Package Evaluation Training2package forming customer

26/09/2012 Package Evaluation T i i Training Package Forming PE-02/2012-04-01 Agenda Date printing Flap sealing Weight LS Overlap Crease line alignment (Tube twist) Design Package defect name PE-02/2012-04-01 /2 26/09/2012 Package basic conditions The four basic package conditions are: • • • • Weight LS Overlap Crease line alignment (Tube twist) Design position All these conditions must be correct prior to any package evaluation Otherwise restore “basic package condition” PE-02/2012-04-01 /3 Terminology Agreement Symbol Description Legal Requirement related check Package Integrity related check Package appearance and line efficiency related check PE-02/2012-04-01 / 26/09/2012 D Date t P Printing i ti Package Forming PE-04/2012-04-01 Date Printing Check the date and code printing Why: Legal Demand How - Visual check Printed code is visible and readable ► Correct position/ information/code etc… ► Time on the package should be the same as time on the TPOP ► If necessary… STOP the filling machine and adjust the date printing according to the instruction supplied with the printer ► PE-02/2012-04-01 / 26/09/2012 Fl Flap Sealing S li Package Forming PE-04/2012-04-01 Flap Sealing Why ► Flap sealing effect the line efficiency and package integrity How Unfold the flaps and check that they are properly sealed ► On the bottom flaps the heat should not be directed on the TS ► Burnt marks might impact on package integrity ► PE-02/2012-04-01 /8 26/09/2012 W Weight i ht Package Forming PE-02/2012-04-01 Weight (Volume) Weight the package - Why ► Legal demand ► Too high weight increase product loss ► Too low weigh could effect package forming and less internal p package g pressure which more difficult for flap sealing PE-02/2012-04-01 / 10 26/09/2012 Weight (Volume) Weight the package - How Set zero the balance with the empty package Weight the filled package, read the weights and record the deviation if any Correlate the weight to volume ► To adjust the package weight, follow the instructions in the OM ► Always check the weight again after adjustment ► ► PE-02/2012-04-01 / 11 LS LS-overlap l Package Forming PE-02/2012-04-01 26/09/2012 LS-Overlap Why ► By y measuring easu g LS-overlap, S o e ap, ca can ccheck ec tthe e tube diameter and packaging material width These are important parameters to produce well formed packages Distance B is Overlap PE-02/2012-04-01 / 13 LS-Overlap How Use the vernier caliper or steel ruler check the width of the overlap ► If the overlap is out of the range indicated, corrective actions should be taken Refer to OM for Overlap distance, Example ► PE-02/2012-04-01 / 14 26/09/2012 LS-Overlap Evaluation PE-02/2012-04-01 / 15 Crease Line alignment (Tube twist) Package Forming PE-02/2012-04-01 26/09/2012 Crease line alignment Why ► Visual inspection to verify the creases are correctly positioned Incorrect crease positions will have an impact on package forming, and could cause mechanical tension tension How ► Unfold the top flap and visual check for the crease line alignment PE-02/2012-04-01 / 17 Crease line alignment Evaluation Tube twist Good < mm If the distance > mm  Adjust tube twist PE-02/2012-04-01 / 18 26/09/2012 D Design i Package Forming PE-02/2012-04-01 Design Why ► Visual inspection to verify the packages are correctly formed Badly formed packages could cause mechanical tension How ► Visual check the preformed crease in the packaging material are correctly aligned along the edge of the package (top transversal crease) PE-02/2012-04-01 / 20 10 26/09/2012 P Package k D Defect f t Package Forming PE-02/2012-04-01 Package defect name Objectives ► To understand the defect appearance pp ► Able to give correct name to package defect when communication 14 26/09/2012 Package Defect Index ► Forming defect 1 Pinching PPH torn and cloudy Corners fold Corner collapsed Fin folding Fin tears Board crack a)) LS crack b) Corner crack TS double folded Wrinkle on/crossing TS 10 Wrinkle on opening area 11 Dented panels 12 Crocodile skin ► Appearance defect 13) Scratches 14) Bottom scuffing 15) Crease dent a) Horizontal b) Vertical 16) Outside PE blister 17) Squeeze from queing ► Integrity 18 TS Al-foil crack 19 K-crease crack leakage PE-02/2012-04-01 / 29 Package defect Pinching - Forming Definition: Pinching is a wrinkled side panel, where the packaging material is “pushed together” and originated from the forming g of a package, normally made by volume flap or gap in forming