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New Materials & New New Materials & New
Markets for ISBMMarkets for ISBM
Patrick Etesse
R&D Packaging, Brussels Innovation Centre
3rd Conference on Rotomoulding
Thermoforming Stretch Blow Moulding
Ecole des Mines, Albi, March 13 2009
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ISBM Packaging ISBM Packaging –– Innovation strategy Innovation strategy
and examplesand examples
1. Procter & Gamble innovation strategy
2. P&G ISBM packaging needs
3. New ISBM Material in Market examples
4. Our ISBM pilot plant facilities
3
ISBM Packaging ISBM Packaging –– Innovation strategy Innovation strategy
and examplesand examples
1. Procter & Gamble innovation strategy
2. P&G ISBM packaging needs
3. New ISBM Material in Market examples
4. Our ISBM pilot plant facilities
4
Over $84 billion in sales in 07/08
300 brands in over 160 countries
#1 or #2 in 80% of our categories
24 billion-dollar brands
Founded in Ohio (USA) in 1837
Procter & GambleProcter & Gamble
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Innovation strategy
“Our vision is simple. We want P&G to be
known as the company that
collaborates – inside and outside –
better than any other company
in the world.”
A.G. Lafley
President and
Chief Executive Officer
Acquire 50% of our innovations from outside P&G
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DisruptiveTechnologies
Improved
ways to reach
consumers
How to participate
in new channels
Shared
testing
facilities
“Cooked”
Products
&
Packaging
New
business
models
What do we look for?
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Innovation strategyInnovation strategyCo-developments in the market
Olay VitaminsCrest New TubesTide Stainbrush
Clairol In-Store Shade Selector
Kandoo WipesPantene Sonic Comb
Mr. Clean Magic Eraser
Glad Press N Seal
Charmin Fresh Mates
Swiffer Duster
Mr. Clean Autodry
Olay Daily Facial Pillows Old Spice
Shave GelVisia Beauty Imaging
Olay Regenerist
Olay White Radiance Facial
Mask
SK-II Facial MaskSK-II Airtouch
Foundation
Prilosec OTC
Crest Scratch N Sniff Pkg.
Crest Liquid Dentifrice
PuR / Whirlpool
Refrigerator Filters
PuR Furnace Filters
OTC Drug Registration
s
Metamucil Capsules
Pringles Dips
Pantene Hair Styling
Products
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ISBM Packaging ISBM Packaging –– Innovation strategy Innovation strategy
and examplesand examples
1. Procter & Gamble innovation strategy
2. P&G ISBM packaging needs
3. New ISBM Material in Market examples
4. Our ISBM pilot plant facilities
10
500350150100Index
3000 -
7000
2500 –
3500500 – 2500500 - 1500
Flexural modulus
(Mpa)
ISBM
PET
ISBM
PP
EBM
PP
EBM
HDPE
Why ISBM ?Why ISBM ?
* Provides access to higher flexural modulus w/o stress cracking
* Significantly increases material flexural modulus
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Expected benefitsExpected benefits
Small sizes (200-500ml) 15% lighter
Large sizes (1L & up) 30% lighterMore sustainable
Close coupling when needed
Create scale in preform (from 80 to 12-15 P&G necks)
Design for one machine platform
Win on cost
Shine, Clarity when needed
Speed to market: fast color/size change overWin on shelf
ISBM benefits vs. EBM
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Packaging innovation needsPackaging innovation needs
Convert 80% of today’s bottle business to ISBM
80%
19%1%
HDPE
PET
PP
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-
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
15-250 250-600 600-1500 1500-2500 2500-9000 unknown
MM units
Weight
Size range distributionSize range distribution
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ISBM for P&GISBM for P&G
Challenges
• PET is not always the best material for household products
• Wide aspect ratio (up to 4)
• Size range extends up to 9L
Solutions
• Extend processing capabilities to other materials
• Preferential heating
• Ergonomic handle for large sizes
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Example: ISBM PPExample: ISBM PP
1) The opportunity
2) The blow process
3) The injection process
4) Small Size Proof of Principle – Iris 400 ml
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Defining the opportunity - Materials selection charts
Lines if equivalency for different requirements
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Initial topload modelling – data from standard InstronequipmentPET - topload PP -
topload
322
208
162
210
199
290
Using these results we can generate lines of equivalency for a material selection chart
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Accuracy of input data is critical
- New Instron Advanced Video Extensometer
- P&G has installed a video extensometer at BRTC
Performed at Instron UK (High Wycombe)
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Materials selection charts – comparing 1903 & PET
Only for Mars shape can 1903 outperform PET
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Materials selection charts – comparing 1685 & PET
1685 outperforms PET for all shapes
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-0.4%-5.2%-9.8%Stretchene 1685
+11.2%+4.4%-2.0%Stretchene 1903
ShrekMagnetMarsMaterial
Predicted weight change for PP resins to achieve equal topload performance to PET.
