Tekni Tekni - - Films Films Troubleshooting Troubleshooting Thermoformable Thermoformable Packaging Packaging Optimizing the thermoforming Optimizing the thermoforming process with differing materials. process with differing materials. TEKNI-FILMS TEKNI-FILMS A Division of Troubleshooting Troubleshooting Thermoformable Thermoformable Packaging Packaging Optimizing the thermoforming Optimizing the thermoforming process with differing materials. process with differing materials. TEKNI-FILMS TEKNI-FILMS Company A
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Optimizing the thermoformingOptimizing the thermoformingprocess with differing materials.process with differing materials.
TEKNI-FILMSTEKNI-FILMSCompanyA
TekniTekni--FilmsFilms
Defining the Manufacturing ProcessDefining the Manufacturing Process
•• All processes contain variables of threeAll processes contain variables of threediffering types:differing types:
–– Design VariablesDesign Variables
–– Production VariablesProduction Variables
–– Manpower VariablesManpower Variables
•• TekniTekni-Films-Films’’ Troubleshooting Guide will Troubleshooting Guide willaddress the design and production variables.address the design and production variables.
TekniTekni--FilmsFilms
Part I - Design VariablesPart I - Design Variables
Blister Machine Process SchematicBlister Machine Process Schematic
TekniTekni--FilmsFilms
Types of Machines and Sealing DevicesTypes of Machines and Sealing Devices
Rotary, continuous web movement
Platen, indexed web movement
Cam, IMA, Cam, IMA, KlocknerKlockner, , NoackNoack, and , and UhlmannUhlmannproduce indexing machinery.produce indexing machinery.
Bosch, IMA produce Bosch, IMA producerotary rotary thermoformersthermoformers
TekniTekni--FilmsFilms
More Machinery VariablesMore Machinery Variables
•• Film Heating - The number and location ofFilm Heating - The number and location ofcontrolled heating zones allows for morecontrolled heating zones allows for morecontrolled and consistent web heating.controlled and consistent web heating.Ideally the heating plates are 3 indexesIdeally the heating plates are 3 indexeslong.long.
•• Blister Cavities can be filled either byBlister Cavities can be filled either byflooding the fill zone with pills, or byflooding the fill zone with pills, or bydedicated filling manifolds.dedicated filling manifolds.
•• Cooling plates after forming and sealing toCooling plates after forming and sealing tobe present.be present.
•• Molds may be coated with special releasingMolds may be coated with special releasingmaterials to aid in blister separation from thematerials to aid in blister separation from thetooling. Different coatings may aid intooling. Different coatings may aid inseparating one type of film, but may enhanceseparating one type of film, but may enhancethe bond to another.the bond to another.
•• Plug assisted cavities physically Plug assisted cavities physically ““pushpush”” the thematerial prior to itmaterial prior to it’’s final pressurized airs final pressurized airforming.forming.
TekniTekni--FilmsFilms
Part II- Production VariablesPart II- Production Variables
Controlling the process toyield optimal results.
TekniTekni--FilmsFilms
Film Heating StationFilm Heating Station
General Suggestions:
• Use the lowest setting possibleto minimize film shrinkage andcurl, while still forming completecavities.• Make sure platens are flat,parallel in alignment and gap.• Adjust temperature in 5O
increments.• Heating plate length: 3 indexes.
T1 T2 T3
T4 T5 T6
TekniTekni--FilmsFilms
Film Heating StationFilm Heating Station
PVC - Upper and lower platens set to thesame temperature, zones need not beincreased for best thermoforming results.
PCTFE PCTFE or PVdC coating -- Platen facingPCTFE or PVdC coating should be lowerthan that facing PVC. Incremental rise intemperature zones is generally desirable.
