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Packaging Authorization for Refillable PET Bottles
REQUIREMENTS
REFPET Bottle Authorization Matrices REFPET Bottle Specifications PK-RQ-065 PK-SP-045
TEST PROCEDURES
Materials REFPET Bottle Acetaldehyde Test24-Hour REFPET Bottle Acetaldehyde TestGround Preforms REFPET Bottle Appearance and Color Evaluation REFPET Bottle Scientific and Regulatory Affairs Process REFPET Bottle Taste Compatibility Test Dimensional REFPET Bottle Dimensions EvaluationExterior REFPET Bottle Dimensions EvaluationFinish Physical Performance REFPET Bottle Capacity Change (Shrinkage) Test REFPET Bottle Carbonation Retention Test REFPET Bottle Drop Impact Test REFPET Bottle Durability TestAbbreviated Trip-Per-Two-Day Washing REFPET Bottle Durability TestStandard Trip-Per-Two-Day Washing REFPET Bottle Empty Weight and As-Delivered Capacity Test REFPET Bottle Fill-Point Variation Test REFPET Bottle Internal Pressure Test REFPET Bottle Perpendicularity Test REFPET Bottle Plastic Distribution Test REFPET Bottle Support Ledge Strength Test REFPET Bottle Thermal Stability Test REFPET Bottle Vertical Load TestEmpty PK-PR-218 PK-PR-219 PK-PR-220 PK-PR-221 PK-PR-222 PK-PR-223 PK-PR-224 PK-PR-225 PK-PR-270 PK-PR-226 PK-PR-227 PK-PR-228 PK-PR-229 PK-PR-207 PK-PR-208 PK-PR-215 PK-PR-216 PK-PR-217 PK-PR-205 PK-PR-206
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Return to Plastics
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Packaging Authorization for Refillable PET Bottles
TEST PROCEDURES (CONTINUED)
Functional REFPET Bottle Line Trial PK-PR-055
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Contents
General ...........................................................................................................1 Filling Test Packages ....................................................................................2 Materials Authorization Matrix .....................................................................2 Packaging Authorization Matrix...................................................................3
Requirements
General
This document is an integral component of New Package Authorization, PK-RQ-020. The following Materials and Packaging Authorization Matrices summarize the requirements and tests for authorizing a RefPET bottle for a specific set of circumstances. Which evaluations are required depends on whether a specific combination of package components has been used previously. Therefore, it is important to include authorization information in the Global Packaging database. The testing requirements and procedures referenced herein do not preclude any additional testing that may be required where local regulations or business needs make practical or necessary the adaptation of more stringent requirements. To authorize additional plants or divisions to use an approved bottle design (shape, size, weight), the division may delegate authorization responsibility to the bottler for filling line and finish compatibility.
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Nitrogen
Appearance
Color
New Resin from New or Existing Resin Supplier New resin or change in resin formulation (new components) Approved PET resin with approved CyclePET material Any change other than resin chemistry (for example, change in IV or decrease in component levels) New Resin Plant Approved resin New Additives Any new additive used in plastic bottles (for example, colorants and UV additives)
SRA
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Functional Tests
Operational
Transport
Durability
New Supplier or LicenseePlastic Bottles or PreformsNew Plant (Bottle Blowing) Using Approved Resin
Bottles Preforms Resin or additive new to supplier New blow molds for approved design/size New injection molds New bottle design/size Decrease in weight New blow mold plant/ authorized preforms Bottles Preforms
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Warpage
Resin IV
Vending
Field
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Summary of Change
New document.
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Contents
Materials Specifications................................................................................2 Acetaldehyde ............................................................................................2 Appearance...............................................................................................2 Color..........................................................................................................3 Scientific and Regulatory Affairs (SRA) and Certificate of Food Law Compliance .................................................................................3 Taste Compatibility....................................................................................3 Dimensional Specifications..........................................................................5 Exterior ......................................................................................................5 Finish.........................................................................................................5 Physical Performance Specifications..........................................................6 Capacity Change.......................................................................................6 Carbonation Retention ..............................................................................6 Drop Impact Resistance............................................................................6 Durability ...................................................................................................7 Empty Weight and Capacity As-Delivered..............................................7 Fill-Point Variation .....................................................................................8 Internal Pressure Strength ........................................................................8 Perpendicularity ........................................................................................8 Plastic Distribution.....................................................................................8 Support Ledge Strength ............................................................................9 Thermal Stability .......................................................................................9 Vertical Load .............................................................................................9
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Clear resins
The acetaldehyde concentration of freshly blown bottles made from all clear resins shall be as follows:
Measurement Method Standard 24-hour airspace analysis Ground preform Criteria The maximum in any single bottle shall not exceed 5.0 micrograms/liter The maximum in any single bottle shall not exceed 25.0 micrograms/gram
The acetaldehyde concentration of freshly blown bottles made from all green and amber resins shall be as follows:
Measurement Method Standard 24-hour airspace analysis Ground preform Criteria The maximum in any single bottle shall not exceed 15.0 micrograms/liter The maximum in any single bottle shall not exceed 25.0 micrograms/gram
Appearance
Test Procedure: REFPET Bottle Appearance and Color Evaluation, PK-PR-217 Blemishes (bubbles, unmelted resin, dirt specks, pitting, condensation marks) shall not constitute a more objectionable appearance than that of the limit samples submitted to and authorized in writing by a division of The Coca-Cola Company. Except for the exterior bottom of the base, there shall be no foreign material (dirt) on the surfaces of the containers, which would not come off in a typical rinser used for one-way PET bottles. The bottles shall not develop objectionable scuffing more severe than limit samples submitted to and authorized in writing by a division of The Coca-Cola Company when subjected to normal handling.
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Scientific and Regulatory Affairs (SRA) and Certificate of Food Law Compliance
Test Procedure: REFPET Bottle Scientific and Regulatory Affairs Process, PK-PR-200 The material reviewed must meet all internal SRA requirements, as well as comply with local or FDA requirements for food contact use. The material must also meet any requirements established by the Package Development and Design Department to minimize sensory impact. New materials such as resins, additives, and colorants are approved by SRA. After SRA approval is obtained, divisions are responsible for ensuring that the material meets all applicable food laws for the intended countries of use.
