Beverage Can Makers Europe

Stress Corrosion - Technical Bulletin

Beverage Can Makers Europe Stress Corrosion-Technical Bulletin

The recommendations following have been
formulated to minimise the risk of stress corrosion
on aluminium easy open ends used in the packaging
of beverages in aluminium and steel 2 piece
beverage cans.

January 2004
1

Background

Recommendations

Under normal conditions of use, aluminium alloy beer and beverage Ends perform without any

BCME strongly recommend that the following precautions be taken to minimise the risk of

issues however, under certain filling and storage conditions external corrosion takes place in

stress corrosion:

the score area of the End that causes premature opening of the score panel. The cause of this
failure is commonly referred to as stress corrosion, but is otherwise known as (TGSC)

Post Seamer Rinsing

The Can and End should be thoroughly rinsed after seaming to remove any product or

Trans-granular Stress Corrosion.

process residues. The rinse water supply should ideally be electrically interlocked to the
Seamer so that the line cannot run without rinse water sprays being operational.

Stress corrosion typically takes place in products packed in shrink-wrap packaging during
storage in warehouses, but can also occur in non shrink-wrapped packages. The risk of stress
corrosion rises dramatically in hot and humid climates typically +30deg. C and humidity +60%

Note: Conveyor/Track lubricant (soap) and/or product carryover to the warmer water, can

relative humidity (rh). Depending upon conditions, described later, failure can occur in a matter

contribute to corrosion. Build up of these contaminants in the water can be prevented by

of days or take several months.

efficient rinsing prior to entry.

Visible tab staining can be an indicator to the presence of stress corrosion even though the

Can Warmer/Pasteuriser

corrosion mechanism may not yet have developed to the point where the score panel has

The use of a can warmer/pasteuriser is recommended to ensure that the product temper-

opened.

ature at the time of secondary packaging is above the dew point. This will help prevent
condensation from forming on the Cans and Ends during subsequent warehousing. The

For the better understanding of stress corrosion, please refer to the illustrations at the end of

presence of salts such as Chlorates and Sulphates accelerate the stress corrosion

this bulletin.

process therefore management and analysis of the water quality in this area is essential.

Cause and Result

Can & End Rinsing

The corrosion takes place in the score area of the End due to the presence of moisture and

Regardless of whether the filled Can has been through a can warmer/pasteuriser both the

the resultant chemical reaction with the aluminium alloy. The ongoing corrosion occurs at the

Can body and End must be thoroughly rinsed prior to secondary packaging to remove

base of the score, weakening the residual metal. This corrosive weakening together with the

any salts, track lubricant etc.

internal Can pressure and the inherent stress created within the End during manufacture,

This should ideally take place as near as possible to the secondary packaging station but

causes the premature opening of the score panel. The corrosion process is greatly accelerated

immediately prior to the Can & End drying station.

by the increased presence of salts (chlorides and sulphates / halides) which can remain on the
End or be present in any residual rinse water after inadequate drying of the Can body and End.

Failure of one can in a shrink-wrapped pack will normally release moisture and consequently

The Cans and Ends should always be rinsed in single file.

It is recommended that the rinsing takes place on the final can twist prior to the drying
station via fan type nozzles, ensuring that no contaminants remain on the Can or End.
The rinser sprays should ideally be electrically interlocked to the can conveyor control
so that if the rinser is not operational the conveyor will not run.

initiate corrosion in the remaining cans within the pack.

If it is necessary to use track lubricants these should have low chloride/sulphate levels
and be minimally applied at all times.

The concentration level of track lubricant should be minimised and controlled on an

ongoing basis plus ideally interlocked with line controls to prevent excessive foaming.

Background

Recommendations

Under normal conditions of use, aluminium alloy beer and beverage Ends perform without any

BCME strongly recommend that the following precautions be taken to minimise the risk of

issues however, under certain filling and storage conditions external corrosion takes place in

stress corrosion:

the score area of the End that causes premature opening of the score panel. The cause of this
failure is commonly referred to as stress corrosion, but is otherwise known as (TGSC)

Post Seamer Rinsing

The Can and End should be thoroughly rinsed after seaming to remove any product or

Trans-granular Stress Corrosion.

process residues. The rinse water supply should ideally be electrically interlocked to the
Seamer so that the line cannot run without rinse water sprays being operational.

Stress corrosion typically takes place in products packed in shrink-wrap packaging during
storage in warehouses, but can also occur in non shrink-wrapped packages. The risk of stress
corrosion rises dramatically in hot and humid climates typically +30deg. C and humidity +60%

Note: Conveyor/Track lubricant (soap) and/or product carryover to the warmer water, can

relative humidity (rh). Depending upon conditions, described later, failure can occur in a matter

contribute to corrosion. Build up of these contaminants in the water can be prevented by

of days or take several months.

efficient rinsing prior to entry.

