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Geen diatitel

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Corus Group plc: created in 1999 through the merger of Koninklijke ... Duffel. MAASTRICHT 25 - 27 SEPTEMBER 2001 IS IT OKAY TO SPRAY? Protact vs. Ferrolite ... – PowerPoint PPT presentation

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Title: Geen diatitel


1
Crossing Borders with Polymer Coated Steels
David Jones Jan Kleijn
2
Corus Group Plc - The Future in Metal
  • Corus Group plc created in 1999 through the
    merger of Koninklijke Hoogovens and British Steel
  • A multi-metal product portfolio including Carbon
    Steels, Stainless Steels and Aluminium
  • 24 business units, with major production plants
    in the UK, The Netherlands, Germany, USA and
    Canada
  • Total group turnover Euro 15 billion
  • Employees approx. 55,000 world wide
  • Carbon Steel production 20 million tonnes 7th
    largest in the world

3
Corus Group - turnover per region and sector
4
Corus Packaging Plus - Providing Solutions
  • Corus Packaging Plus part of Corus Group.
    Formed through merger of Hoogovens Packaging
    Steel and British Steel Tinplate
  • Production sites in the UK, The Netherlands,
    Norway and Belgium
  • Commercial HQ IJmuiden, The Netherlands
  • Employees 3500
  • Annual turnover approximately 1 billion Euro
  • Annual production 1.5 million tonnes of light
    gauge steel largest in the world

5
Corus Packaging Plus - markets by region and
application
6
Aerosol Market Comparison - USA v Europe
SourceFEA
7
European aerosol production by segment
  • Personal care is the largest and also a
    continuously growing segment
  • Household segment picking up again after a
    decline in 1997
  • Others 1995 level has been achieved again and
    seems to have stabilized at 1 billion

8
European Personal Care Market 1998/1999 -
Product Split
SourceFEA
9
European Aerosols - Major Markets(1999)
SourceFEA
10
Why Polymer Coated Materials?
11
Polymer Coated Steels - Benefits(1)
  • Coil Coating Process
  • Both surfaces can be coated simultaneously
  • Consistent quality and no thickness limitation (
    lt 0.12mm possible)
  • Versatility
  • Can combine properties of several polymers. Clear
    or pigmented coatings, different thicknesses.
  • Formability
  • Excellent for severe deep drawing operations.
    Complex shapes and designs can be formed without
    damage to the coating
  • Manufacturability
  • Excellent forming properties, higher production
    speeds
  • Less process steps, no lacquering

12
Polymer Coated Steels - Benefits (2)
  • Improved Performance
  • Corrosion protection
  • Excellent abrasion resistance
  • Appearance
  • Range of colours available and surface finishes
  • Good printability
  • Environmental Advantages
  • No VOC emissions
  • Food compliant, no issues like BADGE etc.
  • Recyclability
  • Easily recovered by magnetic means from the waste
    stream, or by consumer collection schemes. Can be
    directly charged into the steelmaking process

13
Corus Packaging PlusTwo routes for polymer
coatings
  • Film coating Ferrolite Promica
  • Direct extrusion Protact

14
The Processes
  • Film Coating
  • Ferrolite Promica
  • Direct Extrusion
  • Protact

15
Ferrolite - What is it?
  • Ferrolite is basically a very simple system
    produced by applying polymer films onto a steel
    based substrate under closely controlled
    conditions.
  • Substrate can be tinplate, ECCS or blackplate.
  • Range of different polymer films available (e.g.
    PET, PPN) - also dissimilar films can be applied
    simultaneously.
  • No solvent emissions resulting from the process.

16
Ferrolite - The Product
  • Two layer system
  • top layer color printability adhesion
  • bonding layer adhesion
  • steel substrate tinned ECCS

17
Ferrolite - The Applications
  • Lower volume specialty applications
  • Aerosol components
  • Bottoms
  • Tops
  • Valve cups
  • Drawn food cans
  • Food can components
  • Full aperture easy open ends
  • Peel off lids
  • Drawn beer beverage cans (RBS)

18
Promica - The Product
  • Wide variety of polymer coatings technology
  • Coating with multi layered prefabricated films
  • Typically 3 to 5 layers
  • Eye catching appearance
  • Steel substrate tinned ECCS

19
Promica -The Applications
  • Range of high added value products developed,
    e.g.
  • Promica Pristine high gloss for appliances
  • Promica Lumiforme high reflectivity for light
    fixtures
  • Promica Chimera Holographic for eye-catching
    effects

20
Protact The Product
Exterior
top layer compound adhesion
printability etc.
main layer colour barrier
forming
contact layer adhesion
Interior
steel substrate ECCS
21
Protact - The Applications
Higher volume applications
  • Aerosol tops bottoms
  • Twist Off Caps
  • Full Aperture Easy Open Ends
  • Peelable ends
  • Plain ends
  • Drawn food cans

22
Corus Capabilities
23
Protact vs. Ferrolite within Corus Packaging
Plus
24
Polymer Coated Steels for Aerosol Applications
  • Already widely used for aerosol components mainly
    for personal care markets- domes,cones, valve
    cups
  • Process route developed for welded bodies
  • New 2-piece draw-redraw can making technology
    developed for hard to hold packs

