Manual de Calidad 2006 Retornable

Table of Contents Packaging Authorization for Refillable PET Bottles

Packaging Authorization for Refillable PET Bottles Page 1 of 2 Issued: 20-Dec-2004

REQUIREMENTS

REFPET Bottle Authorization Matrices PK-RQ-065 REFPET Bottle Specifications PK-SP-045

TEST PROCEDURES

Materials

REFPET Bottle Acetaldehyde Test—24-Hour PK-PR-215 REFPET Bottle Acetaldehyde Test—Ground Preforms PK-PR-216 REFPET Bottle Appearance and Color Evaluation PK-PR-217 REFPET Bottle Scientific and Regulatory Affairs Process PK-PR-205 REFPET Bottle Taste Compatibility Test PK-PR-206

Dimensional

REFPET Bottle Dimensions Evaluation—Exterior PK-PR-207 REFPET Bottle Dimensions Evaluation—Finish PK-PR-208

Physical Performance

REFPET Bottle Capacity Change (Shrinkage) Test PK-PR-218 REFPET Bottle Carbonation Retention Test PK-PR-219 REFPET Bottle Drop Impact Test PK-PR-220 REFPET Bottle Durability Test—Abbreviated Trip-Per-Two-Day

Washing PK-PR-221

REFPET Bottle Durability Test—Standard Trip-Per-Two-Day Washing

PK-PR-222

REFPET Bottle Empty Weight and “As-Delivered” Capacity Test PK-PR-223 REFPET Bottle Fill-Point Variation Test PK-PR-224 REFPET Bottle Internal Pressure Test PK-PR-225 REFPET Bottle Perpendicularity Test PK-PR-270 REFPET Bottle Plastic Distribution Test PK-PR-226 REFPET Bottle Support Ledge Strength Test PK-PR-227 REFPET Bottle Thermal Stability Test PK-PR-228 REFPET Bottle Vertical Load Test—Empty PK-PR-229

Table of Contents Packaging Authorization for Refillable PET Bottles

Packaging Authorization for Refillable PET Bottles Page 2 of 2 Issued: 20-Dec-2004

TEST PROCEDURES (CONTINUED)

Functional

REFPET Bottle Line Trial PK-PR-055

REFPET Bottle Authorization Matrices

Packaging Authorization: REFPET Bottles PK-RQ-065 Issued: 20-Dec-2004 CLASSIFIED: Internal Use Page 1 of 4

Purpose To provide the requirements, specifications and test procedures needed to authorize a package.

Scope These requirements were developed for carbonated beverages. Multi-product designs that are also used for noncarbonated products must also meet these requirements. If a specific bottle design is developed exclusively for noncarbonated products, then new specifications may be developed and reviewed with Global Quality and Global Packaging. Applies to suppliers of refillable PET (REFPET) bottles for:

• Carbonated water and soft drinks

• Noncarbonated (NCB) pressurized and non-pressurized water and beverages

Contents General ...........................................................................................................1 Filling Test Packages ....................................................................................2 Materials Authorization Matrix .....................................................................2 Packaging Authorization Matrix...................................................................3

Requirements

General • This document is an integral component of New Package Authorization, PK-RQ-020. The following Materials and Packaging Authorization Matrices summarize the requirements and tests for authorizing a RefPET bottle for a specific set of circumstances. Which evaluations are required depends on whether a specific combination of package components has been used previously. Therefore, it is important to include authorization information in the Global Packaging database.

• The testing requirements and procedures referenced herein do not preclude any additional testing that may be required where local regulations or business needs make practical or necessary the adaptation of more stringent requirements.

• To authorize additional plants or divisions to use an approved bottle design (shape, size, weight), the division may delegate authorization responsibility to the bottler for filling line and finish compatibility.



Filling Test Packages

• If carbonated water is required for a test, then all packages should be filled at the same time just prior to testing in order to utilize laboratory resources efficiently and to ensure maximum carbonation uniformity among the samples.

• If packages are filled in the lab, use the same carbonation or pressure targets used on the filling line. Whenever possible, target the high-end of the specification. You can use the following to simulate CO2 or nitrogen pressure in the lab:

Target… May use… To replace or simulate…

CO2 4.2 vol ± 0.1 vol sodium bicarbonate or citric acid

carbonated water

Nitrogen 40 psi ± 5 psi or as specified by the operating division

carbonated water or sodium bicarbonate

nitrogen pressure if a liquid nitrogen source is not available

Materials Authorization Matrix

App

eara

nce

Col

or

SRA

Tast

e C

ompa

tibili

ty

Phys

ical

Pe

rfor

man

ce T

ests

New Resin from New or Existing Resin Supplier New resin or change in resin formulation (new components) ● ● ● ● ●

Approved PET resin with approved CyclePET material ● ● ● ●

Any change other than resin chemistry (for example, change in IV or decrease in component levels) ●

New Resin Plant Approved resin ●

New Additives Any new additive used in plastic bottles (for example, colorants and UV additives) ● ● ● ●



Packaging Authorization Matrix Physical Performance Tests Functional Tests

Dim

ensi

on T

ests

Ace

tald

ehyd

e

Cap

acity

Cha

nge

Car

bona

tion

Ret

entio

n D

rop

Impa

ct

Res

ista

nce

Dur

abili

ty

Empt

y W

eigh

t /

Cap

acity

Fill

Poi

nt V

aria

tion

Inte

rnal

Pre

ssur

e S

treng

th

Per

pend

icul

arity

Pla

stic

Dis

tribu

tion

Sup

port

Ledg

e S

treng

th

Ther

mal

Sta

bilit

y

Ver

tical

Loa

d

Fiel

d

Line

Tria

l P

ress

uriz

ed

Ope

ratio

nal

Tran

spor

t

Ven

ding

Res

in IV

War

page

New Supplier or Licensee—Plastic Bottles or Preforms—New Plant (Bottle Blowing) Using Approved Resin Bottles ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ▲ ▲ Preforms ● ● ● ● ●

Authorized Supplier—Plastic Bottles or Preforms Resin or additive new to supplier

● ● ● ● ● ● ● ● ● ● ● ▲ ▲

New blow molds for approved design/size

● ● ●

New injection molds ● ● ● ● ● New bottle design/size ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ▲ ▲ Decrease in weight ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ▲ New blow mold plant/ authorized preforms

● ● ● ▲ ▲

New Technology, Design, or Equipment Bottles ● ● ● ● ● ● ● ● ● ● ● ● ● ▲ ▲ ▲ Preforms ● ● ● ● ▲ Test is optional based on the discretion of the division.



Revision History Issue Date Summary of Change 20-Dec-2004 New document.

REFPET Bottle Specifications

Packaging Authorization: REFPET Bottles PK-SP-045 Issued: 20-Dec-2004 CLASSIFIED: Internal Use Page 1 of 10

Purpose To specify the minimum requirements of materials, dimensions and physical performance of REFPET bottles from authorized suppliers. All bottles upon delivery shall meet the specifications in this document. This document is an integral component of New Package Authorization, PK-RQ-020. For the test matrices, refer to REFPET Bottle Authorization Matrices, PK-RQ-065.

Contents Materials Specifications................................................................................2 Acetaldehyde ............................................................................................2 Appearance...............................................................................................2 Color..........................................................................................................3 Scientific and Regulatory Affairs (SRA) and Certificate of Food

Law Compliance .................................................................................3 Taste Compatibility....................................................................................3

Dimensional Specifications..........................................................................5 Exterior ......................................................................................................5 Finish.........................................................................................................5

Physical Performance Specifications..........................................................6 Capacity Change.......................................................................................6 Carbonation Retention ..............................................................................6 Drop Impact Resistance............................................................................6 Durability ...................................................................................................7 Empty Weight and Capacity “As-Delivered”..............................................7 Fill-Point Variation .....................................................................................8 Internal Pressure Strength ........................................................................8 Perpendicularity ........................................................................................8 Plastic Distribution.....................................................................................8 Support Ledge Strength............................................................................9 Thermal Stability .......................................................................................9 Vertical Load .............................................................................................9



Materials Specifications

Acetaldehyde Test Procedures:

• REFPET Acetaldehyde Test—24-Hour, PK-PR-215

• REFPET Acetaldehyde Test—Ground Preforms, PK-PR-216

Clear resins The acetaldehyde concentration of freshly blown bottles made from all clear resins shall be as follows:

Measurement Method Criteria

Standard 24-hour airspace analysis

The maximum in any single bottle shall not exceed 5.0 micrograms/liter

Ground preform The maximum in any single bottle shall not exceed 25.0 micrograms/gram

Green and amber resins

The acetaldehyde concentration of freshly blown bottles made from all green and amber resins shall be as follows:

Measurement Method Criteria

Standard 24-hour airspace analysis

The maximum in any single bottle shall not exceed 15.0 micrograms/liter

Ground preform The maximum in any single bottle shall not exceed 25.0 micrograms/gram

Appearance Test Procedure: REFPET Bottle Appearance and Color Evaluation, PK-PR-217 Blemishes (bubbles, unmelted resin, dirt specks, pitting, condensation marks) shall not constitute a more objectionable appearance than that of the limit samples submitted to and authorized in writing by a division of The Coca-Cola Company. Except for the exterior bottom of the base, there shall be no foreign material (dirt) on the surfaces of the containers, which would not come off in a typical rinser used for one-way PET bottles. The bottles shall not develop objectionable scuffing more severe than limit samples submitted to and authorized in writing by a division of The Coca-Cola Company when subjected to normal handling.



Color Test Procedure: REFPET Bottle Appearance and Color Evaluation, PK-PR-217 All new bottles shall have a color and clarity (pearlescence and transparency) falling within limits or standards previously submitted to and approved in writing by The Coca-Cola Company. Used bottles shall have a color and clarity (haze) falling within limits or standards previously submitted to and approved in writing by The Coca-Cola Company.