Typical Temperature Setting:
T1: 130 O C T2: 135 O C T3: 140 O C
T4: 125 O C T5: 130 O C T6: 135 O C
T1 T2 T3
T4 T5 T6
TekniTekni--FilmsFilms
Blister Cavity FormationBlister Cavity Formation
General Suggestions:
•Always activate plug assist to atleast 50% when available (up to75% ). Plug assist aids in moreuniform cavity thicknessdistribution, and usually resultsin lower platen heat settings.• Air forming pressure of 60-120PSI (4-8 bar) is optimal.• Use matched tooling.
P1
TekniTekni--FilmsFilms
Blister Cavity FormationBlister Cavity Formation
PVC - Almost any cooling conditions andcoatings will form cavities.
PVdC coatings - Require Teflon coatedcavities to lengthen tool life. Cold tools arediscouraged to reduce PVdC cracking.
PCTFEPCTFE -- These materials may bond withTeflon coatings. Mold temperaturesshould be “room temperature”. Plugassist is recommended.
P1
TekniTekni--FilmsFilms
Blister Cavity FillingBlister Cavity Filling
General Suggestions:
•Always insure improperlyoriented solid dosage forms andcrushed product are removedprior to the lidstock lamination.
•A change in film gage will affectproduct fit into the blister cavity.
• Incompletely formed cavitieswill negatively affect fillingperformance
TekniTekni--FilmsFilms
Winding PCTFE OUT
Winding PCTFE IN
Alu Foil LiddingALWAYS SEALS TO THE PVC SIDE
PCTFE on outside of blister
PCTFE Lamination Blister Package
PCTFE Film
PVC
Adhesive
You must specify the winding of the PCTFE side OUT or IN for the slit roll depending on the machine configuration
Film ShrinkageFilm ShrinkageMost Thermoforming films shrink somewhat during the thermoformingprocess. Concern is placed particularly on those films which shrink in
an erratic manner.
PCTFEPCTFE films shrink more than PVC in the trans-machine direction films shrink more than PVC in the trans-machine direction(TD). This shrinking both narrows the web and curls the film.(TD). This shrinking both narrows the web and curls the film.Properly processed film may shrink 3-5% for copolymer and 1-3%Properly processed film may shrink 3-5% for copolymer and 1-3%for for homopolymer homopolymer PCTFE films.PCTFE films.
Note:Note: With all films, tension in the machine direction will result in With all films, tension in the machine direction will result inloss of web width. Lessening the heat or increasing lines speedsloss of web width. Lessening the heat or increasing lines speedswill reduce the TD shrinkage in most films.will reduce the TD shrinkage in most films.
TekniTekni--FilmsFilms
Film CurlFilm Curl
•• Film Curl occurs when two or more films haveFilm Curl occurs when two or more films havedifferent shrinkage rates. This most commonlydifferent shrinkage rates. This most commonlyoccurs with occurs with PCTFE films that are laminated to PVC with films that are laminated to PVC witha PE tie layer.a PE tie layer.
•• Typical solutions to this difficulty are identical toTypical solutions to this difficulty are identical toreducing film shrinkage. Curl can also be reduced byreducing film shrinkage. Curl can also be reduced byduplex laminations and conversion to duplex laminations and conversion to homopolymerhomopolymermaterials.materials.
TekniTekni--FilmsFilms
Film StickingFilm Sticking
• May occur between the heating platens and/or to theforming mold.
• Most common with PVdC/PVC materials (PVdC-coatingrelatively tacky).
• Cleanliness & condition of heating platen surfacesimportant.
• Gap between platens should be uniform over entire area.
• Platens should be replaced or reconditioned periodicallywith a non-stick (e.g., Teflon) surface.
• Additional mold-cooling recommended for PVdC/PVC,but not for PCTFE laminations.
• Sticking may cause MD-stretching and web shrinkage.
TekniTekni--FilmsFilms
Film Film DelaminationDelamination
• PVC/PE/PCTFE - Adhesive is semi-activatedduring lamination, and is fully-activated uponapplication of heat during thermoforming.