Taste Compatibility
Test Procedure: REFPET Bottle Taste Compatibility Test, PK-PR-206 A test package meets the compatibility specification when it imparts no significant taste difference (at a 95% confidence level) when compared to control samples after the required intervals. Sample ballots and statistical tables for interpreting triangle tests are in the test procedure. Any taste test that reveals a significant taste difference (at a 0.05 probability level or 95% confidence level) when compared to the control after each required interval must be repeated within 10 days using extra samples from the test set. If the repeat taste test is also significant, the package fails the taste compatibility test and the subsequent taste interval is canceled. If a trend occurs at any interval, perform a subsequent interval. If a trend occurs again, the package fails the taste compatibility test. If a repeat taste test does not confirm a significant taste result, the package passes the taste compatibility test. A trend is one correct taste judgment less than the number required for a significant taste result at a 0.05 probability level or 95% confidence level. For example, 20 correct taste judgments for a 42- member triangle taste panel are significant according to the
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Finish
Test Procedure: REFPET Bottle Dimensions EvaluationFinish, PK-PR-208 Preforms and bottles must conform to the latest revisions of the preform drawing supplied by the manufacturer and bottle drawing supplied by The Coca-Cola Company. The supplier must provide to the Company or any of its divisions, upon request, copies of the most recent drawings for each finish specified for use with the bottles it will supply. The finish shall be fully formed and free of sharp edges, flash, overhang, or any other irregularity that will adversely affect carbonation retention, removal torque, closure or finish venting, or consumer comfort when the product is consumed from the bottle. Except for damage from abuse, the finish dimensions shall remain within specified drawing tolerances for the life of the bottle. Additionally, finish changes due to age, washing, cycling, and normal use shall not adversely affect finish performance including closure application, removal torque, carbonation retention, and opening performance. Any process or post process changes performed by the manufacturer to minimize finish shrinkage, stress cracking and the like on cycled bottles shall not increase the susceptibility of the finish to damage.
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In addition to the above, all bottles will meet the applicable government requirements on capacity.
Carbonation Retention
Test procedure: REFPET Bottle Carbonation Retention Test, PK-PR-219 The minimum allowable carbonation level of product agitated to equilibrium pressure in an unopened bottle originally filled to the nominal fill-point at 4.0 volumes of CO2 [as read at 22.2C 1.1C (72 F 2F)] and a maximum of 3 bar (4 psig air), at any relative humidity, shall be 3.4 volumes after 24 weeks. All carbonation readings should be taken at 22.2C 1.1C (72F 2F) from the Zahm & Nagel table for CO2 dissolved in water.
Test procedure: REFPET Bottle Drop Impact Test, PK-PR-229 A sealed bottle originally filled to the nominal fill-point with product at 4.0 volumes apparent carbonation (as read at any temperature between 1.7C (35F) and 23.9C (75F) from the Zahm & Nagel table for CO2 dissolved in water) and a maximum of .3 bar (4 psig) air shall not fail when dropped in any mode, except on the finish, from a height of 0.9 meters (3 feet) onto a rigidly fastened steel plate for temperatures between 1.7C (35F) and 37.8C (*100F).
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The filled bottle shall not exhibit sufficient stress cracking or other bottle changes that affect the ability of the bottle to function as intended under normal production, handling, and distribution conditions. The durability of the test bottles must equal or exceed the durability of the control bottles.
The number of bottles having capacities above the tolerance shall not be greater than 2 percent of a sample. The number of bottles having capacities below the tolerance shall not be greater than 2 percent of a sample. All bottles shall be within +1.3/-0 percent of the stated capacity.
The brimful capacity tolerance of new as-delivered bottles shall not exceed 1 percent of nominal as specified on the Company drawing. In addition to the above, all bottles shall meet the applicable government requirements on capacity.
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The internal pressure shall be attained by injecting carbon dioxide gas at the constant rate of .69 bar gauge per second (10 psig per second). The sample group shall be composed of a mixture of bottles ranging in age from 0 to 20 trips.
Internal Pressure Test procedure: REFPET Bottle Internal Pressure Test, PK-PR-225 Strength
The bottle shall withstand a minimum internal pressure of 10.3 bars (150 psi) at any relative humidity and any temperature between 1.6C (35F) and 60C (140F) for 60 seconds without failure.
Perpendicularity
Test Procedure: REFPET Bottle Perpendicularity Test, PK-PR-270 Deviation from the perpendicular shall be less than the appropriate numbers in the table (total indicator reading) when measured with the bottle resting on its base and rotated 360 against a centering device. 500 ml 750 ml 1 liter 2 liter 4.4 mm (0.172 inch) 5.1 mm (0.201 inch) 5.6 mm (0.220 inch) 6.5 mm (0.256 inch)
Plastic Distribution
Test procedure: REFPET Bottle Plastic Distribution Test Test, PK-PR-226 Supplier will use good manufacturing practices to maximize bottle properties through maintaining material distribution. Tolerance in wall thickness is 5.0 percent of nominal.
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The conical label panel shall remain axially flat and not become convex or concave. The following parameters shall not exceed the listed criteria at 38C (100F) and the listed times.
Time (Days) One/Seven Parameter Diameter (%) Height (%) Perpendicularity (mm/in) Fill-point Drop (mm) 500 ml 2.5/3.0 1.5/2.0 4.7/5.2 7.0/9.6 750 ml 2.5/3.0 1.5/2.0 5.5/5.9 8.1/1 1 liter 2.5/3.0 1.5/2.0 6.2/6.7 9.0/12.4 1.5 liter 2.5/3.0 1.5/2.0 7.0/7.6 10.2/14.0 2 liter 2.5/3.0 1.5/2.0 7.1/7.7 10.4/14.0
Vertical Load
Test procedure: REFPET Bottle Vertical Load TestEmpty, PK-PR-229 The minimum vertical load that a bottle shall withstand shall be such that the bottle can be satisfactorily filled with any filler bowl pressure up to 8.3 bars (120 psig) and satisfactorily capped and filled with noncarbonated water. The bottle shall successfully withstand any stacking loads it may incur during normal handling and distribution without developing stress cracking or significant structural weakness. The minimum vertical load strength that empty bottles should exhibit in laboratory tests is 54.6 kg (120 pounds).
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Test Equipment............................................................................................. 1 Procedure ...................................................................................................... 2 Preparing Sample PET Bottles ................................................................ 2 Preparing Acetaldehyde Gas Specifications............................................ 2 Analysis of Bottles ............................................................................. 3 Calculations ....................................................................................... 4 Preparation of Aqueous Acetaldehyde Solutions..................................... 4 Test Equipment and Materials........................................................... 4 Procedure .......................................................................................... 5 Standardization of Aqueous Acetaldehyde Solutions .............................. 6 Reagents ........................................................................................... 6 Test Equipment.................................................................................. 6 Preparation of Solutions .................................................................... 7 Procedure .......................................................................................... 8 Calculations ....................................................................................... 9
Test Equipment
0- to 10-ml syringe (for example, Hamilton 701) 1000-ml Pyrex vessel with closure fitted with a septum Supply of laboratory-grade compressed nitrogen for flushing bottles Bottle closures fitted with septa Standard solution of acetaldehyde in water at a concentration of approximately 1 mg/ml Vacuum pump and gauge Suitable gas chromatograph equipped with a flame ionization detector, 5.0 ml gas sampling loop, and data-processing system
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One hour before you analyze the first PET sample bottle, prepare an acetaldehyde gas standard: 1. Flush a clean 1-liter Pyrex glass bottle with nitrogen for 20 seconds and cap it with a closure fitted with a septum. 2. Inject a 5-ml gas sample from this glass bottle into the gas chromatograph. (Refer to Analysis of Bottles in the following section for details about the injection procedure.) This is a negative control air blank, and the chromatograph of its headspace should not show any peak at the retention time for acetaldehyde. 3. Using a 10-ml Hamilton syringe, inject 4 ml of a standard solution of acetaldehyde in water, at a concentration of approximately 1 mg/ml, into the 1-liter glass bottle. CAUTION: You must know the accurate concentration of the aqueous acetaldehyde solution and the volume of the glass bottle.