Scientific and Regulatory Affairs (SRA) and Certificate of Food Law Compliance

Test Procedure: REFPET Bottle Scientific and Regulatory Affairs Process, PK-PR-200 The material reviewed must meet all internal SRA requirements, as well as comply with local or FDA requirements for food contact use. The material must also meet any requirements established by the Package Development and Design Department to minimize sensory impact. New materials such as resins, additives, and colorants are approved by SRA. After SRA approval is obtained, divisions are responsible for ensuring that the material meets all applicable food laws for the intended countries of use.

Taste Compatibility

Test Procedure: REFPET Bottle Taste Compatibility Test, PK-PR-206 A test package meets the compatibility specification when it imparts no significant taste difference (at a 95% confidence level) when compared to control samples after the required intervals. Sample ballots and statistical tables for interpreting triangle tests are in the test procedure. Any taste test that reveals a significant taste difference (at a 0.05 probability level or 95% confidence level) when compared to the control after each required interval must be repeated within 10 days using extra samples from the test set. If the repeat taste test is also significant, the package fails the taste compatibility test and the subsequent taste interval is canceled. If a trend occurs at any interval, perform a subsequent interval. If a trend occurs again, the package fails the taste compatibility test. If a repeat taste test does not confirm a significant taste result, the package passes the taste compatibility test. A trend is one correct taste judgment less than the number required for a significant taste result at a 0.05 probability level or 95% confidence level. For example, 20 correct taste judgments for a 42- member triangle taste panel are significant according to the



Triangle Difference Test Statistical Table found in PK-PR-201. Nineteen correct taste judgments would be a trend. If there is a significant taste difference and taster comments indicate there could be a preference for the test package, then a Preference Test should be performed to determine acceptance. If you are unsure of how to interpret a set of taste data, send a summary of the taste results for all intervals (degree of difference, panelist choices, and comments for both control and test beverages) to Corporate Quality Assurance for review.



Dimensional Specifications

Exterior Test Procedure: REFPET Bottle Dimensions Evaluation—Exterior, PK-PR-207 The bottle shall conform to the drawing approved in writing by The Coca-Cola Company. Dimensions shall be taken on empty bottles as delivered. Company drawings are the only specifications to be used for the bottles. Dimension tolerances are as follows for individual bottles:

Height ±0.3 percentDiameter ±0.8 percent

Finish Test Procedure: REFPET Bottle Dimensions Evaluation—Finish, PK-PR-208 Preforms and bottles must conform to the latest revisions of the preform drawing supplied by the manufacturer and bottle drawing supplied by The Coca-Cola Company. The supplier must provide to the Company or any of its divisions, upon request, copies of the most recent drawings for each finish specified for use with the bottles it will supply. The finish shall be fully formed and free of sharp edges, flash, overhang, or any other irregularity that will adversely affect carbonation retention, removal torque, closure or finish venting, or consumer comfort when the product is consumed from the bottle. Except for damage from abuse, the finish dimensions shall remain within specified drawing tolerances for the life of the bottle. Additionally, finish changes due to age, washing, cycling, and normal use shall not adversely affect finish performance including closure application, removal torque, carbonation retention, and opening performance. Any process or post process changes performed by the manufacturer to minimize finish shrinkage, stress cracking and the like on cycled bottles shall not increase the susceptibility of the finish to damage.



Physical Performance Specifications

Capacity Change Test Procedure: REFPET Bottle Empty Capacity Change (Shrinkage) Test, PK-PR-218 The capacity tolerance of a random sample of used bottles ranging in trippage from 1 to 20 that have been filled at the nominal fill-point on a normal counterpressure filler at up to 25°C (77°F) and 4 gas volumes carbonation shall meet the following criteria:

Average capacity

Average capacity of a large sample shall not be lower than appropriate capacity for each size, which is 500 ml, 750 ml, 1000 ml, 1500 ml, or 2000 ml at the nominal fill-point.

1.5% below capacity

Not more than 2 percent of all bottles shall have a capacity of less than 1.5 percent below appropriate capacity for each size, which is 500 ml, 750 ml, 1000 ml, 1500 ml, or 2000 ml at the nominal fill-point.

3% above or below capacity

No bottle shall have a capacity of less than 3 percent below or more than 3 percent above appropriate capacity for each size, which is 500 ml, 750 ml, 1000 ml, 1500 ml or 2000 ml at the nominal fill-point.

In addition to the above, all bottles will meet the applicable government requirements on capacity.

Carbonation Retention

Test procedure: REFPET Bottle Carbonation Retention Test, PK-PR-219 The minimum allowable carbonation level of product agitated to equilibrium pressure in an unopened bottle originally filled to the nominal fill-point at 4.0 volumes of CO2 [as read at 22.2°C ±1.1°C (72° F ±2°F)] and a maximum of 3 bar (4 psig air), at any relative humidity, shall be 3.4 volumes after 24 weeks. All carbonation readings should be taken at 22.2°C ±1.1°C (72°F ±2°F) from the Zahm & Nagel table for CO2 dissolved in water.

Drop Impact Resistance

Test procedure: REFPET Bottle Drop Impact Test, PK-PR-229 A sealed bottle originally filled to the nominal fill-point with product at 4.0 volumes apparent carbonation (as read at any temperature between 1.7°C (35°F) and 23.9°C (75°F) from the Zahm & Nagel table for CO2 dissolved in water) and a maximum of .3 bar (4 psig) air shall not fail when dropped in any mode, except on the finish, from a height of 0.9 meters (3 feet) onto a rigidly fastened steel plate for temperatures between 1.7°C (35°F) and 37.8°C (*100°F).



Durability Test procedures:

• REFPET Bottle Durability Test—Abbreviated Trip-Per-Two-Day Washing, PK-PR-221

• REFPET Bottle Durability Test—Standard Trip-Per-Two-Day Washing, PK-PR-222

The filled bottle shall not exhibit sufficient stress cracking or other bottle changes that affect the ability of the bottle to function as intended under normal production, handling, and distribution conditions. The durability of the test bottles must equal or exceed the durability of the control bottles.

Empty Weight and Capacity “As-Delivered”

Test Procedure: REFPET Bottle Empty Weight and “As-Delivered” Capacity Test, PK-PR-270 The required container weight shall be clearly marked on the drawing. The actual container weight shall not vary from the approved mean by more than ±1.0 gram. The as-delivered capacity tolerance of new bottles at the nominal fill-point, as measured from the top of the finish down on each bottle with 0 bar (0 psig) internal pressure, shall be as follows:

Average Capacity

The arithmetic average of a sample of bottles shall be within +0.4/-0 percent of the stated capacity.

Individual Capacity

• The number of bottles having capacities above the tolerance shall not be greater than 2 percent of a sample.

• The number of bottles having capacities below the tolerance shall not be greater than 2 percent of a sample.

• All bottles shall be within +1.3/-0 percent of the stated capacity.

The brimful capacity tolerance of new as-delivered bottles shall not exceed ±1 percent of nominal as specified on the Company drawing. In addition to the above, all bottles shall meet the applicable government requirements on capacity.



Fill-Point Variation

Test procedure: REFPET Bottle Fill-Point Variation Test, PK-PR-229 After exposure to 4.1 bar gauge (60 psig) and 5.5 bar gauge (80 psig) at 24°C (75°F) for 60 seconds at each level, the difference between the pressurized fill-height and the unpressurized fill- height for individual bottles in a sample group, originally filled to the nominal fill-point with water, shall not vary more than:

• 1.5 mm (.060 inch) with 4.1 bar (60 psig), and

• 2.5 mm (.098 inch) with 5.5 bar (80 psig) The internal pressure shall be attained by injecting carbon dioxide gas at the constant rate of .69 bar gauge per second (10 psig per second). The sample group shall be composed of a mixture of bottles ranging in age from 0 to 20 trips.

Internal Pressure Strength

Test procedure: REFPET Bottle Internal Pressure Test, PK-PR-225 The bottle shall withstand a minimum internal pressure of 10.3 bars (150 psi) at any relative humidity and any temperature between 1.6°C (35°F) and 60°C (140°F) for 60 seconds without failure.

Perpendicularity Test Procedure: REFPET Bottle Perpendicularity Test, PK-PR-270 Deviation from the perpendicular shall be less than the appropriate numbers in the table (total indicator reading) when measured with the bottle resting on its base and rotated 360° against a centering device.

500 ml 4.4 mm (0.172 inch)750 ml 5.1 mm (0.201 inch)

1 liter 5.6 mm (0.220 inch)1.5 liter 6.4 mm (0.250 inch)

2 liter 6.5 mm (0.256 inch)

Plastic Distribution

Test procedure: REFPET Bottle Plastic Distribution Test Test, PK-PR-226 Supplier will use good manufacturing practices to maximize bottle properties through maintaining material distribution. Tolerance in wall thickness is ±5.0 percent of nominal.



Support Ledge Strength

Test procedure: REFPET Bottle Support Ledge Test, PK-PR-227 Bottle shall maintain sufficient ledge support strength to function as intended in filling, capping, and uncapping operations.

Thermal Stability Test procedure: REFPET Bottle Thermal Stability Test, PK-PR-228 A sealed bottle originally filled to the nominal fill-point with product at 4.0 volumes apparent carbonation (as read at any temperature between 1.7°C (35°F) and 23.9°C (75°F) from the Zahm & Nagel table for CO2 dissolved in water), and a maximum of .3 bar (4 psig) air:

• Shall not develop a rocker bottom, and

• Shall not demonstrate an objectionable appearance or gross effect to the ability of the bottle to function as intended when exposed to the conditions listed below at any relative humidity

The conical label panel shall remain axially flat and not become convex or concave. The following parameters shall not exceed the listed criteria at 38°C (100°F) and the listed times.

