adding information for density of the packaging material :

Material Density (g/cm3)

Aluminium foil 2.72

PET 1.4

PVC Shrink 1.2

Nylon 1.15

LLDPE 0.92

BOPP 0.91

CPP 0.91

PVdC 1.7

Note : For next articles, I will give another formula to determine the same cases like it, but using different diameter cores such as core 4 inch and 10 inch. Commonly used in Pulp & Paper Industry.

From the author :

Hopefully, this articles usefull for You. Well pleased to sent this FREE information to any people and let Anytime, Anywhere, and Anypeople using this site : http://www.interpak.blogspot.com/ as a references for Packaging & Printing Issues.

Regards,

Mr.Timothy

Marking Code for Plastic part II

This International Code has been made just only for two reason :

• To know the kind of plastic to be used


• To prevent Hazard that happen from uncontrolled using

This International Code has been socialized by The Society of Plastic Industry in 1988 at USA and any other Organization like International Organization for Standardization ( ISO ) has adopted it.


How to check The Code :

1. The Code placed at the bottom of the packaging
   


2. The Code appears as a triangle form



3. There is a number at the center of the triangle



4. There is a type of plastic to be used below the triangle



5. There is a seven number and add with three more number addition, so totally there is a ten number for The Code
   

Properties :

The plastic with This Code number 1 with GREEN color, made from PETE or PET ( Polyethylene Terephthalate )

• PET plastic not stable in warm to hot condition. The skin of Polymer will be damaged and changes to be a Carsinogenic particles that causing a cancer for longterm. Not recommended to be used for warm to hot liquid.


• Transparent appearence, good in clarity
  

Hazards

1. For PET Bottle Plastics not recommended to be re-used. Hazard of Toxic


2. People who works in Plastics Industry specially in PET Plastics must be aware for The Dust of Polymer that carry Anthimony Trioxide particles that hazard for :
   

• Skin irritation and breath respiration system


• For Children, making slow growth till 12 months


• For Women, making unstable for menstruation cycles

Commonly used

• 30% capasity PET plastics in the world used for Platics Bottle


• 60% capasity PET plastics in the world used for Textil
  
  
  
  
  
  
  
  
  

Code number 2 with GREEN color, it's meaning for HDPE ( High Density Polyethylene ) material
Properties :

• Clarity not as good as PET material
• Good in heat resistance
• More stiff and stronger than PET material at the same thickness

Hazards :

Not recommended to re-use because the Anthimony trioxide still released from HDPE resins as long as period of using

Commonly used :

• For milk, water, and any other container for food and drink
• So far, safely for food either in warm condition

Code number 3 with RED color, it's meaning can not recycleable. Code " V " it is meaning for PVC ( Polyvinyl Chloride ) Material.

Properties :

• Good in clarity
• Specifict plastic smell

Hazards :

PVC material contains DEHA that contamined the product packed like food and drink by direct contact through the surface of the PVC film. DEHA melting at -15oC. The product contamined not save for human that causing damage in Kidney, Lever, and any other organ complications.

Commonly used :

For wrapping product ( cling wrap ) such as food wrap, souvenir wrap, PVC Shrink for FMCG Industry, etc.

Code number 4 with GREEN color, it's meaning for LDPE ( Low Density Polyethylene ) material.
Properties :

• Strong
• Clarity not good, rather opact appearence
• Good in flexibility
• Not react with other chemical agent at temperature below 60oC
• Good in water vapor resistance
• Not good in Gas barrier

Hazards :

Not recommended to re-use because the Anthimony trioxide agent still released from LDPE resins as long as period of using.

Commonly used :

For drink and food container

Code number 5 with GREEN color, it's meaning for PP ( Polypropylene ) material

Properties :

• Good in Gas barrier
• Glossy appearence
• Stiff and strong enough
• Good in Fat and oil resistance
• Good in heat resistance

Hazards :

No hazards found, very recommende to use this material to package food and drink product like milk, water, etc. Look for this code below the packaging and ensure it before buy !!

Code number 6 with RED color, it's meaning for PS ( Polystyrene ) material.
Properties :

• Not strong
• Not Stiff
• Unstable material
• Not good in heat resistance

Hazards :

Polystyrene is an aromatic polymer that can release styrene material through direct contact to the food or any other product packaged. You can found styrene also in ciggarete smoke, vehicle smoke, and any construction material building.

Not safe for transmission system for Brain, reproduction organ in women, body growth for children, etc.