4. Allow the 1-liter glass bottle to stand at room temperature for 30 to 45 minutes, until the aqueous acetaldehyde solution has completely evaporated. 5. Make three replicate 5-ml gas sample injections into the chromatograph. Obtain an average acetaldehyde response signal, and determine the response factor (signal per concentration) for that series of injections.
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[volume (ml ) of
AA std . injected ] [concentrat ion (mg / ml ) of AA std .] volume (liters ) of the gas sample bottle
Consequently, the concentration of acetaldehyde, Cb, in /l, in each PET sample bottle is:
Cb = area counts of sample RF
Acetaldehyde is a very unstable compound. It tends to oxidize and/or polymerize, and unless you carefully prepare aqueous solutions as described below, the acetaldehyde will likely degrade, resulting in inaccurate standard solutions. Alternatively, you can purchase specifications of known concentrations. If you do, ensure that the purchased specifications come with a Certificate of Analyses (COA). Micro-distillation apparatus Analytical balance, 160 g, readable to 0.0001 g 250-ml volumetric flask De-aerated distilled water Reagent-grade acetaldehyde Ice Pasteur pipettes Boiling stones or other anti-bumping granules Laboratory-grade nitrogen Variable-wattage heating mantle
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Reagents
Test Equipment
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Concentration of:
actetaldeh yde in =
(normailty of
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Instrument Parameters
Auto Sampler
Oven Temperature Sample Loop Temperature Transfer Line Temperature Sample Equilibrium Time Transfer Line Back Pressure Vial Pressure Vial Pressurization Time Pressurization Equilibrium Time Loop Fill Time Loop Equilibrium Time Injection Time Column Type Column Dimensions Column Coating Detector Type Detector Temperature Inlet Temperature Initial Temperature Initial Time Temperature Program 1 Temperature Program 2 Data Collection Rate 150C 160C 170C 60 min. for PET 17.5 psi 1 psi 0.10 min. 0.10 min. 0.08 min. 0.10 min. 0.20 min. Fused Silica 25 m X 0.53 mm Poraplot Q FID 200C 150C 50C 1 min. 10C/min. to 150C 20C/min. to 220C, hold for 5 min. 5 Hz
Gas Chromatograph
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volume injected (l ) =
If the concentration of stock solution is 1000 parts per million (ppm), then use this formula:
volume injected (ml) = mass of standard (mg )
Expected AA in Sample 10 20 30 40 50 60 70 80 90 100 Mass (ppm) of Std Required (mg) 1 2 3 4 5 6 7 8 9 10 Volume of 1000 ppm Stock Added (ml) 1 2 3 4 5 6 7 8 9 10
Preparing Samples
1. Prepare the 22-ml vials by sealing with Teflon-lined septa. 2. Using a calibrated syringe, inject the appropriate amount of stock solution into the vials. Touch the tip of the syringe needle to the sidewall of the vial to ensure complete transfer. 3. Place the specifications in the auto-sampler to enable them to bracket the samples. Blanks are distributed at the beginning, throughout, and at the end of the samples. 4. Analyze all vials within 12 hours of preparation.
Data Analysis
The acetaldehyde peak from each run is integrated to find the peak area. A calibration plot is produced from the known amounts of the specifications and their corresponding peak areas. Linear regression is applied to determine the slope and intercept of the calibration plot. You can use this information to determine the sample concentration using the equations provided in this procedure.
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Blanks Specifications
1. Prepare blanks as needed. 2. Seal a 22-ml headspace tight with a Teflon-lined cap. Specifications are prepared in triplicate and in order to produce a calibration curve on which the expected sample concentrations will lie. This is accomplished by adding the appropriate amount of acetaldehyde stock solution to the headspace vial according to this procedure.
mass of AA in sample (g ) =
[peak area of sample (area counts)] [intercept (area counts )] slope [area counts/ mass (g )] mass of AA in sample (g ) sample concentration (g/g or ppm ) = mass of sample (g )
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Strong light source Plastic marking pencil Flash-O-Lens magnifier Limit samples
Procedure
1. Having set aside the necessary number of samples required for product compatibility and carbonation retention, select 109 samples for visual inspections. 2. Sort through the 109 samples to determine if all injection and blow mold numbers are included. These numbers are usually located on the finish ring and on the pinch area, respectively. Record any missing numbers and request additional containers, if necessary, to obtain adequate mold number representation. 3. Observe each sample for color and clarity, and set out those containers that do not appear to fall within established limits for these two attributes. If necessary, refer to limit samples, which should be on hand for this purpose. Record the results of these observations. 4. Observe each sample for the presence of defects which include: a. Foreign specks or particles b. Bubbles c. Surface irregularities d. Container deformation e. Scuffing or scratches
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1. For SRA approval of a new resin, the division must have one of the following: a. An MAA with the resin supplier. b. A warranty and indemnification statement from the resin supplier for each country where the resin will be used . 2. The division must: a. Obtain the MAA or warranty and indemnification statement(s) from the resin supplier. b. Enter the appropriate information into the Global Packaging database. c. Review resin sourcing needs with the Cross-Enterprise Procurement Group (CEPG) to determine if suppliers can be CEPG-certified.
d. Successfully complete a permeation test by a third-party laboratory before a new resin can be used for REFPET. Contact Corporate SRA for details on test protocol and capable laboratories.
1. For SRA approval of new colorants and additives, suppliers must: a. Meet the materials requirements found in REFPET Bottle Authorization Matrices, PK-RQ-065. b. Contact the division to initiate the approval process. c. Complete and submit the Material Formulation Approval Request Form, RF-PK-110, to Corporate Quality.
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3. If an Extraction test is required according to PK-RQ-060, then the instructions below must be followed. Typically, third-party laboratories perform extraction testing.