Time (Days) One/Seven Parameter 500 ml 750 ml 1 liter 1.5 liter 2 liter

Diameter (%) 2.5/3.0 2.5/3.0 2.5/3.0 2.5/3.0 2.5/3.0

Height (%) 1.5/2.0 1.5/2.0 1.5/2.0 1.5/2.0 1.5/2.0

Perpendicularity (mm/in)

4.7/5.2 5.5/5.9 6.2/6.7 7.0/7.6 7.1/7.7

Fill-point Drop (mm)

7.0/9.6 8.1/1 9.0/12.4 10.2/14.0 10.4/14.0

Vertical Load Test procedure: REFPET Bottle Vertical Load Test—Empty, PK-PR-229 The minimum vertical load that a bottle shall withstand shall be such that the bottle can be satisfactorily filled with any filler bowl pressure up to 8.3 bars (120 psig) and satisfactorily capped and filled with noncarbonated water. The bottle shall successfully withstand any stacking loads it may incur during normal handling and distribution without developing stress cracking or significant structural weakness. The minimum vertical load strength that empty bottles should exhibit in laboratory tests is 54.6 kg (120 pounds).




REFPET Bottle Acetaldehyde Test—24-Hour

Packaging Authorization: REFPET Bottles PK-PR-215 Issued: 20-Dec-2004 CLASSIFIED: Internal Use Page 1 of 9

Purpose Use this test to ensure that the acetaldehyde concentrations in the walls of REFPET bottles do not exceed established limits.

Corresponding Specification

REFPET Bottle Specifications, PK-SP-045, Acetaldehyde—24-Hour

Contents Test Equipment............................................................................................. 1 Procedure ...................................................................................................... 2

Preparing Sample PET Bottles ................................................................ 2 Preparing Acetaldehyde Gas Specifications............................................ 2

Analysis of Bottles ............................................................................. 3 Calculations ....................................................................................... 4

Preparation of Aqueous Acetaldehyde Solutions..................................... 4 Test Equipment and Materials........................................................... 4 Procedure .......................................................................................... 5

Standardization of Aqueous Acetaldehyde Solutions .............................. 6 Reagents ........................................................................................... 6 Test Equipment.................................................................................. 6 Preparation of Solutions .................................................................... 7 Procedure .......................................................................................... 8 Calculations ....................................................................................... 9

Test Equipment

• 0- to 10-ml syringe (for example, Hamilton 701)

• 1000-ml Pyrex vessel with closure fitted with a septum

• Supply of laboratory-grade compressed nitrogen for flushing bottles

• Bottle closures fitted with septa

• Standard solution of acetaldehyde in water at a concentration of approximately 1 mg/ml

• Vacuum pump and gauge

• Suitable gas chromatograph equipped with a flame ionization detector, 5.0 ml gas sampling loop, and data-processing system



Procedure

Preparing Sample PET Bottles

1. Allow freshly blown PET bottles to cool for at least 5 to10 minutes, then purge with a steady stream of nitrogen for 20 seconds. Bottles must be flushed within six hours of blowing.

2. Immediately cap each bottle with closures fitted with a septum for gas sampling, and mark each bottle with the time and date.

3. Store the bottles in a temperature-controlled environment at 22±1.5°C (72±3°F) for 24±1 hours.

Preparing Acetaldehyde Gas Specifications

One hour before you analyze the first PET sample bottle, prepare an acetaldehyde gas standard: 1. Flush a clean 1-liter Pyrex glass bottle with nitrogen for 20

seconds and cap it with a closure fitted with a septum. 2. Inject a 5-ml gas sample from this glass bottle into the gas

chromatograph. (Refer to Analysis of Bottles in the following section for details about the injection procedure.) This is a negative control “air blank,” and the chromatograph of its headspace should not show any peak at the retention time for acetaldehyde.

3. Using a 10-ml Hamilton syringe, inject 4 ml of a standard solution of acetaldehyde in water, at a concentration of approximately 1 mg/ml, into the 1-liter glass bottle.

CAUTION: You must know the accurate concentration of the aqueous acetaldehyde solution and the volume of the glass bottle.

4. Allow the 1-liter glass bottle to stand at room temperature for 30 to 45 minutes, until the aqueous acetaldehyde solution has completely evaporated.

5. Make three replicate 5-ml gas sample injections into the chromatograph. Obtain an average acetaldehyde response signal, and determine the response factor (signal per concentration) for that series of injections.



Analysis of Bottles

After the sample bottles have been stored for 24 hours at 22°C (72°F), inject a 5-ml gas sample into the gas chromatograph: 1. With the gas sample loop system in the FILL LOOP position

(see Figure 1 below), close valve A, open valve B, and evacuate the loop with the vacuum pump. The level of vacuum is registered on the vacuum gauge. Close valve B.

2. Pierce the septum of the sample bottle with the syringe needle and open valve A. A 5-ml gas sample transfers from the bottle into the loop, and the reading on the vacuum gauge falls essentially to zero. Close valve A.

3. Turn the six-port sampling valve C to the INJECT position. The nitrogen carrier gas stream now diverts through the loop and flushes the sample into the column.

4. After the sample has eluted from the gas chromatographic column, return valve C to the FILL LOOP position, and repeat the process with the next sample.



Calculations Refer to the following formula to calculate the concentration in µg/l, Cs of acetaldehyde in the gas standard:

( )[ ] ( )[ ]( ) bottlesamplegastheoflitersvolume

stdAAofmlmgionconcentratinjectedstdAAofmlvolumeCs./. ×

=

Then use this formula to calculate the response factor, (RF):

sCstandard,gasofionconcentratstandardgasforcountsareaaverageRF =

Consequently, the concentration of acetaldehyde, Cb, in µ/l, in each PET sample bottle is:

RFsampleofcountsareaCb =

Preparation of Aqueous Acetaldehyde Solutions

Acetaldehyde is a very unstable compound. It tends to oxidize and/or polymerize, and unless you carefully prepare aqueous solutions as described below, the acetaldehyde will likely degrade, resulting in inaccurate standard solutions. Alternatively, you can purchase specifications of known concentrations. If you do, ensure that the purchased specifications come with a Certificate of Analyses (COA).

Test Equipment and Materials

• Micro-distillation apparatus

• Analytical balance, 160 g, readable to 0.0001 g

• 250-ml volumetric flask

• De-aerated distilled water

• Reagent-grade acetaldehyde

• Ice

• Pasteur pipettes

• Boiling stones or other anti-bumping granules

• Laboratory-grade nitrogen

• Variable-wattage heating mantle



Procedure You should complete this entire standard preparation and standardization procedure in the same day: 1. Set up the distillation equipment with chilled water running

through the condenser and the receiving flask immersed in ice. Place about 50 ml of acetaldehyde in the distillation flask and heat gently to distill the acetaldehyde.

2. Discard the first 5 to 10 ml of distillate, and then collect the next 10 to 20 ml of acetaldehyde that distills over at 22°C (72°F).

3. Remove the receiving flask, flush with nitrogen, and seal with a ground glass stopper.

4. Fill a 250-ml volumetric flask with about 245 ml of distilled water. Bubble nitrogen through this for about an hour to remove any dissolved oxygen.

5. Determine accurately the tare weight of the flask, water, and stopper on the balance, and then quickly add about 250 mg of freshly distilled acetaldehyde to the water. This is difficult because of the volatility of acetaldehyde, and is best done using a Pasteur pipette. Seal the flask with a ground glass stopper and mix the contents well.

6. Dilute the flask to the mark with de-aerated distilled water, mix well, flush the headspace with nitrogen, and seal once more with a ground glass stopper.

7. Analyze three 2.0-ml aliquots of this solution by the standard titration test procedure to determine the exact concentration of acetaldehyde in the solution. Do this as soon as possible after you have prepared the solution.

8. Transfer portions of the solution by Pasteur pipette into 1- or 2-ml vials with Teflon-lined septum seals. Fill the vials to overflowing to eliminate headspace, and then seal with the septum seals. Mark each vial with the concentration and store refrigerated (4±1°C) until needed for use. Again, transfer the solution to the storage vials as soon as possible.

9. Use one of the small vials of standard for only about a week (or until an air space appears) before discarding it.

If you follow this procedure exactly, you can safely store unopened vials of aqueous acetaldehyde solution at 4°C (38°F) without deterioration for at least six months.



Standardization of Aqueous Acetaldehyde Solutions

An aqueous solution containing approximately 1 mg/ml acetaldehyde is prepared for use as a standard to calibrate the gas chromatograph in the determination of headspace acetaldehyde in REFPET bottles. The solution is standardized volumetrically by adding sodium bisulfite to form the aldehyde-bisulfite complex, then destroying the complex with base and titrating the liberated bisulfite with standard iodine.

Reagents • Potassium iodide

• Iodine

• Sodium bisulfite

• 0.100 N standard sodium thiosulfate solution

• Anhydrous sodium carbonate

• Acetaldehyde solution in water

• Starch indicator solution

• Glacial acetic acid

Test Equipment

• Burettes: 50 and 25 ml

• Pipettes: 50, 25, 10, and 2 ml

• Volumetric flasks: 1,000, 500, 250, and 100 ml

• Pasteur pipettes

• Erlenmeyer flasks: 125 ml

• Graduate cylinders: 50 and 10 ml

• Small beakers



Preparation of Solutions

All solutions must be prepared fresh each time the procedure is used. 1. For sodium carbonate buffer: Dissolve 80 g of anhydrous

sodium carbonate in approximately 500 ml of distilled water in a 1-liter volumetric flask. When all solids have dissolved, slowly add 20 ml of glacial acetic acid and then dilute to the 1-liter mark with distilled water.

