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Final Presentation

Final Presentation. Mark Barthold. December 13 th 2012. Agenda. About Me Smirnoff Ice Chipped Finish Issue Captain Morgan 1.75L Glass Cavity Testing Liquid Nitrogen Dosing Red Stripe 24oz Bottle Change Zahm & Nagel Modification Project Bottle Panel Gauges

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Final Presentation

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  1. Final Presentation Mark Barthold December 13th 2012

  2. Agenda • About Me • Smirnoff Ice Chipped Finish Issue • Captain Morgan 1.75L Glass Cavity Testing • Liquid Nitrogen Dosing • Red Stripe 24oz Bottle Change • Zahm & Nagel Modification Project • Bottle Panel Gauges • Captain Morgan Labels Project • Laser Engraving PET Preforms

  3. About Me • Junior at University of Wisconsin Stout • Packaging Major • Hobbies: • Surfing, wakeboarding, snowboarding, and eating Lou Malnatis pizza • Favorite Sports Teams: • Blackhawks hockey, White Sox Baseball and Bears football.

  4. Smirnoff Ice Chipped Finishes RCPS- Plainfield Trial Scope: • Reduce the amount of chipped finishes on Smirnoff Ice bottles. Background: • Consumer Care received higher level of complaints regarding broken finishes. RCPS team was formed to investigate the root cause. Solution: • Adding arrows in the crown artwork • Implement Lightweight Crowns

  5. Smirnoff Ice Lightweight Crowns- Lightweight Crown: • 75lb vs. 80lb weight, resulting in a .02 gram per crown weight reduction • New Diplast Liner Involvement: • Qualified Lightweight Crowns at: • Diageo- Plainfield, IL • City Brewery- Lacrosse, WI • Delta Beverage- Toronto, ON Benefits of Lightweight Crowns: • Cost saving of 85K annually across the 3 production sites with no change parts needed. Data on qualification results available on request

  6. Captain Morgan 1.75L Glass Cavity Testing Scope: • Prevent blistering and wrinkling in neck, face and back label Background: • Blistering and wrinkling with labels due to glass cavity inconsistency, and heavy glass parting line. Involvement: • Tested 32 cavity on the optical comparator for: inaccurate neck angles, sink and bulge in panel and neck. • Results showed high variation in neck angle and heavy parting line in some cavities. • Participated in the water trail to determine best label substrate.

  7. Captain Morgan 1.75L Glass Cavity Testing • Issues

  8. Captain Morgan 1.75L Glass Cavity Testing Water Trial Results: • Inspected bottles for cavities consistence in blistering and wrinkling labels. • High levels of imperfection were found with paper application to the front label and back label was not an issue Future Outlook: • Data showed that PE for front label, Paper for back label and neck label will be determined after next production.

  9. Liquid Nitrogen Dosing System- Line 8 Background: • Nitro dosing is used to add positive pressure to an uncarbonated or pressurized bottle • It expanded 700 to 1 and is delivered in a liquid form that when delivered turns into a gas Plainfield Line 8: • Inconsistent filling temp during hot summer months • Vacuum formation due to liquid cooling after being capped • Paneling issue with our 1.75L Smirnoff cocktail bottle affecting consumer perception

  10. Liquid Nitrogen Dosing System- Line 8 Involvement: • Working with Cryotech and Vacuum Barrier Corp. to install the system • Conducted pressure testing by cooling bottles to ambient temperature after filled • Tested for bottle PSI with the Zahm & Nagel • Redesign Cocktail bottle base to allow a higher push up Future Outlook: • Potential dosing of Captain Morgan 1.75L PET barrel bottle • Used to increase top load strength • Bottle test results show increased top load, but issue with popped handles and rolled bottom

  11. Liquid Nitrogen Dosing System- Line 8 Dosing Plume Headspace Increase

  12. Red Stripe 24oz Bottle Change Scope: • Increased the headspace on our Red Stripe 24oz bottle Background: • In order to bottle at City's, we needed more headspace to prevent breakage Involvement: • Worked with Pratt and Matthews for updated artwork/files • Write new specs for deposit bottle, non-deposit bottle, shipper, divider, incoming pallet pattern and outgoing pallet pattern

  13. Zahm & Nagel PSI Tester Background: • Needed a method for testing dosed PET bottle for PSI Issue: • Currently Zahm & Nagel doesn't make a tester that can puncture through 33mm closures Involvement: • Research alternative methods for testing PSI in PET bottles • Redesign Zahm & Nagel to puncture through thicker caps

  14. New Bottle Gauges Go & No-Go Gauges: • Used to measure bulge and sink over a 1” area • Gauges are available in the lab for use

  15. New Bottle Gauges AMES Bar Gauge: • Used to test label panels for bulge and sink over a big area and determine glass integrity

  16. Captain Morgan Label Project - Valleyfield Background: • Label supplier Fort Dearborn changed print press from a Gravure to a litho press for all of our 60 Canadian labels • Label specs have tight timeline due to material run-out dates, press has been decommissioned Involvement: • Project manager and lead packaging support • Work with Matthews and Fort Dearborn with new art files • New comp. code are needed

  17. Captain Morgan Label Project - Valleyfield Development: • First 10 Labels went on press last week and are live on SAP, samples are being sent to Plainfield for alcohol and rub testing • Second press run will be determined and labels will be work flowed Future Outlook: • Project will be transitioned

  18. Laser Engraving PET Preforms Background: • Lasers can be used to engrave plastic or glass • By engraving a preform, a small image can be lasered then expanded into a larger image Benefits: • More versatility and detail than in-mold systems, which allows less detail to be needed in the mold • Mold with high detail needs more regular cleaning • Images have a smoked appearance that can only be accomplished with lasering

  19. Laser Engraving PET Preforms Next steps: • Send bottle samples to Dick in Norwalk • Research the benefits of lasering on the preform or the bottle itself • Determine what machinery change parts are needed and if a stand alone system would be more beneficial

  20. Questions?THANK YOU!

  21. Liquid Nitrogen Dosing System- Line 8 Testing Results:

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