Weekly Report

(July 4 – 6)

By Julian Paul V. Querubin

Cadet Engineer
Objectives
 Basics of Can Making
- Lithography of Ends and Bodies
- Can Making Process Flow (Material Preparation, Lid Line Assembly and Body
Line Assembly)
- Quality Control
~ role of QC
~ parameters per process step ( Coil Cutting, Printing
Line, Lid line and Body line )
~ product tests performed by QC
~ in-depth look at double seaming
~ types of defects encountered for each process step
- End Product – Customer Side
- Observation/Recommendation
- References
Lithography of Ends and Bodies
 Lithography is also called litho-offset.
 Offset printing – commonly used technique using a
transfer medium from plate to rubber blanket which then
applied to the printing surface.
 Lithography of Ends and Bodies
Resin Types
Epoxy Epoxy
Polyester Epoxy Ester Organosol Acrylic
Amino Phenolic
- good hardness - basic Ph -used as -used for -universal -cured at low
and flexibility - good heat external DRDs lacquer temp
- good resistance lacquer -good -color gold due -good heat
adherence to to phenol
- good for -used as flexibility, resistance,
metal -used as
sterilization overprint chemical internal lacquer color
- does not
yellow in high @ diff. varnish resistance & -high resistance retention &
temp conditions -good hardness to acidic food substrate
- poor chemical - limited resistance to -resistive to -excellent wetting
resistance flexibility sterilization sulphide flexibility, -bad odor
- expensive due - used as -flexible staining chemical res. &
to plasticizers external -used for wet- -prone to adhesion
-BPA
lacquer on-wet food colorant
(Bisphenol)-
process absorption contained
Can Making Process Flow
 Material Preparation

Incoming Coil Coil Printing/ Oven

Packing
Material Cutting Coating Curing

A B
 Can Making Process Flow
 Lid Line Assembly

Standard
End Compound
Stamping/ Lining &
Scroll Packing Shipping
Curling Oven Curing
Easy Open
End

C
 Can Making Process Flow
 Body Line Assembly

B
C

Side Stripe
Body & Oven Necking/Flanging/
Slitting Forming Beading
Curing
Quality Control
 QC parameters per process step
COIL CUTTING

Japanese Temper
International Surface
Standard Finish
Tinplate Tin
letter Coating
Symbol Weight
Steel Type Batch No.
Thickness Coil Batch
Coil Width 1) Checking of Coiled Tin Plate Before Cutting
 Quality Control
 QC parameters per process step
COIL CUTTING
2) Checking of Coiled Tin Plate Parameters

Base Weight
Control
Tin Coating Coil Width Temper (Plate Coil Width Bur Tin Oxide
Parameters Thickness)

- Tested once per - Teste once per - Tested once - Tested once - Tested once - Tested once
shift skid per coil per coil per coil per kid
Test - Uses stanomatic - Uses a Steel - Uses Rockwell - Must not - Maximum of - Smut Test
Procedures tin coating Rule Hardness exceed 15% of plate
analyzer Tester ± 0.005 mm thickness
/Test of plate - Uses Vernier
Method thickness Caliper
- Uses Vernier
Caliper
To check the To check the To check the To check the To avoid damage To check the
uniformity of tin exactness based exactness based exactness based and scratches to amount of tin
Purpose coating on the tinplate on the tinplate on the tinplate the machine esp. oxide that might
specs specs specs to rollers cause peel-off
Loses some Huge percent Huge percent Huge percent
Possible
Problem/Defects
integrity of the difference of difference of difference of
material parameters parameters parameters
Quality Control
 QC parameters per process step
COIL CUTTING