Promotional Inks Food Grade Approved Not Food Grade Approved Tests Required Taste test Extraction test Taste test Special Instructions Division reviews all test results SRA reviews all test results Division reviews all test results
4. Whether the material is food grade approved or not, all information required by step 2 must be submitted to SRA. 5. Corporate SRA will review the information provided, approve the material, or request additional information. 6. When Corporate SRA gives initial approval of the material: a. The division is responsible for authorizing the material for use in additional countries or by additional closure suppliers. b. The supplier must provide the division with Certificates of Food Law Compliance for the additional countries of use. 7. SRA, Package Development and Design, or Corporate Quality will determine whether further testing is needed, for example, taste compatibility or thermal desorption. 8. Corporate Quality will maintain a list of SRA-approved materials and regularly update it with current information.
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Scope
This is a general list. There may be equipment requirements that are specific to the product under test. For both carbonated and noncarbonated product: Source for treated water that has been filtered through a 0.2micron filter or a carbonated water source Closures known to perform properly in taste compatibility tests Capping machinery capable of applying the closure to the RefPET bottles and the glass control bottles Stainless steel 10-liter (2.5-gallon) product tanks, properly passivated and rinsed Large glass container (4-liter jug) for treated filtered water Digital thermometer Coded 60-ml taste-test glasses Safety equipment, including safety glasses, gloves, hair restraint, and so forth Source of CO2 for recarbonating test and control samples Carbonation pressure gauge Carbonation Computer Dial
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Package type All CB, except recycled content CB, Recycled content: colorless CB, Recycled content: green All NCB except water and recycled content NCB water NCB recycled content
Fill Product Treated filtered or carbonated water Coca-Cola Sprite Refer to #2 below Refer to #2 below Refer to #2 below
Acceptence Criteria No significant difference No significant difference at any interval No significant difference at any interval No more than 2 intervals may be significant No more than 1 interval may be significant No more than 1 interval may be significant
2. All bottles must be filled within fourteen days of bottle production. Bottles intended for NCB must be filled with the product that is normally put into the package being tested, unless a more sensitive or representative product has been identified. Bottles intended for ozonated water must be filled with ozonated water. Bottles intended for non-ozonated water can be tested with treated filtered water. 3. If treated water is used, it must not contain chlorine and must also meet the following specifications:
Attribute TDS Alkalinity Specification <500 mg/l < 85 mg/l
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5. RefPET bottles must impart no significant taste difference at the 95% confidence level when compared to control samples under controlled environmental conditions (212C) after the intervals defined above.
Testing Samples
1. For test bottles of size 1 liter or larger, select a separate subgroup of 20 sample bottles from the main group of samples. For test bottles of size less than 1 liter, select 30 samples; the testing protocol requires a minimum or 4 liters of product per test interval. Ensure that all injection and blowmold cavities are represented uniformly in this subgroup sample set. For bottle submissions from molds with more than 32 or 64 cavities, ensure that no cavity is repeated in the subgroup. 2. Obtain the same number of clean, dry glass control bottles of similar size as the test bottles. Rinse all bottles thoroughly with treated filtered water or carbonated water and drain well. Fill all bottles with carbonated or treated filtered water. If using carbonated water, ensure that volumes are within 3.75 0.25. 3. Store at 211C for the duration of the test. 4. At the end of the storage interval(s), randomly select enough test and control bottles to enable sampling 4-liter portions of test product and glass control product. With liter or larger bottles, take the product from at least four different bottles. Pour the portions into a clean, dry and labeled stainless steel product tank or large glass jug or bottle, and seal the lid.
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d. Close the tank again and bubble more CO2 gas into the tank, with vigorous shaking, until no further gas will bubble into the water. e. Disconnect the gas line, draw samples from each tank and determine that the water tastes acceptable. f. Refrigerate the tank to prepare the contents for taste testing.
6. Bring the temperature of test and control tanks to within a range of 9 to 12C (48 to 54F) and dispense samples into clean, dry coded taste-test glasses and test the beverages with the Triangle method described as follows.
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Test Methodology
Prepare three samples. Make two of the samples the same product and one sample a different product. Ask the panelists to taste the three samples in order from left to right. Then ask the panelists to select the sample they think is different from the other two samples. Present each panelist with three coded samples. Always present the samples simultaneously. Present both products in the test as the odd sample an equal number of times throughout the test. This methodology is typically called a balanced reference design. To ensure reliability in your test data, conduct several practice tests with your panel to familiarize the panelists with taking the Triangle test. A panel size of 30 to 42 tasters is optimal; a minimum of 18 tasters is strongly recommended.
To analyze the Triangle test data, you need to know the following: The number of panelists that tasted, The number of panelists that were correct, and The level of significance to use (for plastic bottle approvals, this is typically a probability of 0.05 or the 95% confidence level).
Using the information, reference the Triangle Difference Test Statistical Table on page 7 to determine if there is a significant difference between the samples in the test. For example, if you had 30 panelists taste and 15 were correct, the test would be significant at the 95% confidence level; therefore, you could conclude that a difference exists between the two products.
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Taste the samples presented to you from ______ (e.g., Left) to ______ (e.g., Right). Two of the samples are the same and one is different. Select the sample you think is the ______ (e.g., Odd) or ______ (e.g., Different) sample by circling the code of the odd sample.
Sample:
Sample:
Sample:
Please describe how the odd sample is different from the like samples.
Test Number:
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1 12 12 13 13 14 14 15 15 15 16 16 17 17
.01 13 14 14 15 15 16 16 17 17 18 18 19 19
1 18 18 18 19 19 20 20 21 21 21 22 22
.01 20 20 21 21 22 22 22 23 23 24 24 25
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Experimental:
Number Correct:
Tasters Comments:
Control
Experimental
Interpretation:
Approved:
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Dial calipers, complete with base Digital height gauge Vernier diameter measurement tape Pi tape Optical comparator Electronic measuring device
Procedure
1. Randomly select the number of filled and capped samples as shown in the table below:
Test Samples Control Samples Total Number of Samples Needed
108
108
2. Select a sub-group of 12 Exterior Dimension samples. 3. Measure the maximum and minimum neck diameters of each bottle using any of the measurement devices listed in the preceding Test Equipment section. Measure at points on the neck immediately below the neck support ring, before the bottle wall begins to flare out toward the shoulder area. 4. Measure the maximum overall height of each bottle. 5. Measure the nominal shoulder diameter of each bottle. When using an optical comparator, make a minimum of two diameter measurements 90 apart. 6. Measure the sidewall diameter of each bottle. When using an optical comparator, make a minimum of two diameter measurements 90 apart.
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Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Scope
This procedure applies to preforms and bottles. The following table lists the measurements that you must collect for each package type.
