Packaging Material Analysis
Packaging Material Analysis
Packaging Material Analysis
1
Finished packaging Issued on : 01/08/2005
Authorised By : CTC
Page : 1/7
CARTONS AND SEPARATORS Revised on : 25/06/2008
Receiving conditions Revision : 02
Materials
The cartons must be made of materials as described below.
Outer layer – Virgin Kraft (VK) paper of desired GSM as specified in the individual
specifications for different types of cartons.
VK paper generally is made from 100% unbleached pulp or from a mixture of bamboo pulp
and wood pulp that will ensure compliance with the requirements as per IS 1397:1990.
Inner layer – Semivirgin (SVK) kraft paper / Agricultural residue kraft paper (APK) of
desired GSM as specified in the individual specifications for different types of cartons.
SVK or APK paper generally is made from bagasse, rice/wheat straw grass, jute, a mixture of
these along with sulphate pulp or any other equivalent materials that will ensure compliance
with IS 1397:1990.
CORRUGATION (ARK) – Non virgin kraft paper (NVK) of desired GSM as specified in the
individual specifications for different types of cartons.
Non virgin kraft paper may be made from 100% waste paper or a mixture of waste paper and
agricultural waste or any other material that will ensure compliance with the requirements as
per IS 1397:1990.
The direction of CORRUGATION (ARK) must be vertical i.e., flutes are vertical to give
maximum stacking strength.
Cartons and separators must be with clear cut edges and be free from die – cut waste.
Mechanical influence during production must not damage the edge nor should cause flute
crushing.
Packaging materials Reference No .: PK- 2.1
Finished packaging Issued on : 01/08/2005
Authorised By : CTC
Page : 2/7
CARTONS AND SEPARATORS Revised on : 25/06/2008
Receiving conditions Revision : 02
Any suitable adhesive capable of firmly adhering the various plies together may be used.
Sodium silicate or any other highly alkaline adhesive shall not be used.
For staples and stitches, flat wire shall be used and there should be minimum 8 staples, two
each at the top and bottom and four staples at the intermediate points at regular intervals.
The staples used should not show the tendencies to rust.
The cartons shall be manufactured to the style and design with respect to the individual
types of cartons as agreed between the supplier and UB Group.
The blanks shall be properly creased and slotted so that when the box is assembled, there
shall be no holes at the corners.
The flaps shall not crack when bent through 90 degree inside and then 90 degree outside.
Printing ink or glue should not cause sticking together of the cartons neither inside nor
outside.
Tear strips should be provided to the cartons and it must be fastened satisfactorily
everywhere to the carton.
Decoration
The colours must be uniform and in accordance with the specifications given.
If an e- marking is part of the decoration the same need to be fulfilled as per the EEC
specifications.
Reference No .: PK- 2.1
Packaging materials Issued on : 01/08/2005
Finished packaging Authorised By : CTC
Page : 3/7
Revised on : 25/06/2008
CARTONS AND SEPARATORS Revision : 02
Receiving conditions
Approval
Any Carton manufacturer who is able to meet our receiving conditions and has proved by
samples that the production apparatus is capable of producing the quality desired both
with regard to colours, technical quality and suitability for the operations may be
nominated as an approved supplier. Initially a trial lot will be tested for a shopfloor
performance before approval. No change of materials, etc. is allowed without the written
acceptance of UB group, Breweries Division. The approval may be withdrawn if the
deliveries are not up to the desired quality standard.
General requirements
Total shortage, calculated on the basis of several units from the same lot, must not in all
total to more than 1% as a maximum to the total quantity in numbers agreed upon. If the
shortage is ascertained to be more than 1%, a credit note or a subsequent delivery in
accordance with shortage ascertained is demanded for the whole lot from the supplier.
The cartons must be marked with the name or logo of the manufacturer.
Quality requirements
The cartons supplied should meet the quality requirements as per the specifications PM d
1 -13 – 1 b to PM d – 13 -1 b, depending on the types of cartons. The lot will be sampled
at random as per the sampling plan stipulated and tested for compliance with respect to
the desired quality requirements as per the specifications. Any deviations observed from
the desired specifications will cause return of the lot.
Laboratory tests
A random sample is taken from 10 packages, out of which 5 are taken as a bundle and
single cartons from 5 other bundles. The following control at the production site is carried
out.
Board
Any deviations from the desired ply will cause return of the lot.
Any deviations observed from the desired standard are conveyed to the supplier for
improvements in the next lot. If subsequent lots don’t meet the desired standard, the lot will
be returned.
Dimensions
Bursting strength
Out of the 9 readings, deviations of more than 2 readings from the specifications will cause
return of the lot.
Board substance
Out of the 9 readings, deviations of more than 2 readings from the desired standard will cause
return of the lot.
Visual defects
Shortage
3. Damaged packages X
5. Wrong packages X
6. Colours missing X
7. Delaminating X
8. Incorrect/wrong colors X X
9. Wrong text X
Any defect not mentioned will be evaluated according to the above classification.