roller PE-02/2012-04-01 / 30 15 26/09/2012 Package defect PPH torn and cloudy - Forming Definition: The o outside tside PE la layer er is torn/r torn/ruptured pt red or clo cloudy d in the PPH area when weak adhesion between outside PE and laminate layer Torn Cloudy PE-02/2012-04-01 / 31 Package defect Corner fold - Forming Definition: A corner fold is a dimple or “negative folding” of the corners both top and bottom corners, bottom PE-02/2012-04-01 / 32 16 26/09/2012 Corner fold - Forming PE-02/2012-04-01 / 33 Package defect Corner collapsed - Forming Definition: A big corner fold with double fold on the flap More sensitive in the machines without crease wheel and shallow crease on packaging material PE-02/2012-04-01 / 34 17 26/09/2012 Package defect Fin folding - Forming Fin folding occurs on top transversal seal when TS bends on the reverse side creating a notable fold PE-02/2012-04-01 / 35 Package defect Fin tear - Forming Definition: A fin tear it’s a board crack that occurs where the top transversal seal meets the flap at the end of the fin corner The fibres must be noticeable Cosmetic fin tear PE-02/2012-04-01 / 36 18 26/09/2012 Fin tear - Forming TBA TWA PE-02/2012-04-01 / 37 Package defect a) LS Board crack - Forming Defiinition: The board cracks are visually detected and the fibres must be noticeable noticeable Board crack is located where the LS meets horizontal top/bottom crease PE-02/2012-04-01 / 38 19 26/09/2012 Package defect b) Corner crack - Forming Definition: The board cracks are visually detected and the fibres must be noticeable noticeable A board corner crack is located on any of the eight corners of the package PE-02/2012-04-01 / 39 Package defect TS double folded - Forming Definition: A folded line on a p package g where the PM should be smooth TS double folding can occur on the flaps of a package PE-02/2012-04-01 / 40 20 26/09/2012 Package defect Wrinkle on/crossing TS - Forming Definition: A wrinkle on/crossing TS is a line on/crossing t transversal l seall area PE-02/2012-04-01 / 41 Package defect 10 Wrinkle on opening area - Forming Definition: Wrinkle on opening area can be small folded line where g the horizontal crease the PM should be smooth or it can through PE-02/2012-04-01 / 42 21 26/09/2012 Package defect 11 Dented panels - Forming Definition: A package is classified to have dented panel(s) when one or several panels are permanently deformed (dented) from its pristine shape A dented panel can be either pre shape pre-sent sent physical deformation or large wrinkles on the panel indicating a previous deformation, which has been squeezed back to shape PE-02/2012-04-01 / 43 Package defect 12 Crocodile skin - Forming Definition: crocodile skin defect is present when the surface of one or more panels of the package is covered by wrinkles PE-02/2012-04-01 / 44 22 26/09/2012 Package defect 13 Out side scratches - Appearance Definition: Scratches are marks on panels that are notable mainly on metallized packaging material PE-02/2012-04-01 / 45 Package defect 14 Bottom scuffing - Appearance Definition: Scuffing are holes or damages in the outer PE at e g the bottom corners or the LS overlap e.g overlap, often due to wear from e.g the conveyor PE-02/2012-04-01 / 46 23 26/09/2012 Package defect 15 a) Crease Dent - Appearance Horizontal Crease Dent Definition: The crease is dented when the horizontal crease (top or bottom) is clearly broken or when there is a wrinkle through the crease crease PE-02/2012-04-01 / 47 Package defect 15 b) Crease Dent - Appearance Vertical Crease Dent Definition: The crease is dented when the vertical (longitudinal) crease is clearly broken or when there is a wrinkle through the crease The dent is located on any of the vertical creases, MD creases PE-02/2012-04-01 / 48 24 26/09/2012 Package defect 16 Outside PE blisters - Appearance Definition: e t o Bubbles ubb es appearance appea a ce o on outs outside de PE,, da damaged aged tthe e pac package age appearance Normally due to weak adhesion of outside PE PE-02/2012-04-01 / 49 Package defect 17 Squeezing or queue pressure marks - Appearance PE-02/2012-04-01 / 50 25 26/09/2012 Package defect 18 TS Al-foil crack Definition: Crack found on the ridge at TS seal and with early bending off after dissolving PE-02/2012-04-01 / 51 TS Al-foil crack in Transversal Seal Dissolved TS with no crack in the Aluminium-foil High bend-off No channel PE-02/2012-04-01 / 52 26 26/09/2012 TS Al-foil crack in Transversal Seal Dissolved TS with a crack in the Aluminium-foil Early bend-off Channel PE-02/2012-04-01 / 53 Package defect 19 K-crease crack leakage Definition: During forming bottom of package, tension is very high g where several layers y of p packaging g g material are folded Note : By nature, there always have K-crack at bottom but not leak by red ink test Left side Right side PE-02/2012-04-01 / 54 27 26/09/2012 E d End Package Forming PE-02/2012-04-01 28 [...]