cushioning presentation

8/14/2019 Cushioning Presentation

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Cushioning Systems

Applications, Properties And Uses


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Goal of Packaging

To get a product from one place to

another without unacceptable loss ordamage in an economic and practical

manner.


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Packaging in Supply Chain

Figure 7.1Figure 7.1


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Global Transportation Options

Major international transportation modes

Sea Air

Road

Rail


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Functions of cushioning

Protecting the product from shocks and

vibrations.

Protecting of delicate and highly finished

surfaces against abrasion.

Protecting small projections on an article.

Filling the void space in the container.


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Properties of cushioning materials

Resilience

Compression set

Rate of recoveryCreep

DampingCorrosion

Hygroscopicity contd...


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Properties of cushioning materials

Micro biological properties

Dusting

Abrasive characteristics

Performance at low temperature

Density


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Cushioning methods

Blocking and bracing

Floatation/ stuffing

Wrapping Suspension

Molded enclosures


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Definition : Shock Pulse

Single Event

High acceleration(Deceleration)

Very short time duration(milliseconds)


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Definition : Vibration Pulse

Multiple Event

Usually Low Acceleration Long time duration


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Classifications of cushioning materials

cushioning materials

space fillers resilient non-resilient


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Resilient cushioning materials

Bonded fiber mat

Rubber-closed cell expanded rubber

rubber open cell Springs and shock-mounds

Plastic foams


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Plastic Foams used in cushioning

Resilient Foam


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Plastic Foams

Plastic foams

ExpandedPoly ethylene

ExpandedPoly styrene

Poly urethane

Resilient Foam

R ili t F


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Expanded poly ethylene

Resilient Foam


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Polyethylene Blowing Agent

Blending

Extrusion + Blowing

Polyethylene Foam


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Polyethylene

Blowing AgentBlending

Cross-linking

Cross-linkedPol eth lene Foam

Cross-linkingAgent

Blowing

Resilient Foam


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Properties of PE foams

It is resistant to common acid alkali andsolvents

non-hygroscopic and non-water absorbing

non-corrosive and non-dusting

stable to temperatures ranging between -20 o

Celsius to +70o

Celsius It has fair resilience, good damping ,low

creep and fair value of compressions set.

Resilient Foam


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Comparison between extruded and

cross-linked PE Foams

Chemical, Mechanical and thermal property ofextruded and cross-linked PE foams are verysimilar.

The cell size of cross-linked foams is generallysmaller and more uniform.

Thickness dimension is more uniform in cross-linked sheet as compare to extruded sheet.

Cross-linked product posses a softer feel than

the extruded product.

Resilient Foam


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Uses of PE foams

Packing materials of

various tiles,

ceramic ware,

glass ware,

handicrafts, electronic goods

Packing materials for instruments.

Cushioning material for export of goods

Resilient Foam


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Uses of PE foams


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Uses of PE foams


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Uses of PE foams


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Uses of PE foams


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Uses of PE foams

Resilient Foam


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Advantages of PE

Excellent cushioning to preventscratching/bruising of item being packaged

Lightweight - easy to handle

Environmentally friendly

Better protection against liquid spills, such

as chemicals and water. 100% waterproof

Resilient Foam

Resilient Foam


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Expanded poly styrene

Resilient Foam

Resilient Foam


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Properties of EPS

non-hygroscopic,

poor water absorbent

low dusting stable to temperatures ranging from -30 o C

to 70 o C

resistant to acids and alkalis

Fair resilience, good damping and low creep.

EPS has a good insulation capability and agood first drop cushioning performance

Resilient Foam

Resilient Foam


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Uses of EPS

EPS foam is commonly found in protectivecushion pads like end caps

Resilient Foam

Resilient Foam


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Advantages of EPS

Low cost

Light weight

Available in various colors Available in fire resistant variety

Recyclable

Resilient Foam

Resilient Foam


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Poly urethane

Resilient Foam

Resilient Foam


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Properties of PU

Non hygroscopic

Non corrosive

Low dusting Stable to temperatures between -10 o C to 55 o C

Good resilience and damping with low creep andlow compression set.

