Page 34 - Plastics News February 2022

FEATURE

understand the performance of the operating conditions so they can two bottles are identical. Whether
bottle. move into routine production. through design, performance or
process, each bottle brings its own
These samples can also run on a This final phase of the process has
customer’s filling line to test bottle become more efficient due to the unique set of requirements. While
performance or make adjustments rapid introduction of intelligent there may be similar expectations
to the customer’s line. In some or “smart” factories that leverage within a vertical market, customers
instances, the customer’s line is the fast-growing array of Industry continue to seek out differentiation
brand new and these samples 4.0 (or Internet of Things, IoT) through their packaging to enhance
can help the customer and other technologies. IoT-equipped sales at point-of-purchase.
vendors fine-tune their equipment. “intelligent factories” can improve New, smart technology can also
A physical sample at this point production performance while help shorten the overall timeline
in the development process is bringing additional efficiencies from engineering design through
also very helpful in showing the and sustainability to the packaging execution and ensure a faster and
customer what to expect long before process. IoT technologies allow smoother transition to production.
commercialization. engineers to monitor production of As packaging companies continue
the bottle during live manufacturing to incorporate higher levels of
Prototyping can also provide post-consumer recycled (PCR)
a feedback loop to simulation, rather than measuring the bottles content in bottles while maintaining
which allows for refinement of after they are produced (and it is too performance standards, the precision
simulation tools and methods to late to catch a problem). IoT allows and reliability afforded by intelligent
improve accuracy, which could technologies allow companies to
eventually lead to the elimination deliver sustainable solutions without
of the prototyping step by relying compromising design, performance
on simulation alone. Validation or cost. This is particularly true
Confirms Specification Compliance when brands convert from glass or
and Bottle Performance: While the aluminum to plastic packaging.
validation process can vary between
packaging companies, it typically As technologies continue to evolve,
involves running a lead mold on the product-development engineers
actual production machinery. This will delve deeper into their
could be an existing asset in one processes to learn what drives
of the production plants or a new for monitoring of certain process the functional characteristics for
machine and mold set fabricated variables that impact different parts a particular package. Advances
by a vendor partner. Either way, of the specification. For example, in blow molding technology give
the validation process ensures engineers can set process limits packaging companies the ability to
the correct mold engineering and and monitor the blow molding think outside the bottle and bring
helps fine-tune the blow molding pressure—knowing that if it drops new designs to market that deliver
equipment and production line. below a certain point, it may impact greater shelf appeal while offering
This phase ends with a transition material distribution. Catching this new levels of sustainability.
to routine, ongoing operations and fault during the process allows Brands looking to optimize their
full customer acceptance of the new adjustments to be made in real time package design should look for a
bottle. rather than after the product run is
complete. These optimizations result packaging company with a history
Intelligent Factories Enhance in greater production efficiencies to of bringing innovative designs to
Execution: Successful execution lower operating costs. market. Their process should take a
requires validating that the holistic approach to understanding
production line is fully capable of Each Bottle Brings a New the complete life-cycle requirements
meeting customer requirements and Opportunity of the package—from concept to
the operations team has optimized One of the more challenging aspects consumer—to reduce supply-chain
process settings and standard of packaging development is that no costs while elevating sales.

34 PLASTICS NEWS FEBRUARY 2022