3. DAMAGED PACKAGES: Packages which have been torn, wrinkled, have cuts or
similar damages that cause operation difficulties.
7. DELAMINATION: Packages where liner and liner and fluting have a tendency to
separate in the glue layer.
9. WRONG TEXT: Text printed on the cartons is different from the corresponding art
work text for that type of carton.
10. COLOURS COMING OFF: The decoration of the package comes off during handling
and/or because of influence of humidity.
11. DISPLACED DECORATION: The decoration is not centered in relation to the package
itself, but dislocated.
For the returnable bottle labels, penetration of hot lye should take place during washing
operations in the washing machine.
The labels should not have any smell.
Decoration
The decoration must be placed correctly. The colours must be uniform and should match
as per the approved colour codes. If an e-marking is the part of decoration, it should be fulfilled
as per the EBC specifications.
The producer should comply with the artwork approved by the Central marketing of UB
Group Breweries Division.
Approval
Any manufacturer who accepts our terms and has proved by samples. That the plant is
capable of producing the quantity required both with regard to colour, technical quality and
suitability for the operations may be asked to supply a lot for trial runs in a high speed bottling
line. Subject to satisfactory trial run, the suppliers manufacturing operations will be audited with
a view to nominate as an approved supplier.
This approval may be withdrawn at any time if delivers are not up to the desired standard.
Packing
The labels should be packed as given in the purchase order.
Trial run
Random sample: 3 packing’s
In case of emergencies i.e. if the labels deviate in minor aspects from the specifications in the
laboratory tests and no stock of labels are available, then a trial run is made on a high speed
labeling machine, and if any difficulties are encountered during the trials, the lot will be rejected.
Quality Requirements:
Laboratory and production tests:
Upon the receipt the lot will be examined on the basis of random sampling.
Lots exceeding 1.5 million labels will be divided into lots of maximum 1.5 million labels.
A random sample will normally comprise 3 packages. The following controls may be adjusted
depending on the vendor rating of the supplier. (Every month vendor ratings need to be carried
out at the unit breweries for each approved supplier with respect to quality, price and delivery.)
Visual Defects
Random sample : 250 labels per package
Major Defects : 22 defect labels cause return of the lot.
Minor Defects : 70 defect labels cause return of the lot.
For defects classification refer defects classification list labels.
Main Dimensions:
Random sample : 1 bundle per package
1 bundle outside the tolerances causes return of the lot.
Grain Direction:
Random sample : 1 label per package
1 label outside the tolerances causes return of the lot.
GSM:
Random sample : 2 labels per package
If there is a minor deviation in the GSM value, a trial run can be run on the labels and if found
any difficulties during the production the lot will be returned.
Printing:
Random sample : 5 labels per package
3 labels with defective text or any mismatching with the reference label in the bottle dress both
causes return of the lot.
Penetration of the lye:
Random sample : 5 labels per package
4 defective labels causes return of the lot.
Cobb value:
Random sample : 5 labels per package
3 defective labels causes return of the lot.
Marking
The labels should be marked with the decoration code and if possible suppliers mark.
Shortage
The shortage in each package should not deviate more than 4% from the number stated.
However, the total shortage should not exceed 2% from the lot quantity.
Any defect not mentioned in will be evaluated as per the above classification.
Materials:
Minimum specifications for Tin free steel (TFS)*, for the manufacture of crown corks are given
under.
Thickness : 0.25mm (±0.02mm)
Normal coating : 40mg/m2
Temper : T 4 (61 ± 3)
Finish : Matte / Stone.
Tin Free Steel: - Steel sheet with a low carbon content & coated by electrolysis on
both side with chromium oxide.
Any change in the specification of Tin Free Steel (TFS), or change in the material for making
crown corks should be approved by UB Group, Breweries Division.
Packaging materials
Closure and protection Caps Reference No .: PK- 3.1
Issued on : 01/08/2005
Authorised By : CSK
PLASTIC LINED CROWNS Page : 2/6
Receiving conditions Revised on : 02/01/2007
Revision : 01
Lacquering:
Single colour printed crowns should have minimum of 25 mg lacquer coating externally.
Multi colour printed crowns should have minimum of 35 mg lacquer coating externally.
Decoration
Decoration colours must be constant, fast to light and must be covered with a transparent
lacquer.
The design, artwork, colour codes for each brand will be issued separately for every approved
supplier.
The producer will not be held responsible for any defect due to a mistake in artwork approved by
UB Group, Breweries Division.
Approval
A crown cork manufacture may be nominated as an approved supplier if the receiving conditions
are accepted. A new supplier must prove by samples in connection with acceptance that the
production apparatus is able to deliver the desired quality. Subsequently their manufacturing
premises will be audited by a technical team from the UB Group, Breweries Division. Further a
lot will be tested for shopfloor performance before approval. Approval may be withdrawn at any
time, if the quality of crowns is not upto the desired standard.
Quality Requirements
The liner of the crowns must not impart any off – flavour to the finished product. The samples
taken at random from a lot should meet the Taste Testing specifications.