2. For 1% sodium bisulfite: Dissolve 1.0 g (±0.1 g) of sodium bisulfite in distilled water, transfer to a 100 ml volumetric flask, and dilute to the 100 ml mark with distilled water.

3. For 0.05 N sodium thiosulfate: Pipette 50.0 mL of 0.100 N sodium thiosulfate into a 100 ml volumetric flask and dilute to the mark with distilled water.

4. For starch indicator solution: Triturate approximately 1g of arrowroot starch in 10 ml cold water. Add to 200 ml of boiling distilled water and boil to a thin liquid with translucent appearance. Let stand overnight, and use the clear supernatant liquid.

5. For 0.01 N sodium thiosulfate: Pipette 25.0 ml of standard 0.100 N sodium thiosulfate solution into a 250 ml volumetric flask and dilute to the mark with distilled water.

6. For concentrated iodine solution 0.1 N: Dissolve 25 g (±0.5 g) of potassium iodide in about 25 ml of distilled water in a 1-liter volumetric flask. Carefully dissolve 12.7 g of iodine in this solution and dilute to 1 liter. Label as Standard Iodine #1.

7. For 0.01 N iodine solution: Pipette 50.0 ml of the Standard Iodine #1 into a 500-ml volumetric flask and dilute to the mark with distilled water. Label as Standard Iodine #2.



Procedure 1. Standardize the iodine solution: Pipette 25.0 ml of Standard Iodine #2 into a 125-ml Erlenmeyer flask and titrate with standard 0.01 N sodium thiosulfate until you observe a faint yellow color. Rinse down the sides of the flask with distilled water. Add a few drops of starch indicator solution and titrate with more 0.01 N sodium thiosulfate until the blue color just disappears. Repeat these steps twice more, then average the results of the three titrations, and calculate the normality of the iodine solution.

2. Standardize the acetaldehyde solution. Do the following steps. 3. Add 10 ml of one percent sodium bisulfite solution to a 125-ml

Erlenmeyer flask. Add 2.0 ml of the cold aqueous acetaldehyde solution by pipette, making sure to keep the tip of the pipette under the bisulfite solution during the addition.

4. Add a few drops of starch indicator solution with a Pasteur pipette, and swirl the flask for two to three minutes to mix the contents thoroughly.

5. Add 0.1 N iodine from a burette until the solution turns a faint blue color. Destroy the excess iodine by adding 0.05 N sodium thiosulfate dropwise with a Pasteur pipette until the solution turns clear again.

6. Add 0.01 N iodine from a burette until the solution turns a faint blue color. There is no need to record the volume added.

7. Chill the Erlenmeyer flask with the solution in an ice bath for 10 to 12 minutes.

8. Add 25 ml of chilled sodium carbonate buffer. 9. Titrate the liberated bisulfite with 0.01 N iodine until a faint

blue color appears. Carefully record the volume of iodine added. Repeat this procedure again, and average the volumes of the two additions.

10. Make a blank determination on 2 ml of distilled water using the same procedure.



Calculations 0.01 N iodine is equivalent to 0.22 mg of acetaldehyde.

iodineofvolumeethiosulfatofvolulmeethiosulfatsodiumofnormalityiodineofnormality ×

=

Concentration of:

( ) ( )useddeacetaldehyofvolume

blankiodineofvolumeiodineofnormailtyinydeactetaldeh×

−××=

01.022.0

Aqueous solution (mg/ml)


REFPET Bottle Acetaldehyde Test—Ground Preforms


Purpose Use these test guidelines for performing ASTM F-2013-00.


REFPET Bottle Specifications, PK-SP-040, Acetaldehyde—Ground Preforms

Test Equipment

• Gas chromatograph with flame ionization detector

• Headspace auto-sampler with 500-ml sample loop

• Headspace vials (22 ml) with Teflon-lined septa

• Aqueous acetaldehyde stock solution of 1000 ppm

• Calibrated precision 0- to 10-ml Syringe

• Course grinding mill (5- to 10-mm screen)

• Fine grinding mill (1.0-mm screen)

• Analytical balance

• Liquid nitrogen

Instrument Parameters

Auto Sampler Oven Temperature 150°C Sample Loop Temperature 160°C Transfer Line Temperature 170°C Sample Equilibrium Time 60 min. for PET Transfer Line Back Pressure 17.5 psi Vial Pressure 1 psi Vial Pressurization Time 0.10 min. Pressurization Equilibrium Time 0.10 min. Loop Fill Time 0.08 min. Loop Equilibrium Time 0.10 min. Injection Time 0.20 min.

Gas Chromatograph

Column Type Fused Silica Column Dimensions 25 m X 0.53 mm Column Coating Poraplot Q Detector Type FID Detector Temperature 200°C Inlet Temperature 150°C Initial Temperature 50°C Initial Time 1 min. Temperature Program 1 10°C/min. to 150°C Temperature Program 2 20°C/min. to 220°C, hold for 5 min. Data Collection Rate 5 Hz



Equations Refer to the following formula to determine the necessary specifications for calibration:

( ) ( )µg/lionconcentratstandardofmasslinjectedvolume =

If the concentration of stock solution is 1000 parts per million (ppm), then use this formula:

( ) ( )mgstandardofmassmlinjectedvolume =

Expected AA in Sample

Mass (ppm) of Std Required (mg)

Volume of 1000 ppm Stock Added (ml)

10 1 1 20 2 2 30 3 3 40 4 4 50 5 5 60 6 6 70 7 7 80 8 8 90 9 9 100 10 10

Preparing Samples

1. Prepare the 22-ml vials by sealing with Teflon-lined septa. 2. Using a calibrated syringe, inject the appropriate amount of

stock solution into the vials. Touch the tip of the syringe needle to the sidewall of the vial to ensure complete transfer.

3. Place the specifications in the auto-sampler to enable them to bracket the samples. Blanks are distributed at the beginning, throughout, and at the end of the samples.

4. Analyze all vials within 12 hours of preparation.

Data Analysis The acetaldehyde peak from each run is integrated to find the peak area. A calibration plot is produced from the known amounts of the specifications and their corresponding peak areas. Linear regression is applied to determine the slope and intercept of the calibration plot. You can use this information to determine the sample concentration using the equations provided in this procedure.



Procedure 1. Immerse the solid samples in liquid nitrogen for three minutes before grinding.

2. For preforms: Grind the frozen material in the coarse mill and immediately transfer the milled product into a sealed vial.

3. For bottles: Cut the bottle into pieces that will easily fit into the fine grinding mill.

4. Fill the fine mill with liquid nitrogen, grind the product of step 2, and immediately transfer the final product into a sealed vial.

5. While the finely ground product is cold, transfer 0.1000±0.0050 g into each of three 22-ml headspace vials, and tightly seal the vials. Record the exact mass of the sample.

6. Repeat steps 1 through 5 for each solid sample.

Blanks 1. Prepare blanks as needed. 2. Seal a 22-ml headspace tight with a Teflon-lined cap.

Specifications Specifications are prepared in triplicate and in order to produce a calibration curve on which the expected sample concentrations will lie. This is accomplished by adding the appropriate amount of acetaldehyde stock solution to the headspace vial according to this procedure.

( ) ( )[ ] ( )[ ]( )[ ]µgmasscounts/areaslope

countsareainterceptcountsareasampleofareapeakµgsampleinAAofmass

−=

( ) ( )( )gsampleofmass

µgsampleinAAofmassppmorµg/gionconcentratsample =


REFPET Bottle Appearance and Color Evaluation


Purpose The visual examination of plastic soft drink containers is, by itself, an essential first part to any testing program. This test covers all aspects of the container that may affect its overall ability to meet the standards of performance.


REFPET Bottle Specifications, Appearance/Color, PK-SP-045

Test Equipment

Strong light source Plastic marking pencil Flash-O-Lens magnifier Limit samples

Procedure

1. Having set aside the necessary number of samples required for product compatibility and carbonation retention, select 109 samples for visual inspections.

2. Sort through the 109 samples to determine if all injection and blow mold numbers are included. These numbers are usually located on the finish ring and on the pinch area, respectively. Record any missing numbers and request additional containers, if necessary, to obtain adequate mold number representation.

3. Observe each sample for color and clarity, and set out those containers that do not appear to fall within established limits for these two attributes. If necessary, refer to limit samples, which should be on hand for this purpose. Record the results of these observations.

4. Observe each sample for the presence of defects which include: a. Foreign specks or particles b. Bubbles c. Surface irregularities d. Container deformation e. Scuffing or scratches

REFPET Bottle Appearance and Color Evaluation



REFPET Bottle Scientific and Regulatory Affairs (SRA) Approval


Purpose To describe the process of reviewing the components of materials that have potential for direct contact with product, determining their compliance with regulatory, sensory, and other Company requirements, and approving them for use.


REFPET Bottle Specifications, PK-SP-045, SRA Approval

Procedure

PET Resin 1. For SRA approval of a new resin, the division must have one of the following: a. An MAA with the resin supplier. b. A warranty and indemnification statement from the resin

supplier for each country where the resin will be used . 2. The division must:

a. Obtain the MAA or warranty and indemnification statement(s) from the resin supplier.

b. Enter the appropriate information into the Global Packaging database.

c. Review resin sourcing needs with the Cross-Enterprise Procurement Group (CEPG) to determine if suppliers can be CEPG-certified.

d. Successfully complete a permeation test by a third-party laboratory before a new resin can be used for REFPET. Contact Corporate SRA for details on test protocol and capable laboratories.

Colorants and Materials other than PET

1. For SRA approval of new colorants and additives, suppliers must: a. Meet the materials requirements found in REFPET Bottle

Authorization Matrices, PK-RQ-065. b. Contact the division to initiate the approval process. c. Complete and submit the Material Formulation Approval

Request Form, RF-PK-110, to Corporate Quality.