Including the neck weight difference at the indicated bottle weights
-4.9%-9.8%-11.9%Stretchene 1685
+6.7%-0.2%-4.1%Stretchene 1903
Shrek (45g)Magnet (45g)Mars (27g)Material
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Conclusions
• A weight saving of 0-10% can be gained by using PP instead of PET if:
a) A specialist material is used
b) A wall thickness distribution and variation equal to PET is achieved
• If the above conditions are not met, PP will require higher weights than PET
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KEY POINT –the wall thickness distribution need to be correct.
For magnet; IF 10% of the material is moved from 1 side to another, toploaddrops by 7%
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The blow process
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Strain hardening with sequential stretch ratios
Performed at the University of Bradford
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Conclusions
• Current process and preform design do not result in optimal material properties
• To achieve these properties very significant changes would be needed to be made to preform design which would have detrimental cycle time effects
• Strain hardening can be seen in PP but this effect is less critical than temperature variation
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The injection cycle
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Conclusions
• Total cycle time for PP is not defined by injection time
• Injection can be quicker than PET for opaque bottles
• Cooling is much slower than PET resulting in overall higher cycle time (4 to 5 s additional)
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Small size proof of principleSmall size proof of principle
• Achieved ISBM PP bottles 15% lighter than EBM HDPE and up to 40% stronger.
• Requires very good process control
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Iris 400 PP Topload
234
309
353343
247
369
100
125
150
175
200
225
250
275
300
325
350
375
400
425
SBO 2/3: 1903 SBO 2/3: 1685 SBO 1/2: 1903
(24h)
SBO 1/2: 1685
(24h)
SBO 1/2: 1903 SBO 1/2: 1685
Machine: Resin
To
plo
ad
(N
)
Max
Min
Mean
Min Spec = 200N
HDPE = 244N
Note:
SBO 2/3: n=12
SBO 1/2 (24 h): n=6
SBO 1/2: n=20
Test 1: SBO 2/3 Test 2: SBO 1/2
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ISBM Packaging ISBM Packaging –– Innovation strategy Innovation strategy
and examplesand examples
1. Procter & Gamble innovation strategy
2. P&G ISBM packaging needs
3. New ISBM Material in Market examples
4. Our ISBM pilot plant facilities
32
Market examplesMarket examplesBeauty Care
Samson
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Market examplesHome Care
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Market examplesMarket examplesAriel Bleach & Laundry Additive
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Market examplesMarket examplesAriel Bleach & Laundry Additive – the innovation
ISBM / PP bottle:• Transparency & soft touch• Excellent ESCR• O2 Permeability for bleach• Low WVTR for shelf life• 15% light weight
ISBM PET doser:• Transparency• ¼ turn opening & seal
Bottle/grip design:• Easy-to-hold grip• 2L handling requirement
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Market examplesMarket examplesAriel Bleach & Laundry Additive – the cooperation
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Market examplesMarket examplesVicks Throat Drops
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Market examplesVicks Throat Drops – the innovations
Optimized cap:• Improved seal integrity• 30% light weighted
ISBM PP jar:• High transparency• Higher moisture barrier• 20% light weighted
Time to market:• 10 months from concept
Vicks PP throat drop jars are the largest & lightest clear Polypropylene jars with an injection molded neck to be commercially manufactured till dateDr. S. Agarwal (Board of directors SPE)
