iip metal containers

Packaging Technology :Metal Packaging Technology :Metal ContainerContainer

Tushar Kanti DattaTushar Kanti Datta

Ex-Joint Director,Ex-Joint Director,

Indian Institute of Packaging.Indian Institute of Packaging.

Ex- Packaging Development Manager,Ex- Packaging Development Manager,

Reckitt Benckiser India Ltd.Reckitt Benckiser India Ltd.

Senior Advisor(Technical), Hindustan Senior Advisor(Technical), Hindustan Tin Works,DelhiTin Works,Delhi

+91 74285 12420+91 74285 12420

Metal Packaging & typesMetal Packaging & types

Tin plate containers.Tin plate containers.– Open Top Cans. Usually round.Application Open Top Cans. Usually round.Application

Food ( Open Top Sanitary Cans ) Three pc. Food ( Open Top Sanitary Cans ) Three pc. Cans.Cans.

– General Line cans. Rectangular & round.Non General Line cans. Rectangular & round.Non Food application ( Grease , Kerosene,Lubricant Food application ( Grease , Kerosene,Lubricant oil.oil.

– DRD Cans ( Draw re-draw ) / Wall ironed DRD Cans ( Draw re-draw ) / Wall ironed cans.Soft drink cans.cans.Soft drink cans.

– Formed cans . Cans for Tuna Fish etc.Formed cans . Cans for Tuna Fish etc.


Aerosol Containers.Spray cans.Aerosol Containers.Spray cans.

Caps & Closures ( Pre threaded caps,Lug Caps & Closures ( Pre threaded caps,Lug caps or twist off caps or quarter turn caps ).caps or twist off caps or quarter turn caps ).

Components in aerosol valves. Components in aerosol valves.


Aluminum containers.Two pc. Cans.Aluminum containers.Two pc. Cans.

Aluminum collapsible tubes.Aluminum collapsible tubes.

Aluminum closures ( ROPP ).Aluminum closures ( ROPP ).

Aluminum based Foil in Packaging.Aluminum based Foil in Packaging.

Tin Plate containerTin Plate container

Often referred to as Tin / TFS / Black Plate Often referred to as Tin / TFS / Black Plate containers.containers.– Tin Plate . Mild steel sheet covered with a very Tin Plate . Mild steel sheet covered with a very

thin layer coating of pure Tin.thin layer coating of pure Tin.– TFS ( Tin Free Steel ) Mild steel sheet covered TFS ( Tin Free Steel ) Mild steel sheet covered

with a very thin layer coating of chromium with a very thin layer coating of chromium oxide.oxide.

» Coating of pure Tin or Chromium oxide provides Coating of pure Tin or Chromium oxide provides corrosion resistance property.corrosion resistance property.

– Black Plate ( Mild steel ) Black Plate ( Mild steel ) No corrosion resistance.No corrosion resistance.

Tin Plate ContainerTin Plate Container

Tin plate UnitsTin plate Units Basis Box Basis Box

– Old system.Weight equivalent of plates in area of Old system.Weight equivalent of plates in area of 112 sheets each of size 20" X 14"112 sheets each of size 20" X 14"

SATSAT– Weight of tin sheet of Standard area of 100,000 sq. Weight of tin sheet of Standard area of 100,000 sq.

inch inch RelationRelation

– SAT is 3.1888 times the size of Basis BoxSAT is 3.1888 times the size of Basis Box Current systemCurrent system

– Millimeters .Standard example ( 0.18mm.)Millimeters .Standard example ( 0.18mm.)


Tin Coating application:Tin Coating application:– Hot dipped .Hot dipped .

» Liable to a considerable variation in thickness from Liable to a considerable variation in thickness from point to point on a single sheet & between sheets & point to point on a single sheet & between sheets & hence mostly obsolete.hence mostly obsolete.

– Electrolytic Tin coating:Electrolytic Tin coating:» More uniform & hence current practice.If both the More uniform & hence current practice.If both the

sides of the plate have equal coating , it is called sides of the plate have equal coating , it is called equally coated & if there is different lavels on each equally coated & if there is different lavels on each face , it is called “Differentially Coated” Tin plate.face , it is called “Differentially Coated” Tin plate.


Tin coating :Tin coating :– More the tin coating better is the corrosion More the tin coating better is the corrosion

resistance.resistance.– Choice of tin coating depends on requirement Choice of tin coating depends on requirement

on internal side as well as required by the on internal side as well as required by the external environment.external environment.

» Some time tin content in internal side helps to Some time tin content in internal side helps to maintin the keeping quality of product . Example tin maintin the keeping quality of product . Example tin disolved in pineapple solution maintains the clarity. disolved in pineapple solution maintains the clarity.