Commonly used :

Used as a styrofoam ( food container ), construction material building, etc. This material was founded by Eduard Simon in 1839, Germany.

Note : If there is no code number 6 founded below the packaging, you can identify this kind of material by burn the material and see the flame will give a color yellow-orange.

Code number 7 with RED color with " OTHER " word, it's meaning for four ( 4 ) material category like :

• SAN ( Styrene acrylonitrile )
• ABS ( Acrylonitrile Butadiene Styrene )
• PC ( Poly carbonate )
• Nylon

Properties :

• SAN & ABS good in heat resistance and chemical resistance
• Good in stiffeness
• Good in tensile

Hazards :

• SAN & ABS recommended for food and drink container
• If there " PC " word below the code number 7, not recommended for Food and drink although so many product in the market using this material today. Be Carefull ! ensure not to use this material because causing organ damage in chromosome, sperm, imunity system, etc.

TIPS for YOU !

• This code of material safe for You : Code number 2 , 4 , 5 , and 7 ( SAN & ABS )
• Not recommended to use palstic packaging that using Top print / Surface Print that can contaminate the food and drink packed. Ink produced from mineral and any other heavy metal like Pb ( Lead ), TiO2 ( Titanium Dioxide ) that causing carcynogenic desease.
• Stainless steel container, Glass bottle, plastic bottle code number 4 and 5 safe for Baby milk container
• Plastic nipple made from latex and plastic code number 7 ( PC ) not recommende used for Baby
• Not recommended to keep material plastic with code number 7 ( PC ) in hot condition
• Not recommended to re-use PET and HDPE bottle for longterm using even in cold condition like in refrigerator. Replace with using Glass or Stainless Container
• Not recommended to keep warm the food package inside plastic container using microwave. Recommended using banana leaf to package the product surroundly before placed on the plastic container inside microwave
• Not recommended to use a plastic for food plate. Replace by using Stainless Steel, wood, Glass, and Ceramic plate

What is plastics ?

Plastics is an aromatic polymer that derivaded from Natural Oil. Plastics contain Bisphenol-A, a toxic material that causing damage any organ like breast, lever, kidney, brain, reproduction organ in men and women. University of Missouri has already surveid the market and Bisphenol-A founded in 5 most brand baby milk bottle like : Avent, Dr.Brown's, Evenflo, Gerber, and Playtex !!!

Plastics already consumed more than 100 million tons a year in the world, and Amazed ! more than 95 % of total popularity in the world ever used plastic that contain Bisphenol-A.

There are two kind of plastic in the public market :

• Thermoplastic, this type will be melt in heating
• Thermosetting, this type can not melt even giving heat, and still hard after heating

How plastics influenced your health ?

• PVC plastic has a properties stiff and rigid. To make more soft, any plastic industry giving Plasticizers like ESBO ( Epoxidized Soybean Oil ), DEHA [ di(2-ethylhexyl)adipate ], PCB ( bifenil poliklorin ). Platicizer like PCB already prohibited because causing cancer for human, also for DEHA and ESBO ( commonly used as an additive for insectiside )
• Don't ever burn the plastic specially PVC. The smoke causing infertility for organ production even for men and women.

Marking Code for Plastic part I

Introduction

Packaging plays a vital part in product distribution and is the major factor in ensuring that the quality that is obtained at the end of the production line finishes up in the hands of the ultimate customer.

The importance of packaging in The U.K National Economy may be gauged by the amount spent on packaging materials, which for the year 1979 was more than 4,000 million poundsterling and plastic packaging at the second ranking after Tinplate packaging.

Plastic made from Polymer Group that derivated from Natural Oil, commonly produced in C4, C6, and C8 Carbon Chain Group either for Polyethylene, Polypropylene, Polyester, Polystyrene, Poly Vinyl Chloride, Vinyl, etc.

The Plastic Industry transform a plastic resin ( granula ) to plastic film or moulded form either using Inject Blow Molding or Thermoforming process. Then The Converting Industry using platic film to be laminated with other type of film to increase The Barrier Protection and giving printing to enhance The Selling Performance. Then, The FMCG ( Fast Moving Consumer Goods ) order the kind of packaging according to their needed, and then the product packed come to final users like YOU !

In this articles posted, I will introduce to you How important to know Marking Code for Plastics to prevent Hazards of Plastic Packaging to Your Health.

Please see The Next Pages for details....