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Market examplesMarket examplesVicks Throat Drops – the cooperation
40
ISBM Packaging ISBM Packaging –– Innovation strategy Innovation strategy
and examplesand examples
1. Procter & Gamble innovation strategy
2. P&G ISBM packaging needs
3. New ISBM Material in Market examples
4. Our ISBM pilot plant facilities
41
P&G Pilot PlantP&G Pilot Plant
Rotary pilot unit (Cincinnati):
SBO 2/10 as of April 2009
Prototyping of sizes below 2.5L
New Materials testing
Validation of ISBM modeling tools
Linear Pilot Unit (Switzerland):
• Compact 2XL linear as of May 2009
• Focus on > 2.5L Sizes but small size capable
• Handled Bottle Development
• Partner with machine manufacturers & non competitors
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Chosen PlatformsChosen Platforms
Hopper + rail + guideHopper + rail + guidePreform Feeding System
pneumaticvariable angle stretching camStretch Rod Speed
< $10M per format change< $10M per format changeCost to size change Machine
129Heating Zones per Module (unit)
510Heating Modules (unit)
6050Pitch (in mm)
PET and PPPET and PPProcess Capabilities
430340Max Bottle Height under neck ring
(mm)
10L2.5LMax Bottle Volume (liters)
200115 shell (up to 140 GUPM)Max Bottle Diameter (in mm)
3535Max Neck Height (mm)
development+/- 10° (+/- 3° in mold)Neck Orientation
5548.5Max neck ring Ø (mm)
developmentYesPreferential Heating
1200 per cavity•1400 per cavity inc. preferential heating•1100 per cavity with +/- 3° neck orientation)
Max Production Rate (bph)
1 or 21 or 2Max. Number of Cavities
Lab Machine > 2.5L @ BICSidel SBO 2XL
Lab Machine < 2.5L @ BRTCSidel SBO 2/10 Lab Universal
Machine Characteristics
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Modeling & Simulation VisionModeling & Simulation Vision
Model that supports our development processes• Bottle/preform design process
• Reheat blowing process
Thick preforms, oval bottles & new materials
Goal
Thicknessdistribution
Mat. propertydistribution
Bottle3D
Processingparameters
ISBMM&S
VPS(topload, squeeze,
drop, conveying…)
Preformdesign
Material
Optimization
Bottleperformance
Bottledesign
Goal
Thicknessdistribution
Mat. propertydistribution
Bottle3D
Processingparameters
ISBMM&S
VPS(topload, squeeze,
drop, conveying…)
Preformdesign
Material
Optimization
Bottleperformance
Bottledesign
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Tools Tools -- approaches of current solutionsapproaches of current solutions
1st Principles• Tailored to Sidel• Pref. heating• Range of PET mats• PP reheat
Proprietary• Cylindrical validated• Cyl mapped to 3D• Range of PET mats• No PP today
Reheat
Stretch-Blow
1st Principles• Flexible oven setup• No pref. heating• Range of materials• PP reheat?
FEM• Elasto-viscoplastic• Any 3D shape• Range of PET mats• No PP today
1st Principles• By Phillips / Fr
FEM• Elasto-viscoplastic• Any 3D shape• Few PET mats• No PP today
• Via internet• Non-expert interface• Output: Abaqus input
System
Virtual PrototypingBy PTI
BlowSimBy NRC Canada
APT Research ProjectBy Univ Belfast & et.
• Software license• Non-expert interface• Output: FEM input• Also does EBM
• Abaqus or internet• Dual interface• Output = input
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Our Needs & PartnershipOur Needs & Partnership
Our Needs
• Reheat model for (indirect) preferential heating
• FEA model for stretch-blow molding of bottles
• Effective constitutive models incl. tests
Partnership
• Validation center w/ SIDEL machines
• Provide IT support
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Patrick Etesse
Temselaan 100
B-1853 Strombeek-BeverTel. +32-2-456-4249
Email etesse.p@pg.com
Thank You!
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