TinTin Plate ContainerPlate Container

Tin coating: The selection on external coating depends on the Tin coating: The selection on external coating depends on the external environment , the finished product is going to get external environment , the finished product is going to get

exposedexposed. .

Tin coatingsTin coatings

Tin CoatingsTin Coatings Coating gradesCoating grades

Tin contents on each sideTin contents on each side E100 11.20 E100 11.20 E50 5.6E50 5.6 E25 2.8E25 2.8

D100/50 11.20/5.60D100/50 11.20/5.60 D50/25 5.60/2.80D50/25 5.60/2.80

Steel Chemistry of Tin plate :Machine performances depends on metal components which form alloys by combining with different elements.( Fe +Phosphorus + Cu + Mn + Mg ) etc etc…Phosphorus ; Copper :: Acid resistancePhosphorus : Imparts Stiffness to sheet rollTin : Corrosion resistance.Formability of plates :Ductility : Folding , seaming stamping… These characteristics are Imparted by annealing which could be through batch annealing or Continuous annealing process … accordingly the plates are refferedTo as BA ( batch annealed ) or CA ( continuous annealed )

BA : For whole coils in batchesCA : Continuously in in single strip form.CA is slightly stronger but somewhat less ductile than BA tinplates.

TinplatesTinplates

Surface finishesSurface finishes : :– Silver Finish Silver Finish

» Flow brightened electrolytic tinplatesFlow brightened electrolytic tinplates

– Matt FinishMatt Finish» Non Flow brightened electrolytic tinplatesNon Flow brightened electrolytic tinplates

– Stone FinishStone Finish» Flow brightened tinplate with base plate finish Flow brightened tinplate with base plate finish

slightly rougher than that of conventional tinplate slightly rougher than that of conventional tinplate but not so rough as either matt or silver glow but not so rough as either matt or silver glow finishes. finishes.

DR PlateDR Plate

Mostly used in stamped & formed Mostly used in stamped & formed components like ends of the cans .components like ends of the cans .

The steel sheet is made by additional cold The steel sheet is made by additional cold reduction process before tinning is done.reduction process before tinning is done.

The thickness is low ( like 0.16mm., The thickness is low ( like 0.16mm., 0.14mm.with higher strength compared to 0.14mm.with higher strength compared to single reduced tinplates.single reduced tinplates.

Benefit : Cost optimization.Benefit : Cost optimization.

Base Plate Nomenclatures.Base Plate Nomenclatures. Chemical composition of tin plate steels has a

significant effect on corrosion behavior, strength & ductility of tinplate . This resulted in development of a series of steel compositions fit for certain broad field of use. The following are the designations of different grades of tin plate which are widely used by tinplate manufacturers.

1.Type L Steel ( High Purity Steel, used for certain food products which demand high internal corrosion resistance)Material Max % CompositionCarbon 0.12Manganese 0.6Copper 0.05Sulphur 0.05Phosphorus 0.015Silicon 0.01

Base Plate Nomenclatures.Base Plate Nomenclatures.Base plate nomenclature & chemical composition of different types of steels.

Nomenclature Description on element % & Comments

Type MR Steel Basically similar to Type L.Max Cu & P Content 0.2% & 0.02% respectively.MR Steel is used as the base plate of most tinplate.

Type N Steel Similar to MR except that the Max Cu Content is limitedto 0.08%.Used in place of Type L steel for more corrosive packs such as fruit Packs.

Type MC Steel Similar to MR except that the Max P & carbon contents are

set at 0.15% & 0.13% respectively .Results in higher mechanical strength & stiffness.Corrosion performance is somewhat poor & hence it isused mostly in lacquered beer can ends.

Tin Plate manufactureTin Plate manufacture

Air Coke Coal

Iron Ore Lime Stone

Blast Furnace

Iron (3.5% Carbon approx.)

Open Hearth Furnace / Bessemer Converter

Steel ( 0.1% Carbon )

Tin Plate manufactureTin Plate manufactureSteel ( 0.1% Carbon )

Hot Rolling

Steel Strip (0.1”Thick )

Continuous cold rolling

Electrolytic Cleaning

Tin Plate manufactureTin Plate manufacture

Electrolytic Cleaning

Batch annealing Continuous annealing

Temper rollingTemper rolling

Sheet SheetStrip Strip

Hot Dipping Hot DippingElectro tinning

Batch annealed cold reduced Hot dipped Tin plate

Batch annealed cold reduced Electrolytic Tin plate

Electro tinning

Continuous annealed cold reduced Electrolytic Tin plate

Continuous annealed cold reduced Hot Dipped Tin plate

Dimensions of Tin plateDimensions of Tin plate

Dimensions Dimensions – Length ; breadth ( width ) ; thicknessLength ; breadth ( width ) ; thickness