Visible tab staining can be an indicator to the presence of stress corrosion even though the

Can Warmer/Pasteuriser

corrosion mechanism may not yet have developed to the point where the score panel has

The use of a can warmer/pasteuriser is recommended to ensure that the product temper-

opened.

ature at the time of secondary packaging is above the dew point. This will help prevent
condensation from forming on the Cans and Ends during subsequent warehousing. The

For the better understanding of stress corrosion, please refer to the illustrations at the end of

presence of salts such as Chlorates and Sulphates accelerate the stress corrosion

this bulletin.

process therefore management and analysis of the water quality in this area is essential.

Cause and Result

Can & End Rinsing

The corrosion takes place in the score area of the End due to the presence of moisture and

Regardless of whether the filled Can has been through a can warmer/pasteuriser both the

the resultant chemical reaction with the aluminium alloy. The ongoing corrosion occurs at the

Can body and End must be thoroughly rinsed prior to secondary packaging to remove

base of the score, weakening the residual metal. This corrosive weakening together with the

any salts, track lubricant etc.

internal Can pressure and the inherent stress created within the End during manufacture,

This should ideally take place as near as possible to the secondary packaging station but

causes the premature opening of the score panel. The corrosion process is greatly accelerated

immediately prior to the Can & End drying station.

by the increased presence of salts (chlorides and sulphates / halides) which can remain on the
End or be present in any residual rinse water after inadequate drying of the Can body and End.

Failure of one can in a shrink-wrapped pack will normally release moisture and consequently

The Cans and Ends should always be rinsed in single file.

It is recommended that the rinsing takes place on the final can twist prior to the drying
station via fan type nozzles, ensuring that no contaminants remain on the Can or End.
The rinser sprays should ideally be electrically interlocked to the can conveyor control
so that if the rinser is not operational the conveyor will not run.

initiate corrosion in the remaining cans within the pack.

If it is necessary to use track lubricants these should have low chloride/sulphate levels
and be minimally applied at all times.

The concentration level of track lubricant should be minimised and controlled on an

ongoing basis plus ideally interlocked with line controls to prevent excessive foaming.

All evidence of track lubricant on the Can/End must be removed at the final rinse station.

The rinse water ideally should have a pH between 6 and 8.0.

Chloride levels should be <10p.p.m and Sulphates and Nitrates<15p.p.m.

ease of inspection. Filled product should be inspected on a regular basis and any pallets

Where water treatment is required water softening by reverse osmosis is the preferred

showing evidence of leakage should be removed immediately. As far as is possible, tem-

option.

perature variations within the warehouse should be avoided.

Regular checks on water quality should be maintained at this critical application point.
7

Storage
Pallets of filled product should be stored in a manner that allows good air circulation and

Treatment of filled Product affected by Stress Corrosion

Can & End Drying

All packs containing any End (single or multiple quantities) with blown score panels

The objective is to achieve zero residual moisture on the Can and End after the drying

should be removed and the entire pack scrapped, along with any other affected stock.

operation and prior to secondary packaging. This applies in particular to the End and
Do not attempt to salvage any wet cans as it is a recognised fact that these cans,

most importantly its score area.

due to product contamination leading to secondary corrosion, have a high risk

themselves of leaking at a future date.

Score Corrosion does not occur on dry Ends.

The Cans and Ends should always be dried in single file. This is more effective than
mass drying.

Transportation of filled Product

The dryer should be electrically interlocked to the can conveyor control so that if

Pallets should be transported so that there is adequate ventilation and room for air

the dryer is not operational the conveyor will not run.

circulation. Use of block stacking in containers is not recommended.

It is strongly recommended that the efficiency of dryers is checked routinely (see: test
Method for Assessing the Dryness of Can Ends).

These guidelines are intended to help minimise the risk of secondary corrosion

It is also recommended that the dryer is subject to an effective maintenance pro-

occurring. For further help and guidance please contact your BCME members

gramme to maintain its optimum performance.

Customer Technical Service Department.

BCME consider that Can and End drying is a critical element of the beverage
filling operation.

The responsibility for adequate Can and End drying rests with the filler.

Secondary Packaging
Existing and future secondary packaging developments must be reviewed in conjunction
with any additional actions required at the filling plants to minimise the risk of stress
corrosion.

Perforated shrink film will help any moisture to evaporate as will vent holes at the end
of each pack.