Resilient Foam

Resilient Foam


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Advantages of PU

It can be easily molded into custom shapes

suitable for a variety of products, from

extremely fragile to those with irregularshapes and contours.

Resilient Foam

Resilient Foam


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Applications of PU Foams

Resilient Foam

Resilient Foam


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Foam in Place

This packaging solution blocks the productand gives protection against shocks. Thepolyurethane foam is created through achemical process, where two liquids reactand expand rapidly.

In a very short space of time, the foamexpands more than 200 times

Resilient Foam

Resilient Foam


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Foam in Place

Resilient Foam

Resilient Foam


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Foam Profiles

Foam profiles are easy to convert whichgives great possibilities in terms ofcustomisation.

Corner protection - normally L-shaped- Edge protection - normally U-shaped

- Tubular protection profiles

es e t oa


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Air cushioning

FillerBuffer


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Modes of air cushioning

Aircushioning

Inflatablepackaging

EncapsulatedAir

cushioning


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Advantages of air cushioning

ease of handling

no hygroscopic

highly versatile largely insensitive to extreme climatic

conditions (heat, cold)

elevated recovery and ideal shockabsorption characteristics


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Cushioning methods Air Pad

Air pad is an efficient filling solution that canalso be used for blocking lightweightproducts.

This packaging solution fills the emptyspaces in the box, effectively protecting and

stabilising the product. Air pads are suitable for regular shaped

products without sharp edges and protrudingparts.


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Benefits include:- Reusable and recyclable- Strong with extremely low weight- Humidity insensitive

- Clean and easy to handle

- Very cheap solution for void filling


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Since air pads can be formed at the point ofuse, there is not a need for costly storage.

The low weight reduces shipping costs andmake handling easier


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Air cushioning (Bubble wrap)

Increased cushioningproperties

reduced material cost

labor savings

lower shipping costs


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Bubble Wrap cushioning


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Cushioning methods Bubble wrap

Advantages and characteristics:- Light and elastic- Transparent, impermeable insulation- Recyclable

- Improved product presentation

- Short packaging times- Extremely good humidity resistance


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Cushioning methods Bubble wrap


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Cushioning material- Corrugated Board

Used as

pads

separators and inserts (double faced) wrappers (single faced)

Limitations limited shock absorption capability

non resiliant

absorbs moisture


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Applications

filled glass packaging wrapping

handicraft products wrap furniture's

wrap machine parts


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Cushioning methods Honey Comb

Low cost

High strength - withstands top to bottom

compression Flexible design

Completely recyclable

Thermal conductivity and insulation abilities


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Cushioning methods Honey Comb

It can be used to protect anything from smallelectronic components to large generatorsfor shipment.

Packaging can be designed for products aslight as a cell phone or as heavy as several

tons of automotive parts.


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Mi ll th d d t d b k g


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Miscellaneous methods adopted by packagers

to provide extra cushioning

Loose fill cushioning materials 100% recycled expanded poly styrene loose

fill

Starch based loose fills: ECOFOAM andNATURPACK

Corrugated loose fills Loose fill molded paper pulp (fiber flow)

Wood shavings (Curl pack )

Popped corn

Miscellaneous methods adopted by


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Miscellaneous methods adopted by

packagers to provide extra cushioning

Antistatic poly urethane (PU) foam Specialized custom reticulated foam (PU)

Foam-in-Place Kraft paper

Custom Wood Assemblies


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Cushioning methods

Blocking and bracing Floatation/ stuffing

Wrapping Suspension

Molded enclosures


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Cushioning methods

Blocking and bracing the main purpose of this solutions is to block

and fixate the product inside.


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An Industrial application


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Custom wood assembly


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Packaging of Marble


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CFB as Cushioning Material


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Packaging in PS Foam Box


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Loose Fill Application


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Paddy Straw Application


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Blocking Application


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Molded Paper Pulp


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STEPS TO CUSHION SELECTION

1) ASSES DISTRIBUTION HAZARD

2) DECIDE ON NUMBER OF DROPS &

DROP HEIGHT

3) ASSES PRODUCT FRAGILITY


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STEPS TO CUSHION SELECTION

4) CHOOSE CUSHIONING MATERIALS

5) MAKE PROTOTYPES

6) TEST PROTOTYPES


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