REFPET Bottle Scientific and Regulatory Affairs (SRA) Approval


2. The submitted request form must list all qualitative components of the material and their regulatory status, including Food Law Compliance, as follows. Refer to RF-PK-111 and RF-PK-112 for examples of what to submit. a. The common name of each component b. The CAS number of each component c. The regulatory body (for example, FDA or EU) that

governs the use of the component 3. If an Extraction test is required according to PK-RQ-060, then

the instructions below must be followed. Typically, third-party laboratories perform extraction testing.

Promotional Inks Tests Required Special Instructions

Food Grade Approved Taste test Division reviews all test results

Extraction test SRA reviews all test results Not Food Grade Approved

Taste test Division reviews all test results 4. Whether the material is food grade approved or not, all

information required by step 2 must be submitted to SRA. 5. Corporate SRA will review the information provided, approve

the material, or request additional information. 6. When Corporate SRA gives initial approval of the material:

a. The division is responsible for authorizing the material for use in additional countries or by additional closure suppliers.

b. The supplier must provide the division with Certificates of Food Law Compliance for the additional countries of use.

7. SRA, Package Development and Design, or Corporate Quality will determine whether further testing is needed, for example, taste compatibility or thermal desorption.

8. Corporate Quality will maintain a list of SRA-approved materials and regularly update it with current information.


RefPET Bottle Taste Compatibility Test

Packaging Authorization: RefPET Bottles PK-PR-206 Issued: 20-Dec-2004 CLASSIFIED: Internal Use Page 1 of 9

Purpose To ensure that RefPET bottles are capable of containing the products of The Coca-Cola Company without causing a significant taste difference in any of those products or otherwise imparting any significant off-taste or off-odor to them.

Scope This test applies to the following package types:

• Carbonated Water and Soft Drinks

• NCB Pressurized

• NCB Non-pressurized


REFPET Bottle Specifications, PK-SP-045, Taste Compatibility

Test Equipment

This is a general list. There may be equipment requirements that are specific to the product under test. For both carbonated and noncarbonated product: • Source for treated water that has been filtered through a 0.2-

micron filter or a carbonated water source

• Closures known to perform properly in taste compatibility tests

• Capping machinery capable of applying the closure to the RefPET bottles and the glass control bottles

• Stainless steel 10-liter (2.5-gallon) product tanks, properly passivated and rinsed

• Large glass container (4-liter jug) for treated filtered water

• Digital thermometer

• Coded 60-ml taste-test glasses

• Safety equipment, including safety glasses, gloves, hair restraint, and so forth

For carbonated product only: • Source of CO2 for recarbonating test and control samples

• Carbonation pressure gauge

• Carbonation Computer Dial



Procedure

Preparing Samples

1. The package should be filled with the product specified and tested according to the intervals in the table below. Add additional intervals for retests. If any interval is significant, and the retest is not significant, then the interval is considered satisfactory. In addition to the acceptance criteria in the table, the lab manager may accept results with one or two significant intervals based on a review of data, such as taster comments.

Package type Interval (weeks)

Number of Intervals Fill Product Acceptence Criteria

All CB, except recycled content

2 1 interval + 1 retest = 2

Treated filtered or carbonated water

No significant difference

CB, Recycled content: colorless

2, 4, 10 3 intervals + 2 retest = 5

Coca-Cola No significant difference at any interval

CB, Recycled content: green

2, 4, 10 3 intervals + 2 retest = 5

Sprite No significant difference at any interval

All NCB except water and recycled content

3, 6, 9, 12, 16, 24

6 intervals + 2 retest = 8

Refer to #2 below No more than 2 intervals may be significant

NCB water 2, 4, 8, 12 4 intervals + 2 retest = 6

Refer to #2 below No more than 1 interval may be significant

NCB recycled content

2, 4, 6, 9, 12, 16, 24

7 intervals + 2 retest = 9

Refer to #2 below No more than 1 interval may be significant

2. All bottles must be filled within fourteen days of bottle production. Bottles intended for NCB must be filled with the product that is normally put into the package being tested, unless a more sensitive or representative product has been identified. Bottles intended for ozonated water must be filled with ozonated water. Bottles intended for non-ozonated water can be tested with treated filtered water.

3. If treated water is used, it must not contain chlorine and must also meet the following specifications:

Attribute Specification

TDS <500 mg/l

Alkalinity < 85 mg/l



4. To calculate the number of bottles needed for the test, find the bottle size in the table below and then multiply the number of bottles by the number of intervals. Always use the smallest size bottle the supplier produces.

Size Number of bottles needed for test

390 ml 11 x number of intervals

500 ml 8 x number of intervals

360 ml (12 oz) 11 x number of intervals




1.5 liter 3 x number of intervals

2 liter 3 x number of intervals 5. RefPET bottles must impart no significant taste difference at

the 95% confidence level when compared to control samples under controlled environmental conditions (21°±2°C) after the intervals defined above.

Testing Samples 1. For test bottles of size 1 liter or larger, select a separate subgroup of 20 sample bottles from the main group of samples. For test bottles of size less than 1 liter, select 30 samples; the testing protocol requires a minimum or 4 liters of product per test interval. Ensure that all injection and blow-mold cavities are represented uniformly in this subgroup sample set. For bottle submissions from molds with more than 32 or 64 cavities, ensure that no cavity is repeated in the subgroup.

2. Obtain the same number of clean, dry glass control bottles of similar size as the test bottles. Rinse all bottles thoroughly with treated filtered water or carbonated water and drain well. Fill all bottles with carbonated or treated filtered water. If using carbonated water, ensure that volumes are within 3.75 ±0.25.

3. Store at 21°±1°C for the duration of the test. 4. At the end of the storage interval(s), randomly select enough

test and control bottles to enable sampling 4-liter portions of test product and glass control product. With liter or larger bottles, take the product from at least four different bottles. Pour the portions into a clean, dry and labeled stainless steel product tank or large glass jug or bottle, and seal the lid.



5. Filling with carbonated water: Because carbonation is lost more rapidly from the RefPET bottles than from the glass controls during the course of the test, both test and control water must be recarbonated prior to taste testing: a. Measure the temperature of the water, and then use a

Carbonation Computer Dial to determine the required equilibrium CO2 pressure for 3.8 volumes carbonation.

b. Set the regulator gauge of the CO2 source to 14 kPa (2 psig) higher than this equilibrium pressure and connect the CO2 source to the tank.

c. Add CO2 gas to the tank until the established pressure is reached, then open the tank valve to the atmosphere and release the headspace contents. This will flush out much of the initial air content of the tank headspace.

d. Close the tank again and bubble more CO2 gas into the tank, with vigorous shaking, until no further gas will bubble into the water.

e. Disconnect the gas line, draw samples from each tank and determine that the water tastes acceptable.

f. Refrigerate the tank to prepare the contents for taste testing.

6. Bring the temperature of test and control tanks to within a range of 9° to 12°C (48° to 54°F) and dispense samples into clean, dry coded taste-test glasses and test the beverages with the Triangle method described as follows.

Taste Testing CSD, NCB, or Water Samples

1. Use a panel of testers to taste test the samples. A minimum of 18 tasters is strongly recommended. An optimal panel size is 30 to 42 tasters. It is best if the panel can be divided in multiples of 6 to ensure a balanced presentation. Refer to Triangle Taste Test on page 6.

2. Dispense all beverages from the containers into the taste test cups as follows: a. Noncarbonated beverages or water: without any cooling or

other treatment. b. All carbonated beverages and water: refrigerate the

samples for three hours and use a cooling plate when dispensing the water to the taste panel.



3. Taste test the beverage exposed to the test bottles using the beverage exposed to the control bottles as a reference.

4. Record all results. Forms and statistical tables for interpreting taste tests begin with Triangle Taste Test on page 6.

Test Methodology

• Prepare three samples. Make two of the samples the same product and one sample a different product.

• Ask the panelists to taste the three samples in order from left to right. Then ask the panelists to select the sample they think is different from the other two samples. Present each panelist with three coded samples. Always present the samples simultaneously.

• Present both products in the test as the odd sample an equal number of times throughout the test. This methodology is typically called a balanced reference design.

• To ensure reliability in your test data, conduct several practice tests with your panel to familiarize the panelists with taking the Triangle test. A panel size of 30 to 42 tasters is optimal; a minimum of 18 tasters is strongly recommended.

Analysis of the Data

To analyze the Triangle test data, you need to know the following:

• The number of panelists that tasted,

• The number of panelists that were correct, and

• The level of significance to use (for plastic bottle approvals, this is typically a probability of 0.05 or the 95% confidence level).

Using the information, reference the Triangle Difference Test Statistical Table on page 7 to determine if there is a significant difference between the samples in the test. For example, if you had 30 panelists taste and 15 were correct, the test would be significant at the 95% confidence level; therefore, you could conclude that a difference exists between the two products.



Triangle Taste Test Name: Date: Taste the samples presented to you from ______ (e.g., Left) to ______ (e.g., Right). Two of the samples are the same and one is different. Select the sample you think is the ______ (e.g., Odd) or ______ (e.g., Different) sample by circling the code of the odd sample. Sample: Sample: Sample: Please describe how the odd sample is different from the like samples. Test Number:



Triangle Difference Test Statistical Table

Minimum numbers of correct judgment to establish significance at various probability levels for triangle (p = 1/3). Panel size is n. Use a taste panel size of 30 to 42 tasters for optimal statistical sensitivity. At a minimum, use an 18-member taste panel.