The use of board packaging will help absorb retained moisture further minimising the
risk of stress corrosion.

The use of plastic packaging without any cardboard will increase the risk of stress
corrosion.

All evidence of track lubricant on the Can/End must be removed at the final rinse station.

The rinse water ideally should have a pH between 6 and 8.0.

Chloride levels should be <10p.p.m and Sulphates and Nitrates<15p.p.m.

ease of inspection. Filled product should be inspected on a regular basis and any pallets

Where water treatment is required water softening by reverse osmosis is the preferred

showing evidence of leakage should be removed immediately. As far as is possible, tem-

option.

perature variations within the warehouse should be avoided.

Regular checks on water quality should be maintained at this critical application point.
7

Storage
Pallets of filled product should be stored in a manner that allows good air circulation and

Treatment of filled Product affected by Stress Corrosion

Can & End Drying

All packs containing any End (single or multiple quantities) with blown score panels

The objective is to achieve zero residual moisture on the Can and End after the drying

should be removed and the entire pack scrapped, along with any other affected stock.

operation and prior to secondary packaging. This applies in particular to the End and
Do not attempt to salvage any wet cans as it is a recognised fact that these cans,

most importantly its score area.

due to product contamination leading to secondary corrosion, have a high risk

themselves of leaking at a future date.

Score Corrosion does not occur on dry Ends.

The Cans and Ends should always be dried in single file. This is more effective than
mass drying.

Transportation of filled Product

The dryer should be electrically interlocked to the can conveyor control so that if

Pallets should be transported so that there is adequate ventilation and room for air

the dryer is not operational the conveyor will not run.

circulation. Use of block stacking in containers is not recommended.

It is strongly recommended that the efficiency of dryers is checked routinely (see: test
Method for Assessing the Dryness of Can Ends).

These guidelines are intended to help minimise the risk of secondary corrosion

It is also recommended that the dryer is subject to an effective maintenance pro-

occurring. For further help and guidance please contact your BCME members

gramme to maintain its optimum performance.

Customer Technical Service Department.

BCME consider that Can and End drying is a critical element of the beverage
filling operation.

The responsibility for adequate Can and End drying rests with the filler.

Secondary Packaging
Existing and future secondary packaging developments must be reviewed in conjunction
with any additional actions required at the filling plants to minimise the risk of stress
corrosion.

Perforated shrink film will help any moisture to evaporate as will vent holes at the end
of each pack.

The use of board packaging will help absorb retained moisture further minimising the
risk of stress corrosion.

The use of plastic packaging without any cardboard will increase the risk of stress
corrosion.

Test Method for Assessing the Dryness of Can Ends

Recommended Operating Standard
1

Equipment required:
1
2

A balance that is accurate and repeatable to at least 0.001g.

Target average less than 3mg per End

Air tight containers and swabs.

Either

a Sterilin tubes and cotton wool buds

or

b Sealable polythene bags and filter papers

Single End - 9mg or greater

Establish cause & rectify.

Recheck to ensure standard is achieved

4 can average - 7 mg or greater per End

2

Action

Establish cause & rectify.

Recheck to ensure standard is achieved

Test Procedure:
1

Weigh swabs in the sealed containers to an accuracy of 0.001g. Record the weights.

Take samples from the line directly after the dryers and swab immediately.

Visual checks should be carried out on an ongoing basis to verify drying performance is

Carefully use the swab to remove all residual water from each individual End,

maintained.

including under the tab and in the countersink and score.

Reseal the swab into the container.

Reweigh container and swab. Record the weights.

The difference in weight is taken as the amount of moisture remaining on the End.

Test Frequency
Recommended daily, but should be continually reviewed depending on consistency
of results and process capability.

Points to note:
1

The time between sampling and testing should be kept to a minimum.

If drying in single lane, take 4 samples from each lane.

If drying in bulk, take 4 samples evenly across the belt.

Prevention of contamination of the items to be weighed is important to avoid

spurious results.

The swabs should be out of containers for the minimum time between taking
weights to prevent moisture pick up / loss.

Standard to be achieved:
The objective is to achieve zero residual moisture on the Ends but the following is an
achievable minimum practical operating standard, based on available modern equipment.
It is recommended that this specification is used when purchasing new drying equipment.

Test Method for Assessing the Dryness of Can Ends

Recommended Operating Standard
1

Equipment required:
1
2

A balance that is accurate and repeatable to at least 0.001g.

Target average less than 3mg per End

Air tight containers and swabs.

Either

a Sterilin tubes and cotton wool buds

or

b Sealable polythene bags and filter papers

Single End - 9mg or greater

Establish cause & rectify.

