METAL CONTAINERS

2nd Semester
Post Graduate Diploma in Packaging

31st January 2018

 Scope
 Packaging Fundamentals
 History of Development of Tin Mill Products & Metal
Containers
 Manufacture of Metal Packaging Substrates
 Manufacture of Tin Mill Products
 Manufacture of Aluminum
 Conversion of Metal Substrates
 Lacquering & Printing of Metal Substrates
 Manufacture of Metal Containers
 Testing / Inspection of Metal Containers
 Can Defects
 End Uses of Metal Containers
 Metal Protection
A Mid Term Class Test will be held after completion of “ Manufacture of Metal
Packaging Substrates”
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PACKAGING FUNDAMENTALS

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 Classification of Packaging Types

 Function Based
 Primary
 Secondary

 Tertiary

 Form Based
 Rigid
 Flexible
 Foil

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 Function Based Classification
 Primary Packaging
 First Layer that holds the product – in direct contact with
content
 Smallest Unit of Distribution

Metal
- Mostly used for Primary Packaging
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 Function Based Classification
 Secondary Packaging
 Outside the Primary package
 Used for grouping Primary packages together

Metal
- Limited Use for Secondary Packaging
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 Function Based Classification
 Tertiary Packaging
 Facilitates ware house storage
 Used for bulk transportation

Metal
- Very limited application in Tertiary Packaging
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 Form Based Classification
 Rigid Packaging
 Used for Primary, Secondary & Tertiary Packaging
 Flexible Packaging
 Used mainly for Primary Packaging
 Foil Packaging
 Used in combination in Primary Packaging or as
Secondary Packaging
Rigid Flexible Foil

Metal
– Used in all 3 forms
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 Packaging – Basic Needs

 Containment
 Contain a specified quantity of the content
 Permit easy filling of the content
 Ensure integrity of the container after filling
 Portion Control

 Protection
 Leak Proof
 Tamper Resistant / Tamper Evident
 Suitability for Storage conditions

All Packaging forms need to address these

Hygiene Needs
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 Packaging – Basic Needs

 Shelf Life
 Compatibility with Content
 Barrier properties to prevent Corrosion

 Convenience
 Ease in Handling / Storage
 Ease of Opening & Dispensing – Safety / Wastage
 Features facilitating re-closability & reuse of containers
 Ease of disposal & recycling of used containers

Key requirements for

Consumer Satisfaction
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 Packaging – Basic Needs

 Logistic Friendly
 Ease of Warehousing
 Transport worthy

 Visual Communication
 Aesthetics
 Branding
 Content information

Key enablers for

Marketing Packaged Products
Marketing 11
 Packaging – Emerging Imperatives

 Adaptability to Smart Packaging

 Active Packaging – actively interacts with contents to
extend its life while maintaining quality
 Intelligent Packaging – monitors the condition of contents
& gives information on the quality of contents using
sensors & indicators
Active Intelligent

• Oxygen Scavenging • Time – temperature history

• Anti – microbial
• Ethylene Scavenging
• Heating / Cooling
• Odour / Flavour absorbing or
Releasing
• Moisture absorbing
• Microbial growth indication
• Light protection (photochromic)
• Physical shock indication
• Leakage / microbial growth
indication
• Traceabilty / pilferage alert

Enablers to address
Consumers’ increasing health & well being concerns
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 Packaging – Emerging Trends

 Eco Efficiency
 Degradability  Global warming potential
 Eco Toxicity  Ozone depletion potential

Environmental Concerns will be a key factor in

Selection of future packaging options
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 Packaging – Emerging Imperatives

 Future priorities for

spend in packaging

• Design

• Branding

• Environmental
credentials

• Sustainability

Packaging Options / Forms with lowest cost in promoting

these parameters will have competitive edge
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 Packaging –Emerging Imperatives

 Sustainability

Focus Areas in
New Packaging Standards
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 Packaging Standards

ISO 18601 ISO 18602

Packaging – General Requirements Packaging – General Requirements
for the use of Standards in the field of for the use of Standards in the field of
Packaging & Environment Packaging & Environment OPTIMISE/
Evaluation of the Packaging for REDUCE
 Heavy Metals : Annex C
 Dangerous Substances : Annex D
ISO 18604
Packaging – Packaging Recoverable
by Material Recycling RECYCLE/ REUSE
RECOVER
ISO 18605 ISO 18603
Packaging – Packaging Recoverable Recovery Decision Reuse Packaging
by Energy Recovery Reuse