25
Polymer Coated Steel - Aerosol Components
26
Polymer Coated SteelAerosol Components
  • First commercial use of Ferrolite. Use rapidly
    growing for aerosol domes, cones and valve cups
  • The PET coatings offer superior coverage and
    abrasion resistance in the bottom double seam
    area and significantly reduces the risk of
    corrosion particularly where the aerosol is
    stored in a humid (e.g. bathroom) environment
  • For cones, the PET coatings also give superior
    external appearance and protection
  • In general, the internal coatings( normally PP)
    have been shown to give excellent internal
    protection for all components
  • A thick internal coating of PP (e.g. 200µm) on
    valve cups has been shown to act as an effective
    sealant without the use of a separate gasket.
    Alternatively thinner coatings (e.g. 15 - 40µm)
    can be used whilst retaining the seaming gasket

27
Aerosol ComponentsNew Developments
  • New range of colours and finishes. Colour
    co-ordinated cones and domes
  • Application of Promica Holographic for valve cups
  • Protact commercialisation trials for valve cups,
    domes and cones

28
Growth in Polymer Coated Steels for Aerosol
Components
Tonnes
29
Polymer Coated SteelsWelded Aerosol Bodies
  • Welded aerosol bodies can now be produced from
    polymer coated steels
  • Feedstock is Ferrolite with a tinplate substrate
  • The polymer film is removed from the weld margin
    by means of Freis metLam Peeler. This is a
    laser stripping device
  • Powder coated side stripe repair

30
Polymer Coated Welded Bodies- Features
  • Existing line equipment can be utilised. No
    modifications to the welding machines are
    required. Can diameters down to 45mm pose no
    problems
  • Finished can has superior packing performance
  • Uniform thickness and consistent quality of the
    polymer coating
  • Excellent flexibility for subsequent embossing
    and shaping operations
  • Visually pleasing. Homogeneous surface. Special
    coating/effects are possible
  • Excellent environmental profile compared to
    lacquering
  • No overspray around the leading and trailing edge
    on the outside of the can

31
Polymer Coated Steel 2- piece Aerosols
  • Development based on existing CPPs beverage can
    technology.
  • 2-piece deep drawn aerosols
  • Feedstock is Ferrolite with improved coatings.
    Also option of coloured external coatings
  • Substrate 0.22mm up 0.26mm DR depending on
    pressure requirements
  • Wide range of can designs possible
  • including high aspect ratio containers

32
Draw Stretch Redraw Technology for Aerosol Can
Manufacture
  • Key features
  • Use of precoated Ferrolite feedstock
  • Use of CPPs Tenform DR
  • family of high strength steels with improved
    formability
  • No internal lacquers or external base-coats
    required
  • Decorated by U.V. techniques or by shrink wrap
    labels

33
Draw Stretch Redraw Can-Making Technology
  • Can making is based on an updated version of
    draw-redraw technology
  • involves wall thinning
  • new patents applied for
  • Stretch redraw - what is it?
  • Standard Redraw
  • Can wall thickness is not reduced
  • Stretch Redraw
  • Tool profiles/clearances are designed to reduce
    can wall thickness

34
Corus Packaging Pluss Tenform DR
  • CPPs range of
    high strength, formable steels
  • Strength range 500 - 660N/mm2
  • Minimum earing quality
  • To minimise wastage
  • Specifically developed to give the can the
    required strength at light gauges whilst
    maximising the potential for shaping

35
Stretch Redraw AerosolProcess Route
Trimmer
Washer
36
DWI Aerosol- Process Route
37
Ferrolite DRD Aerosols - Can Designs
38
Environmental Profile - Ferrolite Aerosols
  • Solvent emissions
  • Process virtually eliminates solvent emissions.
  • No solvent incineration required. All coatings
    PVC free.
  • Very low level of can making waste products
  • Energy efficiency
  • Ferrolite manufacturing process has received an
    European Community award for energy savings.
  • Recyclability
  • Easily recovered by magnetic means from the waste
    stream, or by consumer collection systems. Can
    be directly charged into steelmaking process.
  • Precoated, waxed feedstock
  • no VOCs
  • If UV cured decoration, then no process VOCs
  • Simple washer required to remove wax

39
Ferrolite Aerosols - Benefits
  • Excellent appearance and aesthetic effect
  • Major pack performance benefits
  • specially developed coatings means that they can
    be used for hard to hold packs
  • No weld, no separate dome (bottom)
  • therefore, less likely to leak in the bottom
    seam.
  • Major environmental benefits
  • no VOC emissions
  • reduced waste products/consumables.
  • Higher production speeds/outputs
  • Versatile system to compete with Al-monobloc
  • Improved external corrosion benefits

40
Polymer Coated Steels - The Future
  • The last 10 years has seen growth in the
    application of polymer coated steels in the
    aerosol sector mainly for components
  • CPP has pioneered the development of polymer
    coated steels and with new application systems,
    and a wider range of coatings now available
  • In future, it is expected to see wider
    acceptance of these products because of the
    major benefits they offer.
  • In parallel, additional production capability
    (with more planned) has been introduced which
    means that there is greater availability of the
    feedstock
  • The development of new can-making technologies
    also means that polymer coated steels can now be
    used for the bodies as well
  • In short, the future for polymer coated steel in
    the aerosol market is indeed bright
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