- It is teste once before start of the shift. pinhole

- A sample tinplate intentionally pinched
with a hole is being ejected at normal
production run.
- The pin hole detector can detect as
small as 25 microns. This is usually tested once per month.
- After the detector passes the test then a coil without a hole is tested
to justify the accuracy of the detector.
3) Cut Sheet with Pinhole
Quality Control
 QC parameters per process step
COIL CUTTING
4) Checking of Cut Coiled Tinplate
Control Cut Length Cut Length Cut Length Tail Size (For Appearance
Parameters Burr Squareness Pre-Scroll)
- Maximum - Maximum of -Tested once per - Tested once -Visual
Test of 15 % 0.15% of cut skid per skid inspection of
Procedures plate length - Uses Vernier rust, punch mark,
/Test thickness Caliper dents, weld
- Uses Vernier joints,scratches
Method Caliper
To avoid damage To check if the To minimize To determine the To determine
and scratches to sides are metal scraps right orientation whether they can
Purpose the machine esp. paralleled during the when coating be released for
to rollers enough process of the next process
slitting
Uneven side
Possible
Problem/Defects angle
Quality Control
 QC parameters per process step
PRINTING LINE
1) Oven Temperature
Actual Temperature
Control Temperature Setting
through the Chart
Parameters of Zones in Monitor
Recorder & Datapaq
- Datapaq and Oven temp - Datapaq and Oven temp
graph graph
Test Procedures
/Test Method

To ensure that the lacquer Monitor actual

Purpose coated is properly cured temperature thru chart
recorder
Possible Underbake or Underbake or
Problem/Defects Overbake Overbake
Quality Control
 QC parameters per process step
PRINTING LINE
2) Speed
Actual Oven Speed
Control
(Speed Per Hour
Parameters
Setting)
SPH (Speed Per
Hour) setting from
Test Procedures equipment monitor
/Test Method

Purpose Monitor oven speed

Possible Underbake and

Problem/Defects Overbake
Quality Control
3) Impression
Distribution Rubber Roller
Control Impression as Impression as
Parameters measured in measured in
thickness (mm) thickness (mm)
Steel rule Steel rule

Test Procedures
/Test Method

Monitor the To control the

impression for wet appearance on
Purpose
film and for dry film coated sheets
weight
Possible High or Low Misalign/Uneven
Problem/Defects inpression rubber roller set-up
Quality Control
 QC parameters per process step
PRINTING LINE
4) Wet Film Weight 5) Dry Film Weight
Wet Film Weight as Actual Dry Film
Control Control
Measured through Weight through
Parameters Parameters
Pfund Gage (mm) SenconTester

Pfund Gauge Sencon Coating

Test Procedures Test Procedures Analyzer and
/Test Method /Test Method Analytical Balance
(Gravemetric
method)
To gage the wet film To ensure that
Purpose dia. for required dry lacquer coated
Purpose
film weight meets the required
DFW / std sheet
Quality Control
 QC parameters per process step
PRINTING LINE
6) Adhesion/Tape Test 7) Sheen Test
Peel Off Rating Scratch Resistance
Control Control
through Tape Pull Rating through
Parameters Parameters
Test Sheen or Pencil Test

Multi Cross Cutter Staedtler pencils

Test Procedures
and 3M Scotch tape Test Procedures from H-5H
/Test Method
/Test Method

To ensure good adhesion

Purpose of the coated lacquer To determine the
sheets Purpose resistance of coating
Peel-off material to scratch effects
Possible
Possible Undercured
Problem/Defects
Problem/Defects
Quality Control
 QC parameters per process step
PRINTING LINE
8) Altek/Lubricity Test 9) Solvent Resistance Test
Control Coefficient of Double Rub
Control
Parameters Friction Performance based
Parameters
on MEK Test
Altek Lubricity
Test Procedures Tester Methyl Ethyl Ketone
/Test Method Test Procedures and Mechanical Rub
/Test Method Tester

To determine the lubricity

Purpose of coated sheets To assess the chemical
Purpose resistance of coated sheets
High lubricity results
Possible
Possible Below the MEK double
Problem/Defects rub standard
Problem/Defects
Quality Control
 QC parameters per process step
PRINTING LINE
10) Registration
Control Bare metal
Parameters Registation