Significance level (%) Significance level (%) n trend 5 1 .01 n trend 5 1 .01 18 10 10 12 13 31 15 16 18 20 19 10 11 12 14 32 15 16 18 20 20 10 11 13 14 33 15 17 18 21 21 11 12 13 15 34 16 17 19 21 22 11 12 14 15 35 16 17 19 22 23 12 12 14 16 36 17 18 20 22 24 12 13 15 16 37 17 18 20 22 25 12 13 15 17 38 18 19 21 23 26 13 14 15 17 39 18 19 21 23 27 13 14 16 18 40 18 19 21 24 28 14 15 16 18 41 19 20 22 24 29 14 15 17 19 42 19 20 22 25 30 14 15 17 19



Triangle Taste Test Results Report Form Test Number: Test Date: Project Name: Product: Product Age: Description Samples Presented: Control: Experimental: Number of Tasters: Number Correct: Statistic Significance: Tasters Comments: Control Experimental Interpretation: Approved:




REFPET Bottle Dimensions Evaluation—Exterior


Purpose Use this test to ensure that packages comply with the dimensions and allowable tolerances specified on the respective bottle design drawings. Refer to the Global Packaging database to obtain the number of the drawing.


REFPET Bottle Specifications, PK-SP-045, Exterior

Test Equipment

• Dial calipers, complete with base

• Digital height gauge

• Vernier diameter measurement tape

• Pi tape

• Optical comparator

• Electronic measuring device

Procedure 1. Randomly select the number of filled and capped samples as shown in the table below:

Test Samples Control Samples Total Number of Samples Needed

108 0 108 2. Select a sub-group of 12 Exterior Dimension samples.

3. Measure the maximum and minimum neck diameters of each bottle using any of the measurement devices listed in the preceding “Test Equipment” section. Measure at points on the neck immediately below the neck support ring, before the bottle wall begins to flare out toward the shoulder area.

4. Measure the maximum overall height of each bottle. 5. Measure the nominal shoulder diameter of each bottle. When

using an optical comparator, make a minimum of two diameter measurements 90° apart.

6. Measure the sidewall diameter of each bottle. When using an optical comparator, make a minimum of two diameter measurements 90° apart.

REFPET Bottle Dimensions Evaluation—Exterior


7. For contour bottles, measure the pinch diameter at its minimum point.

8. Measure the heel diameter of each bottle. 9. Record all observations. These measurements also may be

used as the initial data set for the procedure described in REFPET Bottle Thermal Stability Test, PK-PR-228.

10. Return the 12 sample bottles to the original group of 108 for use in subsequent testing. Alternatively, transfer the set of bottles to the Thermal Stability test for continued analysis.


REFPET Bottle Dimensions Evaluation—Finish


Purpose Use this test to ensure that all thread finishes comply with the dimensions and allowable tolerances specified on the respective bottle finish design drawings. This test also reveals any defects that could hinder the performance of the finish/closure interface.

NOTE: Finish drawings are available at http://www.threadspecs.com. This website is hosted by the International Society of Beverage Technology (ISBT) and sponsored by the ISBT Thread Finish Review Sub-Committee. For other finishes, the closure supplier will specify appropriate drawings.

Scope This procedure applies to preforms and bottles. The following table lists the measurements that you must collect for each package type.

Package Type Required Measurements to Be Collected

Preforms All applicable attributes (See step 3 below.)

Bottles Diameters T, E, F, G, A, C (See step 4 below.)


REFPET Bottle Specifications, PK-SP-045, Finish

Test Equipment

• Profile projection machine such as an optical comparator or other suitable measuring device (vision system, coordinate measuring machine, and so forth)

• Pin gauge set for 1690, 1716, and BPF finishes

• Two sets of each cavity number for preforms and twelve samples for bottles

• Anti-static brush to remove dirt or dust

Procedure 1. Visually inspect preforms for defects, such as air bubbles or handling damage, and place them in numerical order in a sequentially numbered rack.

2. Take all measurements 90° apart, but not at the parting line.

http://www.threadspecs.com/



3. For preforms, measure the following attributes:

Code Description of Attribute

T Thread diameter F Core pin seal diameter (upper ring diameter)

G Thread split seal diameter (lower ring diameter) E Thread root diameter

S Height from top of finish (TOF) to start of full depth thread D Height from TOF to tamper evident bead gauge point

P Thread pitch A Tamper evident bead diameter

LRA Locking ring angle LRR Locking ring radius

TTW Thread tip width SR Seal radius

TR Thread radius TPI Thread per inch

TP Thread projection VSD Vent slot depth

VSW Vent slot width C Control internal diameter at TOF

Overhang F may not protrude past G

Flash Not continuous; minimum allowable -0.12 mm

Deformed Threads

Key pull

Weld Lines Hair line crack in TOF over a vent slot, flow lines on TOF, or short shot (mold not completely filled)

Sealing Land Uniformity

Pull-up mark (hot fill packages)



4. For bottles, measure the following dimensions:

Code Description of Diameter

T Thread

E Thread root

F Core pin seal

G Thread split seal

A Tamper evident bead

C Control internal at top of finish (TOF)

S Height from TOF to start of full depth of thread

X Height from TOF to bottom of support ledge

5. Record all measurements. If any of the dimensions are out of specifications for a bottle from a particular injection mold cavity, measure the second preform with the same cavity number to confirm whether the problem is consistent or isolated.

Revision History Issue Date Summary of Change 20-Dec-2004 New document. Added ‘S’ and ‘X’ dimensions to bottle finish

measurements.

REFPET Bottle Capacity Change (Shrinkage) Test


Purpose This test measures the ability of a plastic container to maintain correct volume without overfilling as the bottle expands and contracts during cycling. The conditions here relate to field performance.


REFPET Bottle Specifications, Capacity Change, PK-SP-045

Test Equipment

Caustic tank and safety equipment Dial caliper with base Pi-Tape or equivalent circumferential tape Mettler PC4000 scale or equivalent Fill-height syringe assembly Rinse basin

Procedure

1. Determine “as-delivered” capacity for 10 bottles, as described in REFPET Bottle Empty Weight and “As-Delivered” Capacity Test, PK-PR-223. Then measure bottle diameter and height dimensions as in REFPET Bottle Dimensions Evaluation—Exterior, PK-PR-207.

2. Condition bottles as follows: a. Bottles numbered 1 through 5 store empty at 72°F, 50%

relative humidity for 7 to 9 days. b. Bottles numbered 6 through 10 store submerged under

water at 72°F for 7 to 9 days. 3. One day before submerging bottles in caustic, measure bottle

height and diameter dimensions along with fill-point capacity. Then, put bottles back in same conditioning environment, described in step 2, overnight.

4. Immerse the bottles in 3.0% +0.5 -0% caustic solution for five continuous hours continuously at 59.5°C ±1°C (139°F ±1.8°F). Measure and record caustic concentration and temperature.

5. Remove the bottles, rinse thoroughly, and repeat the capacity and dimension measurements taken in step 1 above.

REFPET Bottle Capacity Change (Shrinkage) Test


6. Refer to the Density Conversion Table in document Weight to Volume Conversion Table for Capacity Testing, RF-PK-108, to report the weight of the water, temperature of the water, and milliliters for each bottle along with the maximum, average, minimum, and standard deviation for the samples.


REFPET Bottle Carbonation Retention Test—FT IR Method


Purpose Use this test to assess accurately the carbonation loss rate of a REFPET beverage bottle and to extrapolate shelf life to a 17.5% loss for bottles initially carbonated to 4.0 volumes.


REFPET Bottle Specifications, PK-SP-045, Carbonation Retention

Test Equipment

• Calibrated Zahm and Nagel piercing device with pressure gauge (capable of measuring 0 to 100 psi or 689.5 KPa)

• Supply of “bone-dry” CO2 (moisture level not to exceed 15 ppm and CO2 must be at least 99.8% pure)

WARNING: Use protective gloves when handling frozen CO2, and ensure that the area is well ventilated.

• Approved plastic closures that properly fit the test bottles

• Analytical gram balance accurate to 0.1 g

• Approved device to measure bottle diameters accurate to 0.1 mm

− Optical comparator with a minimum magnification of 20X, or

− Laser measuring device

• Approved properly calibrated FT IR instrument (We recommend the Perkin-Elmer FT IR Spectrometer with supporting hardware fixtures and software patented by The Coca Cola Company.)

• Safety glasses/face shield and gloves

• Torque meter to properly apply approved plastic closures

• Permanent black ink marking pen

• Environmentally controlled chamber or room capable of maintaining a constant 22° ±1°C (72° ±2°F) and 50% relative humidity (RH)



Procedure

Sample Preparation

1. Pre-inspect the 12 bottles to be tested to ensure that no bottles are out of perpendicularity or have rocker bottoms.

NOTE: Two extra bottles will be required for validating the initial carbonation level.

2. Mark each sample with an individual number for identification purposes.

3. Mark all 12 sample bottles with an indexing line, on the heel or foot that runs through the center of base. This line is used to ensure that the bottles always can be aligned properly and consistently on the FT IR.

NOTE: The indexing line must not fall on a dimple, flute or bottle parting line, or other irregular surface area of the bottle.