TolerancesTolerances– Technical requirement ; Commercial requirementTechnical requirement ; Commercial requirement

Dimensions depend on rolling width & shear cutDimensions depend on rolling width & shear cut– Currently one can get supplies as per the required size Currently one can get supplies as per the required size

required by customer ( read converter )required by customer ( read converter )

– Available width :In between 25 to 37cmAvailable width :In between 25 to 37cm– Available length : In between 20 to 40cmAvailable length : In between 20 to 40cm


Overage :Overage :– Shearing allowance as per customer need. Always supplied -Shearing allowance as per customer need. Always supplied -

dimensions are over the nominal dimensions of the required dimensions are over the nominal dimensions of the required sheet size.sheet size.

– In USA : Width is over by 0.125” than the nominal & the In USA : Width is over by 0.125” than the nominal & the length is over by 0.25” than the nominal value required by length is over by 0.25” than the nominal value required by customer. customer.

– In UK : Width is over by 0.25” than the nominal & the length In UK : Width is over by 0.25” than the nominal & the length is also over by 0.25” than the nominal value required by is also over by 0.25” than the nominal value required by customer.customer.

This is to ensure that there is no issue in accommodating the This is to ensure that there is no issue in accommodating the component-lay out as per design.component-lay out as per design.


CAMBERCAMBER– Maximum linear deviation of any edge from a Maximum linear deviation of any edge from a

straight line drawn between two ends of that straight line drawn between two ends of that edge. edge.

– Camber is limited to 0.0625” per 48”Camber is limited to 0.0625” per 48”


Out of Square ness:Out of Square ness:– Departure from a right angle of the angle Departure from a right angle of the angle

between to adjacent edges. between to adjacent edges. – Quoted as % deviation & is thus a measure of Quoted as % deviation & is thus a measure of

the square ness of the sheet cut. the square ness of the sheet cut. – This limit may be set at 0.125” for width up to This limit may be set at 0.125” for width up to

& including 36”& including 36”– This is a measure of good rectilinear shape of This is a measure of good rectilinear shape of

cut sheet. cut sheet.

Protective Lacquer/ Decoration systems : Protective Lacquer/ Decoration systems : TinplateTinplate

Protection against internal product.Protection against internal product.– Acidic product(Fruits),Alkaline product(Vegetables), Acidic product(Fruits),Alkaline product(Vegetables),

Chemical resistance ( Insecticides ). Chemical resistance ( Insecticides ).

Protection against external environmentProtection against external environment. . – Protection against moisture, Pollutant atmosphere like Protection against moisture, Pollutant atmosphere like

sulphur ,chlorine gas contaminated atmospheresulphur ,chlorine gas contaminated atmosphere at at highhigh temperature.temperature.

Types of corrosion generally encounteredTypes of corrosion generally encountered..– Heavy corrosion :Heavy corrosion :

» Pitting, (through & through holes , Bimetallic ). Pitting, (through & through holes , Bimetallic ).

– Medium to low corrosion :Medium to low corrosion :» FeatheringFeathering

Protective Lacquer/ Decoration systems : Protective Lacquer/ Decoration systems :

TinplateTinplate.. External Protection :External Protection :

– 1. Size.1. Size.– 2.Roller coating followed by printing.2.Roller coating followed by printing.– Over print varnish.Over print varnish.

Internal protection :Internal protection :– 1.Lacquering. 1.Lacquering.

Substrate : Substrate : – Sheets of Tinplate, TFS, Black-plate.Sheets of Tinplate, TFS, Black-plate.


TinplateTinplate.. Method of Application :Method of Application :

– Stillage inspection & washing ( naptha or Stillage inspection & washing ( naptha or kerosene.).kerosene.).

– Roller coating of individual coats followed byRoller coating of individual coats followed by drying.drying.Quality Control :Quality Control :Incoming materials, In process quality, Finished Incoming materials, In process quality, Finished

goods inspection .goods inspection .Output to conversion Dept.( Forming etc.) Output to conversion Dept.( Forming etc.)


(External)Tinplate(External)Tinplate.. Size Coating :Size Coating :

– Imparts good adhesion , flexibility & strength between Imparts good adhesion , flexibility & strength between metal surface & subsequent coatings.metal surface & subsequent coatings.

– Provides uniform even surface for subsequent roller Provides uniform even surface for subsequent roller coatings.coatings.

– Prevents corrosion.Prevents corrosion.– This is important more for components which are subjected to This is important more for components which are subjected to

deep drawing operations . This might not be required for shallow deep drawing operations . This might not be required for shallow stamping.stamping.