Package Type Preforms Bottles Required Measurements to Be Collected All applicable attributes (See step 3 below.) Diameters T, E, F, G, A, C (See step 4 below.)
Profile projection machine such as an optical comparator or other suitable measuring device (vision system, coordinate measuring machine, and so forth) Pin gauge set for 1690, 1716, and BPF finishes Two sets of each cavity number for preforms and twelve samples for bottles Anti-static brush to remove dirt or dust
Procedure
1. Visually inspect preforms for defects, such as air bubbles or handling damage, and place them in numerical order in a sequentially numbered rack. 2. Take all measurements 90 apart, but not at the parting line.
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T E F G A C S X
5. Record all measurements. If any of the dimensions are out of specifications for a bottle from a particular injection mold cavity, measure the second preform with the same cavity number to confirm whether the problem is consistent or isolated.
Revision History
Issue Date 20-Dec-2004 Summary of Change New document. Added S and X dimensions to bottle finish measurements.
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Caustic tank and safety equipment Dial caliper with base Pi-Tape or equivalent circumferential tape Mettler PC4000 scale or equivalent Fill-height syringe assembly Rinse basin
Procedure
1. Determine as-delivered capacity for 10 bottles, as described in REFPET Bottle Empty Weight and As-Delivered Capacity Test, PK-PR-223. Then measure bottle diameter and height dimensions as in REFPET Bottle Dimensions Evaluation Exterior, PK-PR-207. 2. Condition bottles as follows: a. Bottles numbered 1 through 5 store empty at 72F, 50% relative humidity for 7 to 9 days. b. Bottles numbered 6 through 10 store submerged under water at 72F for 7 to 9 days. 3. One day before submerging bottles in caustic, measure bottle height and diameter dimensions along with fill-point capacity. Then, put bottles back in same conditioning environment, described in step 2, overnight. 4. Immerse the bottles in 3.0% +0.5 -0% caustic solution for five continuous hours continuously at 59.5C 1C (139F 1.8F). Measure and record caustic concentration and temperature. 5. Remove the bottles, rinse thoroughly, and repeat the capacity and dimension measurements taken in step 1 above.
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Issue Date 20-Dec-2004 Summary of Change New document.
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Calibrated Zahm and Nagel piercing device with pressure gauge (capable of measuring 0 to 100 psi or 689.5 KPa) Supply of bone-dry CO2 (moisture level not to exceed 15 ppm and CO2 must be at least 99.8% pure)
WARNING: Use protective gloves when handling frozen CO2, and ensure that the area is well ventilated. Approved plastic closures that properly fit the test bottles Analytical gram balance accurate to 0.1 g Approved device to measure bottle diameters accurate to 0.1 mm Optical comparator with a minimum magnification of 20X, or Laser measuring device Approved properly calibrated FT IR instrument (We recommend the Perkin-Elmer FT IR Spectrometer with supporting hardware fixtures and software patented by The Coca Cola Company.) Safety glasses/face shield and gloves Torque meter to properly apply approved plastic closures Permanent black ink marking pen Environmentally controlled chamber or room capable of maintaining a constant 22 1C (72 2F) and 50% relative humidity (RH)
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NOTE:
Two extra bottles will be required for validating the initial carbonation level.
2. Mark each sample with an individual number for identification purposes. 3. Mark all 12 sample bottles with an indexing line, on the heel or foot that runs through the center of base. This line is used to ensure that the bottles always can be aligned properly and consistently on the FT IR. NOTE: The indexing line must not fall on a dimple, flute or bottle parting line, or other irregular surface area of the bottle.
You must determine the bottle volume first so that you can use the proper amount of dry ice to achieve the correct internal pressure. To determine the proper amount of dry ice: 1. Place one sample bottle on an analytical balance and tare the scale to zero. 2. Fill the sample bottle to the brimful capacity (that is, to top of the bottle finish) with water of a known temperature. 3. Record the weight of the water in grams. 4. Convert the water weight (g) to bottle volume (ml) using the following conversion table:
Water Temperature 19C or 66.2F 20C or 68.0F 21C or 69.8F 22C or 71.6F 23C or 73.4F Water Density (g/ml) 1.002637 1.002838 1.003039 1.003261 1.003492
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1. Place one empty bottle and closure on the balance and then tare their combined weight. 2. Continue to add small pieces of dry ice to the bottle until the weight exceeds the previously calculated weight (refer to step 5) by approximately 0.3 g. 3. Put an approved plastic closure on the bottle finish and screw down loosely without completely sealing the bottle. Observe the balance reading. As the dry ice sublimates, the weight of the sample bottle will decrease. When the balance reading is approximately 0.1 g greater than the calculated dry ice weight (from step 5 above), quickly tighten the closure on the bottle. Tighten the plastic closure by hand to the application torque recommended by the closure manufacturer. 4. By hand, gently swirl the bottle at ambient temperature (approximately 22C) until all the dry ice evaporates inside the bottle. Do not hit the bottles on tables or on any other rigid objects to break up the dry ice. This may affect the physical characteristics of the bottle. 5. After all the dry ice has evaporated in the capped bottle, check the internal pressure of the sample using a Zahm and Nagel piercing device. The pressure should 56 2 psi at a temperature of 221C (or alternatively, 60 2 psi).
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1. After the samples have been filled and capped, and all of the dry ice has sublimated, measure the bottle diameters. The initial diameter measurements must be made within 10 to 30 minutes after the dry ice has sublimated. 2. Measure each bottle at 86 mm up from the base of the bottle. This corresponds to the exact point where the FT IR beam passes through the bottle. Ensure that all bottles are aligned consistent with their heel mark (refer to step 3 in the Sample Preparation section). Record this as the initial diameter for each sample. NOTE: All diameters need to be measured at the same distance from the base for each interval.
Calibrate the IR instrument according to the manufacturers recommended procedure. 1. After you have pressurized the 12 test bottles and measured the initial diameters, evaluate the test bottles on the FT IR to establish the initial CO2 concentration. 2. After have measured all 12 test bottles for CO2 concentration, store the samples in a conditioned environmental chamber (221C or 722F at 50% RH). 3. At each interval shown in the table below, the CO2 level will need to be measured on the FT IR. You do not need to measure the diameters at every interval. To see a suggested frequency for diameter measuring, refer to Schedule for Measuring Samples below.
Sample Storage
Store all test bottle samples in an environmentally controlled room or chamber at 221C or 722F, 50% RH, between each test interval throughout the entire test period.
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*Measure diameter at every interval if performing an accelerated test. For a standard test, the software does not use the diameter measurement at these intervals to calculate shelf-life.