ISO 18606 End of Functional

Packaging – Packaging Recoverable Life
by Organic Recovery

ISO 18600 – Global Standards on Packaging for Self Assessment

Based on the 4 R’s of Sustainability
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 Packaging Standards – Emerging Requirements

 Demonstration of Source Reduction Efforts in any of the

following areas:
 Product Protection
 Packaging Manufacturing Process
 Packing Filling Process
 Logistics (transport / warehousing / handling)
 Product presentation / Marketing
 Information
 User & Consumer acceptance
 Safety
 Legislation
 Other issues
Packaging industry is expected to focus on minimizing in usage of
Packaging industry is expected to focus on minimization of
usage of resources across the packaging value chain
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 Packaging Standards – Emerging Requirements

 Absence or efforts towards minimization of hazardous

substances or mixtures in emissions caused as a result of
incineration or landfill of packaging or residues of operation or
Packaging wastes
 Hazardous Substance – classified as presenting an environmental
hazard according to the UN Globally Harmonized System for
classification & labelling of chemicals
 Absence or efforts towards minimization of heavy metals in
packaging components
 Lead
 Mercury
 Cadmium
 Hexavalent Chromium

Environmental Concerns will need to be addressed proactively in

Designing future packaging
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Credentials of Metal Substrates for Packaging

Metal

Metal Substrates seem almost

Tailor Made for Packaging
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History of Development of Metal Containers

Metal Containers

Steel Aluminium

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 Types of Steel Based Containers

 Blackplate
 Electrolytic Tinplate (ETP)
 Tin Free Steel (TFS)
OR
Electrolytic Chromium Coated Steel (ECCS)
 Riverwelt (Ni diffused Steel electrolytically coated with
tin)
 Polymer Coated ETP or ECCS

Steel is being used as a Packaging material for over

2 centuries
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 Evolution of Tin Coated Products

 Discovery of decorative value, corrosion resistance &

non toxic nature of tin

 Earliest application in 1st Century AD – tin coated on

copper vessels to enhance aesthetic value

 Tin coated ironware first produced in 14th Century AD –

used for culinary items to prevent corrosion

Suitability of Tin for food contact applications was

established over 2000 years ago
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 Development of Tin Mill Products

 Key Milestones
 Hot Dipped Tinplate initiated in 17th Century AD – wrought iron
plates coated with tin used for oil / lubricant conatiners
 Wrought iron replaced by steel base in 19th Century AD – 1880
 Development of continuous cold rolling process
 Development of Electrolytic Tinning Process by US – 1937
 Development of Double Reduced Electrolytic Tinplate – 1960
 Development of TFS or ECCS as a substitute for Electrolytic
Tinplate – 1965
 Development of Riverwelt – 1985
 Development of polymer coated ECCS – post 2000

-
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 Development of Aluminium for Packaging

 Milestones

 Discovered – 1807 (2nd most abundant element)

 First isolated – 1826
 Commercialized – 1886 (invention of the Hall – Heroult
production process) – now second most used metal
 Sheet form used for cooking utensils – pre 1900
 Aluminium foil rolling – 1903
 Hot / Cold Continuous Rolling Mills – 1926
 Development of Al alloys for enhanced corrosion resistance –
1926
 Aluminium foil in sheet & coil form 1931

All Metal working techniques are adaptable to

Aluminium & its alloys
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 Development of Metal Containers
 Developments prior to World War II
 Wrought iron plates coated with tin used for containers for
storing oils & lubricants – 17th Century AD
 Patent obtained by Peter Durrand for food cans – 1810
 Development of dies & machines for can fabrication (late 1840s)
– led to increase in can manufacturing outputs from 6 to 60 cans
per hour
 Development of sealed soldered cans – 1886
 Development of automatic can making machines – 1880-1890
 First patent for aerosol cans obtained in 1899 – modern version
developed in 1922 & patented in 1926
 Use of aluminium foil for packaging – 1921
 First beverage beer can introduced in US – 1935
Packaging of edibles constitutes over 65% of the usage of
Metal Containers
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 Development of Metal Containers

 Developments post World War II

 Aluminium Cans introduced – 1957

 First Aluminium beer can produced – 1959
 Invention of Easy Open Ends – 1960
 Development of 2 piece cans – 1964
 Development of Drawn & Wall Ironed (DWI) Cans – 1968
 Development of welded cans – late 1960s
 Introduction of shaped cans – 1997
 First aluminium drawn bottles – 1998
 Introduction of TULC – Toyo Ultimate Can – polyester laminated
aluminium 2 piece cans – post 2000

Development of the 2 piece can has had the most

significant impact on the sustainability of Metal Containers
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 Evolution of Metal Can Industry in India