Determining Sample Volume and Dry Ice Weight

You must determine the bottle volume first so that you can use the proper amount of dry ice to achieve the correct internal pressure. To determine the proper amount of dry ice: 1. Place one sample bottle on an analytical balance and tare the

scale to zero. 2. Fill the sample bottle to the brimful capacity (that is, to top of

the bottle finish) with water of a known temperature. 3. Record the weight of the water in grams. 4. Convert the water weight (g) to bottle volume (ml) using the

following conversion table:

Water Temperature Water Density (g/ml)

19ºC or 66.2ºF 1.002637

20ºC or 68.0ºF 1.002838

21ºC or 69.8ºF 1.003039

22ºC or 71.6ºF 1.003261

23ºC or 73.4ºF 1.003492



5. Convert the bottle volume (ml) to the weight of dry ice (g) using the following formula:

( ) ( ) ginicedryofweight0.0077mlinvolumebottle =×

This weight of dry ice should yield an internal bottle pressure of 56 ±2 psi at 22°C, which is the equilibrium pressure of 4.0 volumes of CO2 at 22°C, or 60 ±2 psi at 22°C which is the equilibrium pressure of 4.2 volumes of CO2 at 22°C. It is preferred to fill the bottles to an equivalent of 4.2 volumes, but if the FTIR software is pre-set to calculate CO2 loss based on 4.0 volumes, then the shelf-life based on 4.2 volumes can be extrapolated after the test is completed. For RefPET, it is acceptable to calculate the shelf-life based on 4.0 volumes.

WARNING: While filling the sample bottles with dry ice, wear safety glasses and gloves to prevent skin burns.

Filling Samples with Dry Ice

1. Place one empty bottle and closure on the balance and then tare their combined weight.

2. Continue to add small pieces of dry ice to the bottle until the weight exceeds the previously calculated weight (refer to step 5) by approximately 0.3 g.

3. Put an approved plastic closure on the bottle finish and screw down loosely without completely sealing the bottle. Observe the balance reading. As the dry ice sublimates, the weight of the sample bottle will decrease. When the balance reading is approximately 0.1 g greater than the calculated dry ice weight (from step 5 above), quickly tighten the closure on the bottle. Tighten the plastic closure by hand to the application torque recommended by the closure manufacturer.

4. By hand, gently swirl the bottle at ambient temperature (approximately 22°C) until all the dry ice evaporates inside the bottle. Do not hit the bottles on tables or on any other rigid objects to break up the dry ice. This may affect the physical characteristics of the bottle.

5. After all the dry ice has evaporated in the capped bottle, check the internal pressure of the sample using a Zahm and Nagel piercing device. The pressure should 56 ±2 psi at a temperature of 22°±1°C (or alternatively, 60 ±2 psi).



6. If necessary, use an additional bottle to adjust the amount of dry ice until the correct pressure is obtained. When the correct pressure has been confirmed, fill 12 test bottles with the confirmed amount of dry ice according to the procedure described in steps 1 through 3.

Measuring Initial Bottle Diameters

1. After the samples have been filled and capped, and all of the dry ice has sublimated, measure the bottle diameters. The initial diameter measurements must be made within 10 to 30 minutes after the dry ice has sublimated.

2. Measure each bottle at 86 mm up from the base of the bottle. This corresponds to the exact point where the FT IR beam passes through the bottle. Ensure that all bottles are aligned consistent with their heel mark (refer to step 3 in the Sample Preparation section). Record this as the initial diameter for each sample.

NOTE: All diameters need to be measured at the same distance from the base for each interval.

IR Calibration Calibrate the IR instrument according to the manufacturer’s recommended procedure.

Sample Testing 1. After you have pressurized the 12 test bottles and measured the initial diameters, evaluate the test bottles on the FT IR to establish the initial CO2 concentration.

2. After have measured all 12 test bottles for CO2 concentration, store the samples in a conditioned environmental chamber (22°±1°C or 72°±2°F at 50% RH).

3. At each interval shown in the table below, the CO2 level will need to be measured on the FT IR. You do not need to measure the diameters at every interval. To see a suggested frequency for diameter measuring, refer to Schedule for Measuring Samples below.

Sample Storage Store all test bottle samples in an environmentally controlled room or chamber at 22°±1°C or 72°±2°F, 50% RH, between each test interval throughout the entire test period.



Schedule for Measuring Samples

Measure the CO2 level for each test bottle according to one of the following schedules:

Days Diameter Measurement Test Interval

0 (10 to 30 minutes after filling)

X 1 (initial)

1 X 2

10 X 3

14 optional* 4

18 optional* 5

25 X 6

33 optional* 7

40 optional* 8

44 optional* 9

49 X 10

*Measure diameter at every interval if performing an accelerated test. For a standard test, the software does not use the diameter measurement at these intervals to calculate shelf-life.

CAUTION: Follow the schedule as closely as possible so you do not miss a measurement interval; otherwise, the final results may be affected.

You can neither miss nor delay the initial (#1) or the 1 day (#2) interval measurements. The initial measurement will be used as the baseline from which the subsequent CO2 loss and shelf life will be calculated. The 1 day (#2) is not used in the CO2 loss calculation. However, it can be used to characterize the CO2 loss within the first 24-hour period, if necessary.

If you cannot perform a measurement at the scheduled time (in case of a holiday or weekend), you may perform the measurement up to three days later (except intervals 1 and 2). A late or delayed measurement will result in a longer test period, but there is no negative influence on the accuracy of final test results. Never perform a measurement before its scheduled interval.



Data/Report Requirements

1. Report all data in a standardized format. The data should include the projected shelf life and the percentage of CO2 loss per week.

2. If the data is to be submitted to Packaging Design and Development for approval, you must report the shelf life data in the Carbonation Shelf Life and Standard Lab Conditions fields of the Submission Data Form (SDF). The SDF is located in the Global Packaging database.


REFPET Bottle Drop Impact Test


Purpose The drop impact resistance test simulates abuse that plastic soft drink containers may be subjected to in its normal life cycle.


REFPET Bottle Specifications, Drop Impact Resistance, PK-SP-045

Test Equipment

Carbonator Cold storage facility Drop area/concrete floor Safety glasses or face shield

Procedure

1. Select at random 23 samples previously inspected for visual defects. Mark each sample with an identification number in a continuous sequence. Fill and cap these containers to achieve 4.0 ±0.2 volumes of carbonated water when measured at 22.2°C (72°F).

2. Store all samples for 24 hours at the following temperatures: a. 2 - 11 at 4.4°C (40°F) b. 1 and 12 - 23 at 22.2°C (72°F)

3. Check and record pressure, temperature and CO2 level of samples 1, 12, and 23.

4. In a suitable test area, mark a door or wall to a height of 1 meter above a smooth concrete floor. The person performing the drop should wear either safety glasses or a protective face guard, and be instructed to tip the sample away from his or her line of vision.

5. Hold each sample at an approximately 30° angle from the vertical at a height of 1 meter.

6. Release each sample uniformly so that it falls freely, impacting the bearing surface of the container. After dropping each sample, inspect the container for breakage, excessive deformation, or separation. In addition, place the tested container upright on the floor. If it will not stand unassisted, note the sample as a failure. Record all findings.

REFPET Bottle Drop Impact Test



REFPET Bottle Durability Test—Abbreviated Trip-Per-Two-Day Washing


Purpose The durability of a filled plastic bottle is critical to allow it to function. The conditions tested include a minimum of three months with an abbreviated sample size and relate to field performance.


REFPET Bottle Specifications, Durability, PK-SP-045

Test Equipment

Caustic tank and safety equipment Filler Fill-height syringe Capper Environmental control chamber Rinse area Mettler PC 4000 scale or equivalent Dial caliper with base Pi-Tape or circumferential tape Depth gauge Optical comparator

Procedure

1. Randomly select a 24-bottle sample. On each bottle, put the test request (TR) number and number the bottles sequentially. Also, always include a control group for comparison.

2. Select samples 1 through 5. Measure fill-point capacity on each of these bottles at completion of 0 and 25 washes.

3. On the same samples and at the same frequency as in step 2, measure and record the following if checked: a. Overall height b. Pinch diameter c. Upper label diameter d. Base push-up height e. Finish dimensions E1, E2, E3, E4, T1, T2 and A (see

Finish Measurements)



4. Precondition bottles by immersing in water at 41°C ±3°C (105.8°F ±5.4°F) then empty and immerse the bottles completely in 3.0% +0.5% -0% caustic and 0.15% +0.05% -0% Henkel P3 stabilon Al Fluessig additive at 59.5°C ±1.0°C (139°F ±1.8°F) for 15 minutes ±1 minute. (If this chemically aggressive Henkel additive is not available, then use an approved additive at nominal field use concentration but increase contact time).

5. Measure and record on Data Form I “Wash Conditions” in this document the caustic concentration, additive concentration, temperature, and soak time at each washing. We recommend installing an alarm system and setting at 61°C (141.8°F) to monitor maximum temperature.

6. Remove the emptied bottles and immediately rinse them thoroughly with potable (fresh tap) water by completely immersing in water, completely filling bottles and emptying 2 times, followed by a fresh water spray rinse as follows.

First rinse Water immersion at 41°C ±3°C (105.8°F ±5.4°F)

Second rinse Immersion at ambient

Third rinse Ambient using jetting for 15 seconds at 30 psi with an inside stream type 2 mm (5/64 inch) nozzle and external dispersion type nozzle on an inverted bottle

7. As it is extremely important that there is no caustic carryover, check for caustic carryover each cycle by allowing 3 drops of phenolphthalein to run down both the base exterior and the inside of the bottle. No color indicates no caustic. If pink color develops, add 10 ml of distilled water. If pink color persists, caustic is present and more thorough rinsing is necessary.

8. Fill bottles 15 through 24 three-fourths full of water and counterpressure to 5.5 bars (80 psi) for 20 seconds, then empty.

9. Wipe a thin layer of Diversey SUPERPET C line lubricant or equivalent diluted at 1 part line lubricant to 100 parts water (1.0 percent ±0.1 percent) on the entire bottom and to a height of 3 mm up the heel on each bottle. Store the one percent lube moisture in a sealed container when not in use or make a new batch daily. This is necessary to ensure that evaporation does not cause the ratio to drift outside of the stated tolerance.



10. Fill all of the bottles with carbonated water to achieve 4.2 volumes ±0.2 volumes carbonation at 22.2°C (72°F) after 24 hours and apply new plastic closures. Use only Metal Closures, MCA finial plastic closures applied at 10-12 inch-pounds, or other approved plastic closure for REFPET bottle.

