Effects of Mould Surface Roughness on Press Forming Process of Polymer Coated Paperboard

Tanninen, Panu; Matthews, Sami; Leminen, Ville; Pesonen, Antti; Eskelinen, Harri; Varis, Juha

doi:10.1016/j.promfg.2017.07.338

Cited by 4 publications

(3 citation statements)

References 8 publications

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“…Extensive research and development on paper-based materials have been conducted to increase their market potential and meet the growing demand. Previous studies have predominantly focused on the frictional forces of paperboards in forming processes such as deep drawing [18] and press forming [19]. Some of this research includes the ability to improve the influence of friction and formability of paperboards [20,21].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Frictional Influence and Thermal Analysis of Flexible Paper‐Based Materials Used in the Vertical Form–Fill–Seal Process: An Experimental Study

Merabtene,

Tanninen,

Pesonen

et al. 2024

Packag Technol Sci

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This study evaluated the frictional behaviour of flexible polymer‐coated and dispersion‐coated materials used in vertical form–fill–seal (VFFS) machines. A laboratory‐scale friction measurement device was developed to investigate the relationship between different surface topographies, roughness and frictional properties. Furthermore, surface roughness, contact angle and surface energy of the material were analysed and a microscopic analysis was performed to further understand the effect of material properties on friction. Thermal camera analysis was performed to measure the temperature changes within the material during the film‐transport stage of the VFFS machine. The friction measurement results indicated that the sliding direction did not affect the static and kinetic coefficients of friction. The significant influence of friction on the surface topography of the plate (forming shoulder and tube) was particularly evident. Some materials experienced the stick–slip phenomenon during sliding, depending on the surface type. Teflon tape, which is commonly used in the forming tubes of VFFS machines, exhibited the lowest coefficient of friction. Thermal camera analysis revealed that polymer‐coated paper materials generated more heat than dispersion‐coated papers during VFFS trials and thermoplastic films generated the least heat. No clear relationship between the surface roughness of the paper, fibre orientation, surface energy and friction coefficient was noted. Furthermore, paper‐based materials exhibited a higher coefficient of friction, which is possibly related to the dispersion components of surface energy. The findings of this study provide additional knowledge for designing the forming tube, shoulder geometry and surface plate to minimize the occurrence of defects, such as wrinkles, in paper‐based packages.

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Section: Introductionmentioning

confidence: 99%

Evaluation of Frictional Influence and Thermal Analysis of Flexible Paper‐Based Materials Used in the Vertical Form–Fill–Seal Process: An Experimental Study

Merabtene,

Tanninen,

Pesonen

et al. 2024

Packag Technol Sci

Self Cite

View full text Add to dashboard Cite

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“…In the press forming process, an improved heating distribution could be achieved by using an advanced oil‐heated tooling unit, ultimately improving the stability of manufactured trays and reducing the overall production costs 6 . Moreover, advancements have been made in controlling friction and temperature in press forming processes by adjusting the mould surfaces via polishing 7 . Furthermore, a small‐scale press forming unit was designed to test the experimental materials on a pilot scale while providing a production‐scale environment 8 .…”

Section: Introductionmentioning

confidence: 99%

“…6 Moreover, advancements have been made in controlling friction and temperature in press forming processes by adjusting the mould surfaces via polishing. 7 Furthermore, a small-scale press forming unit was designed to test the experimental materials on a pilot scale while providing a productionscale environment. 8 The deep drawing process underwent several investigations to determine the impact of geometric parameters of tooling on the occurrence of defects and the deep drawing performance of different materials.…”

Section: Introductionmentioning

confidence: 99%

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

et al. 2023

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Advances in the three‐dimensional (3D) forming of fibre‐based materials require the formulation of more formable materials and the development of process lines, machinery, and tools. Using a thermoforming process to convert fibre‐based materials into 3D forms is an emerging area of research which requires further investigation into the practicality of the process line and tooling in forming such materials. Accordingly, this study evaluated the impact of the thermoforming process operation and tooling on the thermoformability of plastic‐coated paperboards. The main objective was to provide design recommendations for the future development of thermoforming lines, followed by guidelines for tooling design to improve the performance of materials utilising the currently available machinery. This study examined the thermoforming behaviour of two different plastic‐coated paperboards in vacuum and pressure thermoforming by investigating their maximum acquired depth, shape accuracy, and damage mechanisms. The research findings, based on the depth and linear elongation achieved, indicate that the inferior performance of plastic‐coated paperboards in thermoforming cannot be wholly attributed to restrictions in the three‐dimensional formability of materials; the inability of the current process lines to utilise the maximum potential of materials can also lead to their inferior performance. Notably, the method of pressure supply and cooling of materials requires adjustment of these materials. From a tooling perspective, owing to the spring‐back effects, the enlargement of the mould dimensions should be considered during the design stage. Additionally, based on potential opportunities with the current unmodified machinery and materials, products in the size of standard food trays have a higher likelihood of being optimised with tooling design than smaller sized shapes, which still require additional developments in materials. Moreover, designing moulds without draft angles can reduce the risk of rupture owing to the prevention of localised stress formation in materials.

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Foam-laid extensible paper for improved extensibility and press-forming performance

Kouko,

Tanninen,

Leminen

et al. 2024

Cellulose

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This study was motivated by the recent raising interest for the sustainable plastic-free dry 3D formable materials. 3D forming processes are capable to produce large unit quantities, but the process conditions for packaging applications have been typically very demanding for cellulose-based materials. This study covers some of the key factors affecting the extensibility of cellulose fibre-based materials and presents a laboratory-scale development study of a press-formable material concept. The investigation focused on comparisons of two refining concepts for bleached softwood kraft (BSK) pulp and two sheet forming concepts, namely water-laid and foam-laid forming. Additionally, influence of thermoplastic additives on the extensibility and 3D forming performance were investigated. In-plane compaction was applied with Expanda® laboratory device. Performance of the materials was evaluated by tensile tests and depth of the 3D formed shapes. In this study, in-plane compaction at first in cross-machine direction (CD) and then in machine direction (MD) led to over 30% elongation with BSK-based laboratory sheets containing latex as a binder and foaming agent. In addition to high elongation, optimal strength was needed for the best press-forming performances. In-plane compaction was the most significant factor regarding the elongation, but it also decreased the strength of the materials. Similar press-forming performance was found with two materials with either highly anisotropic or more isotropic elongation. The elongation anisotropy was created by one-way and two-way in-plane compactions. The results indicate that a reasonable performance for BSK-based materials for 3D forming applications can be reached using the presented concept.

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Effects of Mould Surface Roughness on Press Forming Process of Polymer Coated Paperboard

Cited by 4 publications

References 8 publications

Evaluation of Frictional Influence and Thermal Analysis of Flexible Paper‐Based Materials Used in the Vertical Form–Fill–Seal Process: An Experimental Study

Evaluation of Frictional Influence and Thermal Analysis of Flexible Paper‐Based Materials Used in the Vertical Form–Fill–Seal Process: An Experimental Study

Effects of thermoforming operation and tooling on the thermoformability of plastic‐coated fibre‐based materials

Foam-laid extensible paper for improved extensibility and press-forming performance

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