Recheck to ensure standard is achieved

4 can average - 7 mg or greater per End

2

Action

Establish cause & rectify.

Recheck to ensure standard is achieved

Test Procedure:
1

Weigh swabs in the sealed containers to an accuracy of 0.001g. Record the weights.

Take samples from the line directly after the dryers and swab immediately.

Visual checks should be carried out on an ongoing basis to verify drying performance is

Carefully use the swab to remove all residual water from each individual End,

maintained.

including under the tab and in the countersink and score.

Reseal the swab into the container.

Reweigh container and swab. Record the weights.

The difference in weight is taken as the amount of moisture remaining on the End.

Test Frequency
Recommended daily, but should be continually reviewed depending on consistency
of results and process capability.

Points to note:
1

The time between sampling and testing should be kept to a minimum.

If drying in single lane, take 4 samples from each lane.

If drying in bulk, take 4 samples evenly across the belt.

Prevention of contamination of the items to be weighed is important to avoid

spurious results.

The swabs should be out of containers for the minimum time between taking
weights to prevent moisture pick up / loss.

Standard to be achieved:
The objective is to achieve zero residual moisture on the Ends but the following is an
achievable minimum practical operating standard, based on available modern equipment.
It is recommended that this specification is used when purchasing new drying equipment.

Fig.1:

Typical configuration of Stay-on-Tab Easy-Open-End and Score

Fig.2:

Environmental Stress Crack Development in Aluminium End Score

Score region shown in Figure 2

Score Residual Thickness

Material Thickness

Figure 1a

Figure 1b

EO End Exterior Plan View

Scored Region

Environmental stress crack showing typical branching progressing from pit beneath score
exterior. Secondary sites of corrosion and crack development are present at the left-hand
edge of the score. Field of view width = 200m.

Material Thickness

Score Residual Thickness

Section B - B
Figure 1c
Score Section profile

Fig.1:

Typical configuration of Stay-on-Tab Easy-Open-End and Score

Fig.2:

Environmental Stress Crack Development in Aluminium End Score

Score region shown in Figure 2

Score Residual Thickness

Material Thickness

Figure 1a

Figure 1b

EO End Exterior Plan View

Scored Region

Environmental stress crack showing typical branching progressing from pit beneath score
exterior. Secondary sites of corrosion and crack development are present at the left-hand
edge of the score. Field of view width = 200m.

Material Thickness

Score Residual Thickness

Section B - B
Figure 1c
Score Section profile

Fig. 3:

Environmental Stress Cracking: Fracture Surface of Aluminium End Score

Fig. 5:

Fracture of Aluminium End Score Physically Induced by Pressurising to

Bursting Strength

Top of score
residual

Top of score
residual

Secondary
cracks
Fan shaped

Ductile cups

cleavage cracks

and cones
visible

Inside edge of
score residual
Environmental stress cracking: Surface of score residual fracture showing fan shaped
cleavage cracks. Secondary cracks typical of environmental stress cracking are also visible.
Field of view width = 230m.
Fig. 4:

Fracture of Aluminium End Score Showing Fatigue Effects

Top of score

Inside edge of
score residual

Fracture surface of unused aluminium end score blown under pressure showing ductile
cup/cone physical failure effects. Field of view width ~190m.
Fig. 6:

Tab staining on Ends affected by Stress Corrosion

Typical unlacquered Tab

residual

Striations

Inside edge of
score residual

Fracture surface of aluminium end score showing horizontal striations indicating fatigue
effects. Field of view width = 180m.
10

11

Fig. 3:

Environmental Stress Cracking: Fracture Surface of Aluminium End Score

Fig. 5:

Fracture of Aluminium End Score Physically Induced by Pressurising to

Bursting Strength

Top of score
residual

Top of score
residual

Secondary
cracks
Fan shaped

Ductile cups

cleavage cracks

and cones
visible

Inside edge of
score residual
Environmental stress cracking: Surface of score residual fracture showing fan shaped
cleavage cracks. Secondary cracks typical of environmental stress cracking are also visible.
Field of view width = 230m.
Fig. 4:

Fracture of Aluminium End Score Showing Fatigue Effects

Top of score

Inside edge of
score residual

Fracture surface of unused aluminium end score blown under pressure showing ductile
cup/cone physical failure effects. Field of view width ~190m.
Fig. 6:

Tab staining on Ends affected by Stress Corrosion

Typical unlacquered Tab

residual

Striations

Inside edge of
score residual

Fracture surface of aluminium end score showing horizontal striations indicating fatigue
effects. Field of view width = 180m.
10

11

12