Characteristics :Characteristics :– Clear varnish with low viscosity capable of coating a very low Clear varnish with low viscosity capable of coating a very low

thickness film ( 0.5 to 1.0mgm./sq.inch ) & suitable for stoving as thickness film ( 0.5 to 1.0mgm./sq.inch ) & suitable for stoving as required to make it tack free hard ductile layer of polymer coat.required to make it tack free hard ductile layer of polymer coat.


(External)Tinplate(External)Tinplate.. Roller Coating EnamelsRoller Coating Enamels::

– Generally pigmented ( White coating ) compositions. Generally pigmented ( White coating ) compositions. Forms a background coat for subsequentForms a background coat for subsequent colors.colors.

Characteristics:Characteristics:– Good color retention even on repeated baking.Good color retention even on repeated baking.– Excellent flow characteristics at the time of application.Excellent flow characteristics at the time of application.– Good covering capacity in one coat operation. Good Good covering capacity in one coat operation. Good

coating thickness in single pass (8 to 12 mgm./sq.inch)coating thickness in single pass (8 to 12 mgm./sq.inch)– High degree of flexibility.High degree of flexibility.– Excellent mechanical properties like toughness,mar Excellent mechanical properties like toughness,mar

resistance,shallow/deep stamping & tooling properties.resistance,shallow/deep stamping & tooling properties.


(External)Tinplate(External)Tinplate.. Over Print VarnishOver Print Varnish ::

– Finishing coat over print.Protects inner layers.Finishing coat over print.Protects inner layers.– Clear with good color retention.Clear with good color retention.– Have gloss, Mar resistance,Scuff resistance.Have gloss, Mar resistance,Scuff resistance.– Good flow while application.Good flow while application.– Mechanical properties, High degree of flexibility.Mechanical properties, High degree of flexibility.– Good inter coat adhesion between it & roller coating enamels.Good inter coat adhesion between it & roller coating enamels.– UV Resistance in some special cases.UV Resistance in some special cases.

Types :Types :– Oleo Resinous Oleo Resinous – Alkyd / Amino Alkyd / Amino – Epoxy Amino etc.Epoxy Amino etc.


(Internal)Tinplate(Internal)Tinplate.. Internal Lacquer :Internal Lacquer :

– To protect the tins from chemical attack of the content.To protect the tins from chemical attack of the content. Food Lacquers & Non Food Lacquers.Food Lacquers & Non Food Lacquers. Food Lacquers:Food Lacquers:

– Non toxic . FDA approval.( Free from Pb, As & Cu )Non toxic . FDA approval.( Free from Pb, As & Cu )– No Smell in storage.( Odorless )No Smell in storage.( Odorless )– No or limited reaction with sulphur bearing products.(Fish, pickle, No or limited reaction with sulphur bearing products.(Fish, pickle,

Fruits etc…)Fruits etc…)– Excellent adhesion even on prolonged contact with contents.Excellent adhesion even on prolonged contact with contents.– To withstand tooling even for deep stamping products.To withstand tooling even for deep stamping products.

Non Food Lacquers :Non Food Lacquers :– Same as those for Food application except for the FDA approved Same as those for Food application except for the FDA approved

components.components.


(Internal)Tinplate(Internal)Tinplate.. Types of Internal Lacquers:Types of Internal Lacquers:

– Oleo Resinous. Acid resisting Gold Lacquers,Non Oleo Resinous. Acid resisting Gold Lacquers,Non Toxic ( for colored fruits,tomato juices etc..)Toxic ( for colored fruits,tomato juices etc..)

– Modified phenolic sulphur absorbing pigmented gold Modified phenolic sulphur absorbing pigmented gold lacquer, non poisonous for inside of can ( peas, lacquer, non poisonous for inside of can ( peas, vegetables, meat packs..etc…)vegetables, meat packs..etc…)

– Phenolic acid & sulphur resisting gold lacqure,non Phenolic acid & sulphur resisting gold lacqure,non toxic ( Hams, solid meats etc…)toxic ( Hams, solid meats etc…)

– Epoxy Ester based ( for butter, fats etc…)Epoxy Ester based ( for butter, fats etc…)– Epoxy phenolics (High degree of Chemical Epoxy phenolics (High degree of Chemical

Resistance )Resistance )– Epoxy acrylic based lacquer.Epoxy acrylic based lacquer.


(Internal)Tinplate(Internal)Tinplate.. Method of Application :Method of Application : Roller coating.Roller coating. First coat is internal lacquer which is baked at First coat is internal lacquer which is baked at

temperature higher than other coates like size temperature higher than other coates like size coat , white coat , print & varnish.coat , white coat , print & varnish.

Baking is important .Baking is important .

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