 Hot Dipped Tinplate

• Prior to World War I: Cans made from imported Hot

Dipped Tinplate, mainly from Wales

• 1922: First indigenous Hot Dip Tinning Plant set up at

Jamshedpur – a Joint Venture between TISCO & Burmah
Oil

• Initially Hot Dipped Tinplate used mainly for kerosene cans

Earliest tinplates produced in India were also

used for Packaging a petroleum product
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 Evolution of Metal Can Industry in India
 Electrolytic Tinplate
• 1965: First Electrolytic Tinning Line set up at Rourkela by SAIL
• 1979: Dual Electrolytic Tinplate / Tin Free Steel manufacturing facility
set up by TCIL – commissioned with imported Tin Mill Black Plate
(TMBP) coils
• Mid 70s to mid 80s: Indigenous TMBP coils initially produced at SAIL’s
Rourkela & Bokaro Steel plants – tandem mill route
• 1994: TMBP manufacturing facility set up at Jamshedpur by TCIL –
through 6 Hi reversing mill route
• 2005 – 2010: Two more electro-tinning lines were set up in India – GPT
& VTPL
• 2008: TCIL commissioned its 2nd dual (ETP / TFS) line
• 2018: A 4th facility (Dual ETP / TFS) line of capacity 200 KT p.a is being
erected by JSW on the west coast likely to be operational by mid 2018
Domestic Consumption of Tin Mill products is about
600,000 MT annually
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 Evolution of Metal Can Industry in India

 Metal Containers

• Up to 1980s
‒ Mainly soldered cans till late 1980s
‒ Indigenous tinplate used for processed foods from mid 80s
• 1990s
‒ Welded cans introduced
‒ Availability of Aluminium 2 piece cans & EOEs
• Post 2000s
‒ Initiation of shaped cans
‒ First steel / aluminium beverage can facility set up

Per capita consumption in India is 0.45 kg as compared to

Over 10 kg in developed countries & > 1 kg in China
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 End Uses of Cans made from Tin Mill Products
 Processed Food Cans
Packaging of  Dairy products (liquid / dry / semi solid)
Edibles  Edible Oils
 Beverages (carbonated / non carbonated)
 Pharmaceutical Products
Health & Personal  Dentifrices
Care products
 Cosmetic Products
 Battery Components
 Paint Cans
 Insecticide / Pesticide cans
Non Food  Chemical / Ink containers
Applications  Engineering uses – filters
 Cable armour
 Candle stands / incense stick containers / mosquito stands
 Miscellaneous – Toys / Gift boxes / Trays / Bill Boards
Cans produced from Tin Mill Products are suitable for a
Wide range of applications & sizes (bulk & consumer packs)
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 Applications of Aluminium in Packaging
 Food
 Milk Products: Yogurt, Curd, Cheese, Sterilised Milk
 Sweets: Chocolate bars, Ice Cream, Chewing Gum
 Dry Foods: Coffee, Tea, Baby Food, Soup, Cereals
17%
 Beverages: Beer, Soft drinks, Juices, Milk 33%

 Ready Made Meals

 Pet Food 23%

 Tobacco
27%
 Pharmaceuticals: Tablets, Capsules, Ointments
 Cosmetics: Tooth Paste, Shampoo Rigid Semi Rigid
 Industrial Goods: Glues, Ink Cartridges, Chemicals Flexible Laminated

Aluminum Packaging
- Mainly used for Consumer Packs
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Market Share: Metal Containers & Tin Mill Products

World:
World: Share of Tin Mill Products in
Share of Metal in Packaging Packaging

3%
10%

36% 11%
17%

89%

34%

Paper Plastic Metal Glass Other Tinplate Others

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Market Share: Metal Containers & Tin Mill Products

India: India:
Share of Metal in Packaging Share of Tin Mill Products in
Packaging
10%
3% 22%
6%
6

10%

18%
10%

17%

Flexible Rigid
Printed Cartoons Metal
Glass Caps/Closures Tinplate Others
Labels Others

Growth Rate of Tin Mill Products is

6–7%
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 Metal Packaging Consumption

Aluminium Usage By End Use

Sector
Total Usage: 2.5 million T

5% 5%
8% India:
37%
8%
Total Steel production 40 Million T

Total Production of Tin Mill Products 0.6 Million T

11%
1.25 % of Total Steel production is used for Packaging

26%

Electrical/Electronics Transportation
Construction Packaging
Consumer Durables Industrial
Others

Total Consumption of Metal for Domestic Packaging is 0.8 Million Tons

(0.2 Million Ton Aluminum + 0.6 Million Ton Tin Mill Products)
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