... design error when it is bigger than 1 mm PE-02/2012-04-01 / 26 13 26/09/2012 7 P 7 Package k D Defect f t Package Forming PE-02/2012-04-01 7 Package defect name Objectives ► To understand the defect appearance pp ► Able to give correct name to package defect when communication 14 26/09/2012 7 Package Defect Index ► Forming defect 1 1 Pinching 2 PPH torn and cloudy 3 Corners fold 4 Corner collapsed... K-crease crack leakage PE-02/2012-04-01 / 29 7 Package defect 1 Pinching - Forming Definition: Pinching is a wrinkled side panel, where the packaging material is “pushed together” and originated from the forming g of a package, normally made by volume flap or gap in forming roller PE-02/2012-04-01 / 30 15 26/09/2012 7 Package defect 2 PPH torn and cloudy - Forming Definition: The o outside tside PE la... corner crack is located on any of the eight corners of the package PE-02/2012-04-01 / 39 7 Package defect 8 TS double folded - Forming Definition: A folded line on a p package g where the PM should be smooth TS double folding can occur on the flaps of a package PE-02/2012-04-01 / 40 20 26/09/2012 7 Package defect 9 Wrinkle on/crossing TS - Forming Definition: A wrinkle on/crossing TS is a line on/crossing... outside PE and laminate layer Torn Cloudy PE-02/2012-04-01 / 31 7 Package defect 3 Corner fold - Forming Definition: A corner fold is a dimple or “negative folding” of the corners both top and bottom corners, bottom PE-02/2012-04-01 / 32 16 26/09/2012 3 Corner fold - Forming PE-02/2012-04-01 / 33 7 Package defect 4 Corner collapsed - Forming Definition: A big corner fold with double fold on the flap... PE-02/2012-04-01 / 36 18 26/09/2012 6 Fin tear - Forming TBA TWA PE-02/2012-04-01 / 37 7 Package defect 7 a) LS Board crack - Forming Defiinition: The board cracks are visually detected and the fibres must be noticeable noticeable Board crack is located where the LS meets horizontal top/bottom crease PE-02/2012-04-01 / 38 19 26/09/2012 7 Package defect 7 b) Corner crack - Forming Definition: The board cracks are...26/09/2012 6 Design Evaluation  Low crease position Adjust “ +” or “Clock wise” High crease position - Adjust “ ” or “Counter clock wise” PE-02/2012-04-01 / 21 6 Design Adjust the shape of the package PE-02/2012-04-01 / 22 11 26/09/2012 6 Design Adjust the shape of the package Guide: • Package Low crease position, Adjust “+” • Package High crease position, position Adjust... on/crossing t transversal l seall area PE-02/2012-04-01 / 41 7 Package defect 10 Wrinkle on opening area - Forming Definition: Wrinkle on opening area can be small folded line where g the horizontal crease the PM should be smooth or it can through PE-02/2012-04-01 / 42 21 26/09/2012 7 Package defect 11 Dented panels - Forming Definition: A package is classified to have dented panel(s) when one or several... PE-02/2012-04-01 / 43 7 Package defect 12 Crocodile skin - Forming Definition: crocodile skin defect is present when the surface of one or more panels of the package is covered by wrinkles PE-02/2012-04-01 / 44 22 26/09/2012 7 Package defect 13 Out side scratches - Appearance Definition: Scratches are marks on panels that are notable mainly on metallized packaging material PE-02/2012-04-01 / 45 7 Package defect... bend-off Channel PE-02/2012-04-01 / 53 7 Package defect 19 K-crease crack leakage Definition: During forming bottom of package, tension is very high g where several layers y of p packaging g g material are folded Note : By nature, there always have K-crack at bottom but not leak by red ink test Left side Right side PE-02/2012-04-01 / 54 27 26/09/2012 E d End Package Forming PE-02/2012-04-01 28 ... PE-02/2012-04-01 / 48 24 26/09/2012 7 Package defect 16 Outside PE blisters - Appearance Definition: e t o Bubbles ubb es appearance appea a ce o on outs outside de PE,, da damaged aged tthe e pac package age appearance Normally due to weak adhesion of outside PE PE-02/2012-04-01 / 49 7 Package defect 17 Squeezing or queue pressure marks - Appearance PE-02/2012-04-01 / 50 25 26/09/2012 7 Package defect 18 TS Al-foil