CAUTION:
Follow the schedule as closely as possible so you do not miss a measurement interval; otherwise, the final results may be affected. You can neither miss nor delay the initial (#1) or the 1 day (#2) interval measurements. The initial measurement will be used as the baseline from which the subsequent CO2 loss and shelf life will be calculated. The 1 day (#2) is not used in the CO2 loss calculation. However, it can be used to characterize the CO2 loss within the first 24-hour period, if necessary.
If you cannot perform a measurement at the scheduled time (in case of a holiday or weekend), you may perform the measurement up to three days later (except intervals 1 and 2). A late or delayed measurement will result in a longer test period, but there is no negative influence on the accuracy of final test results. Never perform a measurement before its scheduled interval.
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Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Procedure
1. Select at random 23 samples previously inspected for visual defects. Mark each sample with an identification number in a continuous sequence. Fill and cap these containers to achieve 4.0 0.2 volumes of carbonated water when measured at 22.2C (72F). 2. Store all samples for 24 hours at the following temperatures: a. 2 - 11 at 4.4C (40F) b. 1 and 12 - 23 at 22.2C (72F) 3. Check and record pressure, temperature and CO2 level of samples 1, 12, and 23. 4. In a suitable test area, mark a door or wall to a height of 1 meter above a smooth concrete floor. The person performing the drop should wear either safety glasses or a protective face guard, and be instructed to tip the sample away from his or her line of vision. 5. Hold each sample at an approximately 30 angle from the vertical at a height of 1 meter. 6. Release each sample uniformly so that it falls freely, impacting the bearing surface of the container. After dropping each sample, inspect the container for breakage, excessive deformation, or separation. In addition, place the tested container upright on the floor. If it will not stand unassisted, note the sample as a failure. Record all findings.
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Caustic tank and safety equipment Filler Fill-height syringe Capper Environmental control chamber Rinse area Mettler PC 4000 scale or equivalent Dial caliper with base Pi-Tape or circumferential tape Depth gauge Optical comparator
Procedure
1. Randomly select a 24-bottle sample. On each bottle, put the test request (TR) number and number the bottles sequentially. Also, always include a control group for comparison. 2. Select samples 1 through 5. Measure fill-point capacity on each of these bottles at completion of 0 and 25 washes. 3. On the same samples and at the same frequency as in step 2, measure and record the following if checked: a. Overall height b. Pinch diameter c. Upper label diameter d. Base push-up height e. Finish dimensions E1, E2, E3, E4, T1, T2 and A (see Finish Measurements)
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7. As it is extremely important that there is no caustic carryover, check for caustic carryover each cycle by allowing 3 drops of phenolphthalein to run down both the base exterior and the inside of the bottle. No color indicates no caustic. If pink color develops, add 10 ml of distilled water. If pink color persists, caustic is present and more thorough rinsing is necessary. 8. Fill bottles 15 through 24 three-fourths full of water and counterpressure to 5.5 bars (80 psi) for 20 seconds, then empty. 9. Wipe a thin layer of Diversey SUPERPET C line lubricant or equivalent diluted at 1 part line lubricant to 100 parts water (1.0 percent 0.1 percent) on the entire bottom and to a height of 3 mm up the heel on each bottle. Store the one percent lube moisture in a sealed container when not in use or make a new batch daily. This is necessary to ensure that evaporation does not cause the ratio to drift outside of the stated tolerance.
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14. Measure and record on Data Form II temperature and relative humidity of the chamber, then remove the bottles from storage. Immediately measure and record the unshaken pressure and temperature of one bottle from each case or at the following storage locations: a. Top stack corner b. Middle stack center c. Bottom stack opposite corner The target average unshaken opening pressures are:
Weekend/holiday storage 24-hour storage 67 3 psi for at 35.6C 1C (96F 1.8F) 70 3 psi at 36.8C 1C (98.2F 1.8F)
15. Open and two-thirds empty remaining bottles, leaving bottles one-third full of water and uncapped during empty bottle storage. Upon opening bottles, look for lack of venting which could indicate improper sealing or small stress crack leakage. On the 24-hour cycle only, remove all closures by hand at normal opening speed and note any closure releases or unusual closure performance.
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17. After every 5th cycle, record the condition of each bottle with respect to breaking, cloudiness, stress cracking, or any other noticeable change in appearance. Record the severity of stress cracks at each location on the bottle using the stress crack reference photographs in the Appendix or this scale:
Stress crack Severity A = Minor, very shallow cracks B = Moderate, shallow cracks C = Major, moderately deep cracks D = Major, deep cracks Quantity = 1 to 10 = 11 to 100 = 101 to 500 = 500+
18. Record on Data Form III Stress Crack Severity in this document the stress crack severity and quantity of cracks at: a. bottom bearing surface b. inside radius of the bottom bearing surface c. sprue d. area between the sprue and the inside radius e. finish f. neck g. top flute h. bottom flute i. heel
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Cycle
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Cycle
*T = Top stack corner M = Middle stack corner S = Bottom stack opposite corner to top
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Push-Up
Sprue
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Caustic tank and safety equipment Filler Fill-height syringe Capper Environmental control chamber Rinse area Mettler PC 4000 scale or equivalent Dial caliper with base Pi-Tape or equivalent circumferential tape Depth gauge Optical comparator
Procedure
1. Randomly select a 154-bottle sample. On each bottle, put the test request (TR) number and number the bottles sequentially. Also, always include a control group for comparison. 2. Set aside bottles numbered 145 to 154 and retain as controls for the foaming test in step 25. 3. Select samples numbered 1 through 10. Measure fill-point capacity on each of these bottles at completion of 0, 5, 15, and 25 washes. 4. On the same samples and the same frequency as in step 3, measure and record the following if checked: a. Overall height b. Base push-up height c. Pinch diameter d. Finish dimensions, E1, E2, E3, E4 (see drawing) e. Perpendicularity, T1, T2, and A f. Upper label diameter
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8. As it is extremely important that there is no caustic carryover, check for caustic carryover each cycle by allowing 3 drops of phenolphthalein to run down both the base exterior and the inside of the bottle. No color indicates no caustic. If pink color develops, add 10 ml of distilled water. If pink color persists, caustic is present and more thorough rinsing is necessary. 9. Fill the bottles numbered 124 through 144 about three-fourths full of water and counterpressure to 5.5 bars (80 psi) for 20 seconds and then empty. 10. Wipe a thin layer of Diversey SUPERPET C line lubricant or equivalent line lubricant diluted at 1 part line lubricant to 100 parts water (1.0 percent 0.1 percent) on the entire bottom and to a height of 3 mm up the heel on each bottle. Store the one percent lube mixture in a sealed container when not in use or make a new batch daily. This is necessary to insure that evaporation does not cause the ratio to drift outside of the stated tolerance.