Positive pattern
Test Procedures
/Test Method

To determine if the bare

Purpose metal meets the required
dimension and specs
Off-set/baremetal/Off-
Possible registration
Problem/Defects
Quality Control
 QC parameters per process step
PRINTING LINE
11) Registration
Final Drum
Control Drum Viscosity Tank or Basin
Viscosity after
Parameters After Stirring Viscosity
Dilution
Ford cup # 4 Ford cup # 4 Ford cup # 4
Test Procedures
/Test Method

To guide the To determine the To determine the

lacquer mixer if initial velocity and changes in lacquer
Purpose
dilution is needed control the DFW viscosity
or not
Possible HighViscosity HighViscosity LowViscosity
Problem/Defects
Quality Control
 QC parameters per process step
PRINTING LINE
12) Dilution 13) Lacquer Batch
Amount of Solvent Control
Control Lacquer Batch
added during Parameters
Parameters
dilution

Test Procedures Graduated Cylinder Test Procedures N/A

/Test Method /Test Method

To control the max. Amt.

Purpose of solvent to be added in To establish traceability of
lacquer Purpose lacquer used per
Over Dilution production run of skids
Possible
No or wrongly recorded
Problem/Defects Possible
Problem/Defects
Quality Control
 QC parameters per process step
LID LINE
1) Checking of Coated Sheets to be Scrolled or Slitted
Control Tinplate
Released Tag Size and Description
Parameters Information Sheet

- Tested once per - Tested once per - Tested once per

Test Procedures shift shift shift
/Test Method - Visual inspection - Visual inspection - Visual inspection

To check if the coated To check if the coated To check if the coated

Purpose sheets are ready for sheets are ready for sheets are ready for
scrolling and slitting scrolling and slitting scrolling and slitting
Possible
Problem/Defects
Quality Control
 QC parameters per process step
LID LINE
2) Scrolling/Slitting
Control Strip Height Strip Height
Strip Length Burr Appearance
Parameters Low Side High Side

Test
Procedures
/Test
Method

Purpose
Possible
Problem/
Defects
Quality Control
 QC parameters per process step
LID LINE
3) Checking of Strips before Feeding to Press
Tinplate
Control Size and
Information Released Tag Batch Code
Parameters Description
Sheet

Test
Procedures
/Test
Method

Purpose
Possible
Problem/
Defects
 Quality Control
 QC parameters per process step
LID LINE
4) Punching/Curling of Lids

Control Countersink Curl Curl Flange Stacking per Hammer

Bead Depth Curl Height Chuck Fit
Parameters Depth Opening Diameter Width 2” Test

Test
Procedures
/Test
Method

Purpose

Possible
Problem/
Defects
Quality Control
 QC parameters per process step
LID LINE 5) Compound Lining and Curing of Lids
Compound Compound Compound
Control Compound Clearance Four Flat/Under
Appearance
Parameters Weight from Cut Segment Curl
Edge Distribution Distribution

Test
Procedures
/Test
Method

Purpose
Possible
Problem/
Defects
 Quality Control
 QC parameters per process step
LID LINE
6) Checking the Porosity of Finished Lids 6) Checking Tags of Bottom Lids in a box
Enamel Control Production
Control Copper Released Tag
Rating Value Parameters Tag
Parameters Sulfate Test
Test

Test Test
Procedures Procedures
/Test /Test
Method Method

Purpose Purpose
Possible Possible
Problem/ Problem/
Defects Defects
 Quality Control
 QC parameters per process step
BODY LINE

1) Blanking/Slitting
Blank Blank
Control Sheets
Blank Length Blank Height Squareness Squareness Burr Baremetal
Parameters Identification
along Length along Height

Test
Procedures
/Test
Method

Purpose

Possible
Problem/
Defects
 Quality Control
 QC parameters per process step
BODY LINE
2) Body Forming
Plug Welding
Welding Welding Welding
Diameter Integrity
Control Welding Welding Welding Integrity Integrity Integrity
Overlap (Change in thru Flange
Parameters Thickness Pressure Current thru Tear thru Ball thru Pinch
plug Test/Cone
Test Test Test
Diameter) Test

