Test Objective: The objective of this series of tests was to validate the test results of the M-Rule Shelf-life Prediction model using the Agr PPT3000™ and document the efficacy of this
Trang 1M-Rule Shelf-life
Field Test Comparison
®
Trang 2PPT3000 M-Rule Shelf-life
Field Test Comparison
This document contains information on the
PPT3000 M-Rule Shelf-life field test comparison
study conducted at a major PET converter with
the assistance of an independent test lab
Information on the procedure and the materials
used to obtain the data are as follows
Test Objective:
The objective of this series of tests was to
validate the test results of the M-Rule Shelf-life
Prediction model using the Agr PPT3000™
and document the efficacy of this method in
comparison to traditional methods for measuring
CO2 loss in a given PET container
Purpose of Tests:
Verify that M-Rule CO2 predictive shelf-life test
results obtained using the PPT3000 test system
are comparable to results obtained through
traditional real-time test methods
Tests Performed:
A detailed test plan was developed to adequately
test the M-Rule Shelf-life prediction capabilities
of the PPT3000 A common set of bottles was
produced and used to test for CO2 loss Tests
were performed and results compared according
to the following test methods:
● M-Rule Web Model
● PPT3000 M-Rule Feature
● Headspace measurements
-Zahm-Nagle CO2 loss test
● Headspace measurements
-Septum CO2 test
Conditions for all tests were established in
advance and controlled
Equipment used for tests:
PPT3000: Agr Proto unit #001
Software v1.0.0.5
Test Samples:
Mono-layer PET containers, of three different
styles and capacities, were used for this series
of tests Styles included:
● 20 oz (591 ml)
● 1 liter
● 2 liter
Samples of each style were selected from
the same production run, cavity sorted and
randomized Strict attention was paid to the preparation and selection of samples to reduce the chance of variable test results due to sample defects or production anomalies
Sample Set Preparation
1 Samples were produced on SIPA blowmolder
2 Three production sets of bottles were gathered for each style/capacity in the following manner: (# cavities + 100 additional samples representing all cavities)
3 To ensure that at least three containers from each mold of the blow molder were contained in the set, the SIPA machine was sampled from one side
4 All containers were aged (set aside in ambient conditions) for a period of at least 24 hours
5 All containers were measured for thickness
in the shoulder, mid-sidewall and heel area One measurement per location per container
6 Containers were sorted for testing as follows: a) One set (one bottle from each cavity) was randomly pulled from the population for routine pressure and volume expansion tests on the PPT3000 pressure tester The purpose of this was to determine if the population is part of a statistically normal distribution
b) A second set (one bottle from each cavity) was randomly pulled from the population This sample set was tested in the PPT3000 for CO2 shelf-life using the M-Rule
profile
c) The remaining samples were divided into two groups, boxed and shipped to two different test labs for long-term testing using the Zahm Nagel and Septum CO2 loss testing protocols
Methods of testing:
● AGR PPT3000 w/M-Rule calculation
● Long-term shelf-life using Zahm-Nagel
CO2 loss test
● Long-term shelf-life using Septum CO2 loss test
● M-Rule Prediction using M-Rule Web Model
Trang 3Actual Testing for Study
Long-term tests:
Bottles were cold-filled with carbonated water
and tested at the normal intervals, per Pepsi
qualifications, using the Zahm-Nagle and
Septum test methods
PPT3000 M-Rule tests:
Test profiles were developed for each of the
three bottle styles and loaded into the PPT3000
Sample sets were tested on the PPT3000 based on
these profiles and results documented
M-Rule Web Model:
M-Rule calculations were run using the “empty”
containers model, surface area was supplied by
the Design group, and weights of the bottles
prepared for this test
Test Results
The following graphs show consolidated data
on each of the sample sets Each chart plots test
results based on the Zahm-Nagel and Septum
real-time tests as well as predictive data from the
M-Rule Web Model and the PPT3000 M-Rule
Shelf-life tests
Notes:
1) PPT3000 test results are shown on the chart as a cluster of points rather than a trend This is because the PPT3000 is an instantaneous test and offers only one value for the predicted end result shelf life.
2) The Septum tests were performed with a higher initial carbonation level than the other tests This accounts for the position on the graphs.
Executive Summary of Results
Real-Time Tests:
Long-term shelf life tests conducted during this study performed as expected Both the Zahm-Nagle and Septum produced similar CO2 loss patterns This is evidenced in each of the charts for the representative bottle type Note that during this study, the Septum test was performed using a higher carbonation level than the other tests This accounts for the off-set of the graph However, when a correction is factored in for the higher initial carbonation levels, one can see a direct correlation of test results
Study results
Test run 20 oz 1 liter 2 liter Test
M-Rule Model 55 58 83 20 minutes PPT3000 M-Rule 55 62 89 60 seconds Pressure-based test
Internal CO2 test- 56±6* 56±7* 88±8* 84 days
Zahm-Nagle Internal CO2 test- 54±6* 67±7* 89±8* 84 days
Septum Test
* Note: Standard deviation for the Septum and Zahm-Nagel tests is between 0.02 and 0.1 volumes of CO 2
Trang 4Predictive Methods:
M-Rule Web-based Model, when appropriate
bottle parameters such as surface area, brimful
capacity, material characteristics, sidewall
thickness, and test conditions were input into
the program, produced similar results to both of
the real-time tests The PPT3000 using the
M-Rule Model likewise produced results that
corresponded favorably to the long term tests
Note, however, that the results from the PPT3000
represent shelf-life at a specific point in time
In this case it was when the CO2 loss reached
the 20% value
Conclusions
This series of tests show that the M-Rule
prediction methods for shelf-life determination
provide comparable results to long-term tests
using the same group of bottles under similar
conditions The results of these tests also
demonstrate that it is possible to provide accurate
shelf-life prediction of a container design using
the M-Rule Model in the laboratory based on the
analysis of bottle design characteristics
Tests with the PPT3000/M-Rule Model
further validate the prediction capabilities of the
M-Rule Model Tests involving the PPT3000
also show that shelf-life prediction capabilities
can be taken to the production floor to provide
real-time shelf-life data on production bottles, at
the time of production, and at an accuracy level
that corresponds with long-term test results
These test results confirm that the PPT3000 with M-Rule can provide shelf-life prediction data with reasonable accuracy in a fraction of time
it takes to do traditional tests This combination
of predictive analysis along with actual bottle performance data using the PPT3000 pressure/ expansion tests stands to offer a number of benefits to bottle manufacturers and fillers including:
● Capability to monitor shelf-life on a real-time basis
● Improved shelf-life management of production containers
● Faster response in the event of process-related issues
● Up-front data and documentation of predicted shelf-life performance prior
to container filling and shipment
● Potential to reduce or eliminate long-term testing
● Ability to monitor material utilization as
it pertains to package performance, at the time of production
The predictive capabilities offered by the M-Rule in the PPT3000 system make it possible
to perform on-the-floor evaluation of production bottles in a fast and economical way, with accurate results that correspond to traditional long-term testing methods When used in conjunction with a traditional long-term testing program, the PPT3000 with M-Rule can be a valuable tool for managing and maintaining the expected shelf-life of production bottles on an on-going basis
Copyright 2007
Rev 2