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14. Measure and record temperature and relative humidity of the chamber then remove the bottles from storage. Immediately measure and record temperature of one bottle from each of the following storage locations: a. Top stack corner b. Top stack center c. Middle stack corner d. Middle stack center e. Bottom stack corner f. Bottom stack center The target average unshaken opening pressures are:
Weekend/holiday storage 24-hour storage 67 3 psi for at 35.6C 1C (96F 1.8F) 70 3 psi at 36.8C 1C (98.2F 1.8F)
15. Open and two-thirds empty remaining bottles, leaving bottles one-third full of water and uncapped during empty bottle storage. Upon opening bottles, look for lack of venting which could indicate improper sealing or small stress crack leakage. On the 24-hour cycle only, remove all closures by hand at normal opening speed and note any closure releases or unusual closure performance.
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17. At the completion of every fifth cycle, record the condition of each bottle with respect to breaking, cloudiness, stress cracking, or any other noticeable changes in appearance. Record the severity of stress cracks at each location on the bottle using the stress crack reference photographs in the Appendix or the following scale:
Stress crack Severity A = Minor, very shallow cracks B = Moderate, shallow cracks C = Major, moderately deep cracks D = Major, deep cracks Quantity = 1 to 10 = 11 to 100 = 101 to 500 = 500+
18. Record on Data Form III Stress Crack Severity the stress crack severity and quantity of cracks at the following: a. bottom bearing surface b. inside radius of the bottom bearing surface c. sprue d. area between the sprue and the inside radius e. finish f. neck g. top flute h. bottom flute i. heel 19. Record all bottle failures by bottle location and cycle. Save all bottles. If bottle has two different conditions of stress cracking at any location, then note both, for example B4, D1 on bearing surface.
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25. Conduct foaming tests using control samples numbered 145 to 154 from step 2 and select 10 samples after 25 washings. Control samples should be washed once prior to filling. All samples should be wet before filling. a. Fill all samples with Coca-Cola and note foaming/snift characteristics. Store filled and capped overnight. b. Open bottles and note foaming characteristics by measuring distance from top of finish to top of foam or amount of foam-over. Empty the bottles and rinse thoroughly. Repeat foaming procedure using diet Coke.
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Cycle
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Cycle
*T = Top stack corner M = Middle stack corner S = Bottom stack opposite corner to top
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Push-Up
Sprue
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1. Select at random 10 samples previously inspected for visual defects. Mark each sample with an identification number in a continuous sequence. 2. Weigh each bottle and record the weight to the nearest 0.1 grams. Report each bottle weight and the maximum, average, minimum, and standard deviation for the sample group. 3. Place each bottle on a digital scale and tare the weight so that the readout is at 0.0. 4. Fill the bottle with water at a known temperature to a level above the fill-point. 5. With a preset fill-height syringe, remove the excess water down to the proper fill-point. 6. Record the weight and water temperature. 7. Use the Density Conversion Table found in RF-PK-108 to adjust to milliliters. 8. With the bottle still on the scale, add water until the level is just above the finish. 9. Record the weight and water temperature. 10. Use the Density Conversion Table found in RF-PK-108 to convert to milliliters. 11. Report the weight of the water, temperature of the water, and milliliters for each bottle and the maximum, average, minimum, and standard deviation for the sample group.
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Carbon dioxide source Hypodermic needle/pressure transducer assembly Height gauge Fill-height syringe assembly Thomas septums (fitted) Capper
Procedure
1. Select 10 samples which provide the best representation of all mold numbers that have previously been inspected for visual defects. 2. Fill each container with tap water at 22.2C (72F) and syringe each to the proper fill-point. Cap each sample with a closure that has been fitted with a septum. 3. Measure the liquid fill height from the top of each container to the bottom of the meniscus. Record this value. 4. Inject carbon dioxide gas through the septum at a rate of 4.1 bar gauge (10 psig) per second to a level of 4.1 bar gauge (60 psig). Hold this pressure for one minute and then remove the hypodermic needle/pressure transducer from the septum. 5. Repeat step 3. 6. Increase the pressure in the same manner as in step 4 to a level of 5.5 bar gauge (80 psig). Hold this pressure for one minute and then remove the hypodermic needle/pressure transducer from the septum. 7. Repeat step 3. 8. The fill-point variation is the difference between the minimum and maximum fill-points for each pressure.
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1. Select at random 10 samples previously inspected for visual defects. Mark each sample with an identification number in a continuous sequence. 2. Fill each bottle completely with water. 3. Place in a suitable apparatus that will build internal pressure hydraulically. Pressure should be increased steadily until bottle failure. 4. Record the pressure at which the bottle failed, along with the location of failure. 5. Report each failing pressure and location of failure, maximum, average, minimum, and standard deviation for the sample group.
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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1. Using 108 randomly-selected sample bottles as a source, select a subgroup of 12 Perpendicularity samples. 2. Fill each sample bottle approximately half full with tap water and place it in the measuring apparatus. Be sure that the base of each bottle is held securely in the support fixture. 3. Adjust the dial indicator contact so that it rests on the locking ring of the bottle finish. Set the dial indicator to zero. 4. Rotate the bottle through at least 360 degrees and note the maximum and minimum deviation on the gauge on either side of vertical. Set the zero mark of the gauge at that position. 5. Repeat steps 3 and 4 for the remaining samples. 6. Record all measurements.
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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1. Select 10 samples previously inspected for visual defects. 2. Measure the plastic sidewall thickness every 30 around the bottle at the specified heights. 3. Report the maximum height for each bottle, and then the maximum, average, minimum, and standard deviation height for the sample. 4. Measure the neck thickness every 90 around the bottle at 10 mm, 20 mm, 30 mm, and 40 mm down from the support ring for all bottles. For bottles larger than 1 liter, also measure at 50 mm. 5. Report each reading for each bottle along with the maximum average, minimum, and standard deviation for each location for the sample. 6. Measure bottom thickness around the base at five locations according to the test figure. Rotate the bottle 360 to obtain the minimum and maximum thickness for each location. 7. Report the individual measurements for each bottle. Indicate where the mold seam is in relation to the thickness measurements. Report the maximum, average, minimum, and standard deviation for each location. 8. Conduct sectional weight evaluation of the bottle as follows: a. entire bottle b. neck weight (50 mm from top) c. base weight (25 mm from bottom) d. panel weight (remaining midsection)
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Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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REFPET Bottle Specifications, Support Ledge Strength, PK-SP-045 Tensile/compression tester Fixture (to represent support ledges in capper)
1. Select 10 samples that provide the best representation of all preform mold numbers that have previously been inspected for visual defects. 2. Cut off the finish of the container about 6.3 mm (1/4 inch) below the ledge support. Place each finish into the fixture in the compression test apparatus at room temperature. 3. Position the load platen approximately 50 mm (2 inches) above the top of the container and zero the load gauge readout if necessary. 4. Apply the load at a rate of 5 cm (0.2 inches) per minute and record the resulting curve. 5. Report the first failure peak of the ledge support in pounds or kilograms of force. Also, report the maximum, average, minimum, and standard deviation for the peak loads.
