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35 Cards in this Set
- Front
- Back
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Tubes
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PERMITS CONTROLLED AMOUNTS TO BE DISPENSED
GOOD OPENING AND CLOSING ADEQUATE PROTECTION OF THE PRODUCT WITH A MINIMUM RISK OF CONTAMINATION OF REMAINING PRODUCT “SUCK BACK” LIGHT WEIGHT UNBREAKABLE HIGH SPEED FILLING EASILY DECORATED CHEAP |
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End Uses
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TOOTHPASTE
MEDICAL COSMETICS PERSONAL CARE |
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Materials
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PLASTIC
PLASTIC BARRIER LAMINATED METAL |
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FILLER SPEEDS ALL TUBE TYPES
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SINCE THE DIAMETER OF THE TUBE IS LARGE, FILLING SPEEDS ARE EXTREMELY FAST.
HIGH SPEED FILLER, STILL ANOTHER ADVANTAGE OF TUBES. |
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Tube Delivery to User
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Tubes are delivered sealed with the closure already attached from the manufacturer
Filler tube - diameter |
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FILLING LOCATER ALL TUBE TYPES
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IN A HIGH SPEED FILLING OPERATIONS, HOW DO YOU QUICKLY LOCATE THE BACK PANEL FROM THE FRONT TO HEAT SEAL OR CRIMP THE TUBES.
PRINTED MARK [DARK ON LIGHT BACKGROUND ] ON THE BACK PANEL OF A TUBE THAT LOCATES THE FRONT AND BACK PANEL DURING FILLING |
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METAL TUBES TUBE CLOSING
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CRIMPED BY REPEATEDLY
FOLDING THE ENDS OF THE TUBE WITH A SEALING COMPOUND. |
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PLASTIC and LAMINATE TUBE CLOSING (14)
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HEAT IS USED TO HEAT SEAL THE ENDS TOGETHER.
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Plastic and Laminating tubes (15)
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High Frequency – laminate
Ultra Sonic – laminate and plastic Hot Air – laminate and plastic Radiant heat – plastic Heated jaws - plastic |
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DATE/BATCH CODING INFORMATION ALL TUBE TYPES
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SEALING THE TUBE AND DATE AND/OR BATCH CODING IS DONE AT THE SAME TIME
USUALLY BLIND DEBOSSED INTO THE SEAL AREA OF THE TUBE. |
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Components of a tube (26)
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Length
Diameter Orifice Finish/head styles Material - tube Closure |
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PLASTIC AND LAMINATE FINISHES
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BOTH PLASTIC AND LAMINATE FINISHES ARE IDENTICAL, INJECTION MOLDED, THAT CAN ALLOW FOR DISPENSING CLOSURES OR AN ORIFICE SIZE TO DISPENSE PRODUCT.
THESE FINISHES FOLLOW, FOR THE MOST PART, BOTTLE FINISHES – DISPENSING CLOSURES VARIETY OF FINISHES, FLEXIBILITY IN DESIGN PLEASE NOTE THAT METAL TUBE FINISHES ARE VERY DIFFERENT, SEE METAL TUBE FINISHES BELOW |
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Types of tubes
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PLASTIC
LAMINATE METAL |
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Plastic Tube Advantages
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Plastic tubes are lightweight, leak-proof, durable, and nonbreakable.
They are used for products like hand creams, shampoos, and various other cosmetics and toiletries, such as cleansing creams, facial masks, and tanning lotions. They are also used for food, pharmaceuticals, household, and industrial products. The plastic tube has a memory -- it goes back to its original shape after squeezing. It maintains its attractiveness throughout the life of the contents and the tube remains smooth after squeezing. Clear or opaque |
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Plastic tube Manufacturing
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The first phase of the manufacturing process is extrusion. A mixture of resin and color concentrate is placed into an extruder hopper. The extruder is temperature controlled as the resin is fed through to ensure proper melt of the resin. The extruder die shape gives the shape of the tube. This is considered a “thin wall extrusion” vs. a “heavy wall extrusion”. Refer to your reading on extrusions for details.
After extruding, the item needs to be cooled and cut to length [sleeve] prior to “heading” operation. |
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Plastic tube manufacturing continued 1
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The most common method in the U.S. is the "downs" process of compression, molding the head onto the tube. In this process, the sleeve is placed on a conveyor that takes it to the heading operation where the shoulder of the head is bound to the body of the tube while, at the same time, the thread is formed. The sleeve is then placed on a mandrel and transferred down to the slug pick-up station. The hot melt strip or slug is fused onto the end of the sleeve and then transferred onto the mold station. At this point, in one operation, the angle of the shoulder, the thread and the orifice are molded at the end of the sleeve. The head is then cooled, removed from the mold, and transferred into a pin conveyor.
Two other heading methods are used in the U.S. and are found extensively worldwide: injection molding of the head to the sleeve, and an additional compression molding method whereby a molten donut of resin material is dropped into the mold station instead of the hot melt strip or slug. The head is composed of both the shoulder and the finish |
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Plastic tube manufacturing continued 2
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There needs to be a perfect bond between the head and the sleeve to prevent leakers.