Test
Procedures
/Test
Method

Purpose

Possible
Problem/
Defects
 Quality Control
 QC parameters per process step
BODY LINE
3) Side Stripe & Curing
Side Stripe Amount of Dry Film Side Stripe
Control
Width Side Stripe Weight Adhesion Boil Test
Parameters
(Inside) (cured) (Varnish) (Tape Test)

Test
Procedures
/Test
Method

Purpose

Possible
Problem/
Defects
 Quality Control
 QC parameters per process step
BODY LINE
4) Flanging 5) Beading
Control Body Flange Control
Flange Width Flange Width
Parameters Height Parameters

Test Test
Procedures Procedures
/Test Method /Test Method

Purpose Purpose

Possible Possible
Problem/ Problem/
Defects Defects
 Quality Control
 QC parameters per process step
BODY LINE
6) Double Seaming

Control Cover/End Can Body

Countersink Cover Hook Body Hook Seam Width
Parameters Curl Flange

Test
Procedures
/Test
Method

Purpose

Possible
Problem/
Defects
Quality Control
 QC parameters per process step
BODY LINE
6) Double Seaming
Control Seam Pressure Juncture Wrinkle
Overlap
Parameters Thickness Ridge Rating Rating

Test
Procedures
/Test
Method

Purpose

Possible
Problem/
Defects
Quality Control
 QC parameters per process step
BODY LINE
- In-depth look at double seaming

A double seam is that part of the can formed by joining the body of the can and the end (sometimes referred to as the
cover). The body flange and the curl of the end interlock during the double seaming operation to form a strong
mechanical structure.

The double seam is generally formed in two operations, referred to as first

operation and second operation. Each station of the closing machine has a
base plate, a seaming chuck, at least one first operation roll and one second
operation roll. The base plate of
the machine supports the can body. The snug fitting seaming chuck holds
the can end in place and acts as a support surface for the double seaming
roll pressure.
End Product – Customer Side
 Various types of products packed in cans – wet and dry

Tomato Sauce
Condense/Evaporada milk
Meat loaf
Sardines
Corned beef

Wet Can Products Dry Can Products

End Product – Customer Side
 Retorting and Sterilization
1. Retort processing uses saturated steam under pressure
until heat penetrates the product
2. Aseptic processing uses sterilization of the outside
container by pumping it thru heat exchanger
 Shell life
- Canned food can last up to 1-2 years if stored properly.
End Product – Customer Side
 Benefits of canned products
 Canned food is almost fresh as fresh food.
- The food inside the can undergo different processes to preserve its goodness.
 Canned food is not wasted.
- Canning has a long preserved-life as compared to those with plastic containers.
 Nutrients are easily accessible.
- It is packed with nutrients as stated in the Nutrition Facts.
 Canned food is available anywhere & in all seasons.
- Canning has been a universal answer to preservation of almost any kinds of
food.
 Canned food is easy to prepare.
- Just open the can and your food is ready to serve.
 Canned food is budget-friendly.
- One can avail canned foods in any local stores at a reasonable cost.
Observation/Recommendation
 GEMECO is a big manufacturing company that utilizes
modern and even old equipments, machines and tools to
create a tin can as a by-product.
 In three days of training, discusion, demonstration and
correlation are easy to comprehend and understood
 I see some little replacement needed to the non-functional
measuring devices
References
https://www.toyo-seikan.co.jp/e/technique/can/kind/

https://m.indiamart.com/proddetail/tin-can-lid-14253402191.html

https://drive.google.com/file/d/1qCYxlN0OahshXgm8BtXRLJPvqhKtsvRu/view?usp=drivesdk

http://www.offsetprintingtechnology.com/sub-categories/offset-lithography/

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A Guide to Can Defects Basic Components of Double Seam ... - AFDO