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Tensile/compression tester Carbonator Capper Environmental control chamber Perpendicularity gauge assembly Fill-height syringe assembly Pi-Tape or equivalent circumferential tape Dial caliper with base Depth gauge
Procedure
1. Use the same 10 bottles previously tested for empty dimensions and perpendicularity. Randomly select 2 new additional samples. Mark the additional samples as 11 and 12 (the first 10 bottles are already marked 1 through 10). 2. Rinse each sample prior to filling to eliminate dust or dirt particles from the inside surface of the bottle. 3. Fill all samples and controls on Meyer filler, or equivalent, to the proper fill-point with carbonated water to achieve 4.0 0.2 volumes apparent carbonation when measured at 22.2C (72F). Deaerated water should be used if possible to minimize air content in headspace of the bottle. High air content can significantly affect the test results. Samples should be immediately capped after filling. 4. After completion of step 3, immediately measure and record the fill height of samples 1 through 10 within one minute of capping. Measure fill-point from top of closure to bottom of liquid meniscus.
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6. Reclose bottles 11 and 12, then store all 12 samples at 37.8C 1C (100F 1.8F) and 40% 10% relative humidity for 24 hours 1 hour. All bottles are to achieve 36.7C 1C (98F 1.8F). Measure temperature of samples 11 and 12 then recap. Measure samples 1 through 10 as in part 5. Record all findings. 7. Place the samples that havent burst or developed rocker bottoms back into the oven at 37.8C (100F) and store them for six more days. Continue to measure and record temperature of controls and relative humidity daily. 8. Test as per 5 above. In addition, measure and record temperature in samples numbered 11 and 12. All bottles are to achieve 37.8C 1C (100F 1.8F). 9. Randomly divide the remaining intact samples into two groups and designate them as groups I and II. 10. Perform a drop impact test (PK-PR-220) at 37.8C (100F) on group I (drop from one meter or approximately three feet onto a smooth concrete floor and note any failures). 11. Store group II at 22.2C (72F) for 24 hours. Test as per 5 above. 12. Perform a drop impact test on group II (drop from one meter or approximately three feet onto a smooth concrete floor at a 30 angle) and note any failures.
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Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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Tensile/compression tester
1. Select 10 samples which provide the best representation of all mold numbers that have previously been inspected for visual defects. 2. Place each empty container in the compression test apparatus at room temperature (approximately 22C or 72F). 3. Position the load platen approximately 50 mm ( 2 inches) above the top of the container and zero the load gauge readout if necessary. 4. Apply the load at the rate of 51 cm per minute and record the resulting curve. 5. The compression tester readout should be capable of indicating the minimum load between 1.59 mm and 4.76 mm (1/16 inch and 3/16 inch) bottle deflection, the peak load, and the bottle deflection at peak load. 6. Report the minimum load between 1.59 and 4.76 mm bottle deflection for each bottle in pounds or kilograms of force. Also, report the maximum, average, minimum, and standard deviation for these minimum loads. 7. Report the peak load in kilograms (pounds) of force and the bottle deflection at the peak load for each bottle. Also, report the maximum, average, minimum, and standard deviation for the peak loads.
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1. Obtain ten new REFPET bottles 2. Mark them with a caustic-proof adhesive tap around the bottle neck
Operation
1. Select a pallet of REFPET bottle returns identified for immediate production 2. Place the ten new, marked bottles at locations within the pallet. 3. Pass the pallet through the bottling line. 4. Retrieve the ten bottles from the cases after the caser. 5. Empty the contents of the bottles 6. Record the line speed, stoppage information, amount of time bottles are in washer. 7. Repeat for a total of 25 cycles or until bottles reach a scuff level #4, whichever happens first. NOTE To make sure no bottles are misplaced, gather the group of test bottles at the entrance to the washer and manually place the bottles in one row of washer pockets so that all the bottles in the sample come out at the same time and are easier to find. In addition, it may help to gather them after the filler and mark the closure top with black in felt marker. This makes collection mush easier after the caser.
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Operation
Operation
Place the four cases on a route truck in the normal manner in which they are handled, and leave on the truck for ten days of deliveries. Compare the condition of bottles in the wrapped cases with the bottles in the unwrapped cases. If the bottles in the unwrapped cases are noticeably different, take appropriate action. For example, if the bottles are noticeably dirtier, then the covering for the truck is probably not adequate, or the truck bays might need cleaning. If the unwrapped bottles are more scuffed, the case washer is probably inadequate.
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Preparation Operation
Obtain ten new bottles, mark and code them for easy identification. 1. Select a pallet to be sorted and replace ten bottles at random with the new marked bottles. 2. Retrieve the bottles after sorting. 3. Repeat for a total of 25 cycles.
Observations
While the bottles are running, inspect conveyor guide rails, infeed screws, star wheels, washer guides, washer pockets, and other bottle contact surfaces for sand, grit, and dirt. Where appropriate, use photographs and video tape to illustrate handling and storage conditions. Record the visual appearance of the test bottles after every five cycles. It may be found that on some pieces of equipment, the scuffing does not change markedly after reaching a certain level.
After 25 trips the bottles should: Loop Trial Desired show no stress cracks Performance and each have a scuff level 3 or less Scuffing Scores Calculate scuffing scores for each machine by adding the scuff level number for each bottle in the five bottle group after completing five additional cycles. These scores allow comparison of different machines scuffing action, or of the filling process VS distribution.
Corrective Action
1. Thoroughly clean all the bottle contact surfaces of the conveyors, guide rails, and individual pieces of equipment between the uncaser and the washer. Remove all accumulated dirt, sand, oil, or foreign substance of any kind. 2. Lightly rub guide, starwheels, and infeed screw body with a fine sandpaper and wipe off. Replace or repair any part to eliminate all rough spots, nicks, burns, and sharp edges.
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11. Install water sprays to provide bottle cleaning and lubrication. a. in-case bottle pre-rinsing with high pressure water sprays prior to the uncaserMinimize introduction of water spray into the uncapped bottles. b. high-volume, low pressure spray on both sides of the single file conveyor after the uncaser, minimize introduction of water into the container.
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d. low volume, high pressure water spray on the roller of powered roller combiners. e. If after the changes there is still scuffing from the infeed screws, replace the plastic infeed screw with a stainless steel screw, or with brass cast screw, polished and chrome plated.
Revision History
Issue Date 20-Dec-2004 Summary of Change New document.
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