Occurrence of oil or other lubricants which are not approved by the Food authorities of India is
not allowed to any extent. If such an oil or lubricant found on a single crown – outside or inside
– the lot is returned irrespective of the size of the lot.
The lot will be accepted only if the samples taken at random passes with respect to the
specifications and no defect must exceed the limits set out in the attached appendix.
Lots exceeding 1.5 million (15 Lacs) crowns will be divided in to lots of Max. 1.5 million
crowns.
The sample will normally amount to 100 crowns, generally taken at least from 2 packings. The
inspection control can be adjusted, depending on the vendour rating of the supplier. The
measuring control is only made on visually approved crowns.
Main Dimensions
Weight of liner
Pressure retention
When mounted on a geometrical correct finish of crowns without visible defects, must be able to
resist the following internal pressure.
Quality of lacquer
Random sample: 10 crowns
If one or more of the crowns show 3-4 tiny spots after having been submerged in a 20%
CuSO4 solution for 1 minute, a complaint will be made. Unacceptable damage will cause
return of the lot.
Taste testing
Random sample: 5 crowns.
The sample is tested with approved crowns as reference. Any abnormality in the smell or
taste will cause rejection of the lot.
Visual defects
These defects are classified to 3 major groups as under. Please refer to the classification of
visual defects and description list.
Critical defects:
Defects which render the crowns dangerous for persons and/or may cause damage to the
machinery when used in the production. No such defects will be accepted in the random
sample-irrespective of its size.
Major defects:
Defects which affect the quality of the product and which cannot be sorted out during
production. Furthermore, such defects generally reduce the effectiveness of the production
line (AQL- 0.15%).
Packaging materials
Closure and protection Caps Reference No .: PK- 3.1
Issued on : 01/08/2005
Authorised By : CSK
PLASTIC LINED CROWNS Page : 5/6
Receiving conditions Revised on : 02/01/2007
Revision : 01
Minor defects:
Defects, which normally have no effect on the production, but in case of occurrence in too large
a quantity they are unwanted for commercial reasons (AQL-1%).
Trial Run:
Random sample: 1 packing.
In case of emergencies i.e. if the samples fail in the laboratory test in minor aspects, a trial run is
made on the entire random sample on a high speed bottling line. Any causes for difficulties
during production are noted. If there are major non-compliances the lot will be returned.
Packing:
The crowns have to be delivered in suitable packing protecting them against dust, dampness,
deformation and off flavour during storage.
Storage:
Random sample: 1 packing.
If shortage of >1% is found, another random sample of 4 packing is taken. If the mean value of
shortage of the 5 random samples is>0.5%, a credit note or an after delivery will be demanded
from the supplier.
Markings:
The crown corks must be marked with the supplier’s identity.
Packaging materials
Closure and protection Caps Reference No .: PK- 3.1
Issued on : 01/08/2005
Authorised By : CSK
PLASTIC LINED CROWNS Page : 6/6
Receiving conditions Revised on : 02/01/2007
Appendix Revision : 01
CLASSIFICATION OF VISUAL DEFECTS
Note: For Liner Adhesion Test, Lacquer Quality, Taste Testing, Pressure Retention,
Pasteurization Test, Visual Defects, Shortage, Trial Runs & Sampling Please Refer Receiving
Conditions Appendix – Plastic Lined Crowns.
Materials
The basic material used for making pressure sensitive adhesive tapes with plastic base will be
polypropylene.
General requirements
The pressure sensitive adhesive tape shall consist of a base film, coated uniformly on one side
with a suitable pressure sensitive adhesive composition, requiring no moisture, heat or other
special preparation prior to application.
The rolls shall be wound uniformly and evenly on cores so that each succeeding turn coincides
with the one below it.
Each roll of tape shall be reasonably free from overlapping, depressions, distortions or
telescoping and shall unroll without offsetting of the adhesive mass or tearing of the base. When
unrolled, the tape should not show transference of the adhesive to the backing of the underlying
turn.
Colour code if any will be specified separately. The colour shall match the specifications.
Outside printing if any will be specified separately. Printing shall be legible and shall not transfer
to the adhesive side of the adjacent turn.
All tapes shall be normally wound on the cores of the internal diameters specified and shall have
sufficient rigidity to prevent the distortion of the roll under normal conditions of transportation
and use.
The splices in the tape shall be so made so as not to separate when unwound from the roll.
For every 100 rolls, 3 rolls are taken at random for testing.
The lot shall be declared as conforming to the requirements, if the test results obtained meet the
corresponding requirements given in the standards.
Approval
Packing
The rolls shall be packed in suitable containers so that they are adequately protected from
damage in transportation and from deterioration due to climatic conditions and shall not adhere
to each other or to the container.
Marking
2. Width
3. Tensile Strength
4. Elongation at break
6. Total thickness
Sly.
No. Description Specification
1 Dimensions
2 GSM
3 Thickness
4 Bursting Strength
5 Visual Defects
6 Colour Shade / Text / Design