Tremendous pressure is applied to the tube in use of the product at the head – sleeve point of the package. |
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Plastic tube manufacturing 3
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The tube is then ready for decorating
After decorating it is packed for shipment to fillers |
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Plastic materials felx tubes
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MATERIALS
LDPE-SOFT EASY TO SQUEEZE DUPONT ALATHON 2020T PREFER RESIN HDPE PP |
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Coatings
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MOST PLASTIC TUBES MUST BE COATED. COATING RESINS ARE APPLIED TO THE BASIC PLASTIC TUBES TO IMPROVE THE BARRIER PROPERTIES OF THE TUBE. EPOXY AND ACRYLIC COATINGS
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FDA considerations
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COATINGS ARE APPLIED TO EXTERNAL SURFACE OF TUBE, NOT IN DIRECT CONTACT WITH A PRODUCT
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Plastic barrier tube
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TECHNOLOGIES
EVOH LAYER IN A FIVE LAYER BODY WALL. CALLED THE CO-EX TUBE LDPE / TIE /EVOH /TIE /LDPE EVA USED AS A BARRIER MATERIAL |
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Plastic barrier tube advantages
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ADVANTAGES :
A CLEAR TUBE WITH BARRIER PROPERTIES CURRENTLY, THE BARRIER TUBE [LAMINATE] IS NOT A CLEAR TUBE DUE TO THE AL LAYER |
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Laminated Tube advantages
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Laminated squeeze tubes offer a form of tube material with the advantages of plastic but with barrier properties close to those of metal.
Laminated tubes have a good "feel" and maintain their attractiveness throughout the life of their contents. The first laminated tubes were used primarily to package high-volume products like toothpaste, but now are used for many other products ranging from denture adhesives and artists' paints to hair-care products and pharmaceuticals. Opaque only Seam running the entire length |
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Laminate Tube MANUFACTURING
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that is ideal for added flexibility or smaller quantities. Laminate tubes are manufactured by using the laminate feed stock that is simply a poly-foil-poly structure that has polyethylene on either side of a thin gauge of foil. Some laminate structures also incorporate paper.
The most popular way of decorating the laminate feedstock material is by either letterpress or rotogravure printing. Rotogravure printing is used extensively to provide a high quality print buried within the laminate structure. Letterpress printing is used to decorate the surface of the laminate feedstock just prior to tubing |
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Laminate Tube MANUFACTURING
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The laminate tubes are formed by placing the rolls of laminate material onto the needles of the machine.
The material is then taken in a flat state and fed through the forming rolls, which very gently turn the tube and form it into a cylinder of variable size depending on the customer's needs: poly/foil/poly Heat generated by high frequency fuses the sides of the material together to form a solid cylindrical tube. After the tube has been formed, it goes to the cutting station that slices it into various lengths. |
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Laminate tube manufacturing
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After the tube has been formed into the desired cylindrical shape and length, the tube is transferred to the heading operation.
As with plastic tubes, several heading methodologies are available. One particular method uses a preformed head: Injection molded head. The preformed head [shoulder and finish] are fused to the top of the tube by means of heat generated by high frequency energy. Other methodologies apply the head to the sleeve in a similar manner to plastic tubes - either by injection or compression molding whereby heat fuses the head to the tube body. |
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Laminate tube manufacturing in general:
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Heat generated by high frequency fuses the sides of the material together to form a solid cylindrical tube. Critical is the bonding of the head to the tube body
Since there is five layers of material, it only bonds on the inside layer. After the tube has been formed, it goes to the cutting station that slices it into various lengths |
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Metal Tube advantages
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The metal tube is air tight and impermeable and has "no suckback."
These properties give superior protection to contents, keeping them fresh and uncontaminated through long periods of intermittent use. Internal linings applied to the metal give it added compatibility for products that are highly alkaline or acidic. Controlled dispensing The metal tube is opaque Can also manufacture ‘blind ends’ [opening by user by piercing the ‘closed end’-mostly medical products] |
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Metal tube manufacturing
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The metal, lead, tin or, more often, aluminum tube, has been around since 1841. As a testimony to its versatility and resilience, it is now packaged throughout the world with production in excess of a half billion pieces per year in the United States alone.
The manufacture of aluminum tubes starts with an aluminum slug or blank, as it is called. It is fed into a set of tools in the die which then extrude it. This extrusion press then roughly forms a completed tube form. Once this extrusion process takes place, the aluminum becomes work hardened. |
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Metal tube manufacturing
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The next step is to trim the tube to the specified length on both the top and bottom ends. At this point, the tube is threaded which enables us to screw on the cap
The next step, which is used primarily in the pharmaceutical industry, is the spray application of an internal lining. This acts as barrier protection for metal sensitive products between the exposed aluminum and the pharmaceutical, or other product, to be packaged. |
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Coatings lined to protect...include
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LINED TO PROTECT THE
CORROSIVE ELEMENTS OF PRODUCT FROM REACTING WITH MATERIAL COATINGS INCLUDE: EPOXY-PHENOLIC OR ACRYLIC LACQUERS |
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metal tube manufacturing
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If the tube is not internally coated, it will bypass the internal lining step and go to the next step which is the coater rolling of a base coat onto the tube. This coat prepares the tube for the application of offset printing. The base coat is then cured and brought back to a printing machine which puts on the customer's specified colors and copy. You can see all these tubes detailed for the different customers who require different types of decoration.
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Metal tubes decorating
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BEGINS WITH A WHITE BASE COAT
FOR VISIBILITY ON PRINTING PROCESS-OFFSET PROCESS OFFSET/HOTSTAMP OFFSET MOST COMMON [6 COLOR] |
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Metal Tube finishes
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SMALL DIAMETER FINISHES NEED EXTRA THREADS PER INCH AND MORE CLOSURE TO FINISH CONTACT FOR FRICTION=CLOSURE TORQUE RETENTION
NO E DIMENSION ONLY FOR METAL TUBES NO. 12, 16, 20, 28…..SEE ATTACH SLIDE FOR DETAILS ALSO METAL TUBES ALLOW FOR ‘BLIND END’ FINISHES |