11. Measure and record pressure and temperature of one extra bottle at beginning and end of filling operation on Data Form II “Filling and Storage Conditions” in this document.

12. Store at 37.8°C ±1°C (100°F ±1.8°F) and 40% ±10% relative humidity for 24 hours ±1 hours.

13. At every wash cycle, record on Data Form II the exact number of hours bottles are stored at 37.8°C (100°F). All bottles are to achieve 36.8°C ±1°C (98.2°F ±1.8°F) at the end of 24 hours.

NOTE Bottles can be stored full over weekend and/or holidays at 35.6°C ±1°C (96°F ±1.8°F) in order to obtain one or more extra cycles per week. Under no conditions should bottles exceed 25 hours at 37.8°C ±1°C (100°F ±1.8°F).

14. Measure and record on Data Form II temperature and relative humidity of the chamber, then remove the bottles from storage. Immediately measure and record the unshaken pressure and temperature of one bottle from each case or at the following storage locations: a. Top stack corner b. Middle stack center c. Bottom stack opposite corner The target average unshaken opening pressures are:

Weekend/holiday storage 67 ±3 psi for at 35.6°C ±1°C (96°F ±1.8°F)

24-hour storage 70 ±3 psi at 36.8°C ±1°C (98.2°F ±1.8°F) 15. Open and two-thirds empty remaining bottles, leaving bottles

one-third full of water and uncapped during “empty” bottle storage. Upon opening bottles, look for lack of venting which could indicate improper sealing or small stress crack leakage. On the 24-hour cycle only, remove all closures by hand at normal opening speed and note any closure releases or unusual closure performance.



16. Pour out remaining water immediately prior to wash. The internal bottle moisture is necessary to simulate stress crack patterns for this shortened cycle time.

NOTE Achieving target opening temperatures for all bottles

may require the addition of significantly more airflow around bottles. To achieve target opening unshaken pressure may require placing a nucleation particle in bottle just before cap is applied to speed-up CO2 equilibration time for 24-hour storage.

17. After every 5th cycle, record the condition of each bottle with respect to breaking, cloudiness, stress cracking, or any other noticeable change in appearance. Record the severity of stress cracks at each location on the bottle using the stress crack reference photographs in the Appendix or this scale:

Stress crack Severity Quantity

A = Minor, very shallow cracks = 1 to 10

B = Moderate, shallow cracks = 11 to 100

C = Major, moderately deep cracks = 101 to 500

D = Major, deep cracks = 500+ 18. Record on Data Form III “Stress Crack Severity” in this

document the stress crack severity and quantity of cracks at: a. bottom bearing surface b. inside radius of the bottom bearing surface c. sprue d. area between the sprue and the inside radius e. finish f. neck g. top flute h. bottom flute i. heel



19. Record all bottle failures by bottle location and cycle. Save all bottles. If bottle has two different conditions of stress cracking at any location, then note both, for example, B4, D1 on bearing surface.

20. Return empty bottles to the environmental chamber at 37.8°C ±1°C (100°F ±1.8°F) and 40% RH +10% until the next filling (about 20 hours) unless the test is interrupted, then store at 72°F.

21. Repeat steps 4 through 20 for 24 complete cycles. At every tenth cycle, pull one typical reference sample from bottles 6 through 14. Mark test request number and cycle pulled on the bottle.

22. Repeat steps 4 and 5 for one more cycle (cycle 25), then measure as in step 3.

23. Continue testing until at least 10% of bottles fail.

NOTE To better understand stress crack results on wash

test, evaluate the material distribution in the base as outlined in REFPET Bottle Plastic Distribution Test, PK-PR-226.



Test Figure. Finish Measurements



DATA FORM I—WASH CONDITIONS Test Request Number:

Date of Wash Cycle

No. of Bottles

Time Wash

Started

Time Wash

Compl.

Total Wash Time

(Mins.)

Time Rinse

Compl.

Total Rinse Time

(Mins.) % Caustic

Conc. % Additive

Conc.

°C (°F) Caustic Temp.

Caustic Carry-over



DATA FORM II—FILLING AND STORAGE CONDITIONS Test Request Number:

Date of Filling Cycle

Bottle Order

Filling Temp., °C (°F)

Filling Pressure,

Bars (psig)Vols.

Carbonation

Storage Chamber Temp., °C

(°F)

Time Storage Started

Time Storage

Completed

Total Storage

Time (Hrs./ Mins.)

Bottle Storage

Location*Product Temp.**

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

*T = Top stack corner M = Middle stack corner S = Bottom stack opposite corner to top

**Measure temperature is 1 bottle for each location from storage chamber



DATA FORM III—STRESS CRACK SEVERITY T. R. #: Manuf.: Package: Test Type: Bottom Lube: Sample Size:

Stress crack Severity A = Minor, very shallow cracks B = Moderate, shallow cracks C = Major, moderate deep cracks D = Major, deep cracks

Quantity 1 = 1-10 2 = 10-100 3 = 100-500 4 = 500+

Cycle Bottle

Broken Finish Neck Top Flute

Bottom Flute

Top Heel

Middle Heel

Bearing Surface

Inside Radius Push-Up Sprue

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25



Appendix. Stress Crack Photographs








Purpose The durability of a filled plastic bottle is critical to allow it to function. The test conditions specified here relate to field performance in a minimum of nine weeks.


REFPET Bottle Specifications, Durability, PK-SP-045

Test Equipment

Caustic tank and safety equipment Filler Fill-height syringe Capper Environmental control chamber Rinse area Mettler PC 4000 scale or equivalent Dial caliper with base Pi-Tape or equivalent circumferential tape Depth gauge Optical comparator

Procedure

1. Randomly select a 154-bottle sample. On each bottle, put the test request (TR) number and number the bottles sequentially. Also, always include a control group for comparison.

2. Set aside bottles numbered 145 to 154 and retain as controls for the foaming test in step 25.

3. Select samples numbered 1 through 10. Measure fill-point capacity on each of these bottles at completion of 0, 5, 15, and 25 washes.

4. On the same samples and the same frequency as in step 3, measure and record the following if checked: a. Overall height b. Base push-up height c. Pinch diameter d. Finish dimensions, E1, E2, E3, E4 (see drawing) e. Perpendicularity, T1, T2, and A f. Upper label diameter



5. Precondition bottles by immersing in water at 41°C ±3°C (105.8°F ±5.4°F), then empty and immerse the bottles completely in 3.0% +0.5% -0% caustic and 0.15% +0.05% -0% Henkel P3 stabilon Al Fluessig additive at 59.5°C ±1.0°C (139°F ±1.8°F) for 15 minutes ±1 minutes. (If this chemically aggressive Henkel additive is not available, then use an approved additive at nominal field use concentration but increase contact time.)

6. Measure and record on Form I “Wash Conditions” in this document, the caustic concentration, additive concentration, temperature and soak time at each washing. We recommend installing an alarm system and setting at 61°C (141.8°F) to monitor maximum temperature.

7. Remove the emptied bottles and immediately rinse them thoroughly with potable (fresh tap) water by immersing in water, completely filling bottles and emptying 2 times, followed by a fresh water spray rinse as follows.

First rinse Water immersion at 41°C ±3°C (105.8°F ±5.4°F)

Second rinse Immersion at ambient

Third rinse Ambient using jetting for 15 seconds at 30 psi with an inside stream type 2 mm (5/64 inch) nozzle and external dispersion type nozzle on an inverted bottle

8. As it is extremely important that there is no caustic carryover, check for caustic carryover each cycle by allowing 3 drops of phenolphthalein to run down both the base exterior and the inside of the bottle. No color indicates no caustic. If pink color develops, add 10 ml of distilled water. If pink color persists, caustic is present and more thorough rinsing is necessary.

9. Fill the bottles numbered 124 through 144 about three-fourths full of water and counterpressure to 5.5 bars (80 psi) for 20 seconds and then empty.

10. Wipe a thin layer of Diversey SUPERPET C line lubricant or equivalent line lubricant diluted at 1 part line lubricant to 100 parts water (1.0 percent ±0.1 percent) on the entire bottom and to a height of 3 mm up the heel on each bottle. Store the one percent lube mixture in a sealed container when not in use or make a new batch daily. This is necessary to insure that evaporation does not cause the ratio to drift outside of the stated tolerance.



11. Fill all of the bottles with carbonated water to achieve 4.2 ±0.2 volumes carbonation at 22.2°C (72°F) after 24 hours and apply new plastic closures. Use only Metal Closures, MCA finial plastic closures at 10-12 inch-pounds application torque, or other approved plastic closure for REFPET bottle.

12. On Form II “Filling and Storage Conditions” for steps 12, 13, and 14, measure and record pressure and temperature of one extra bottle at beginning, middle, and end of filling operation.

13. Store at 37.8°C ±1°C (100°F ±1.8°F) and 40% ±10% relative humidity for 24 hours ±1 hours. At every wash cycle, record exact number of hours bottles are stored at 37.8°C (100°F). All bottles are to achieve 36.8°C° ±1°C (98.2°F ±1.8°F) at end of 24 hours.

NOTE Bottles can be stored full over weekend and/or holidays at 35.6°C ±1°C (96°F ±1.8°F) in order to obtain one or more extra cycle per week. Under no condition should bottles exceed 25 hours at 37.8°C ±1°C (100°F ±1.8°F).

14. Measure and record temperature and relative humidity of the chamber then remove the bottles from storage. Immediately measure and record temperature of one bottle from each of the following storage locations: a. Top stack corner b. Top stack center c. Middle stack corner d. Middle stack center e. Bottom stack corner f. Bottom stack center The target average unshaken opening pressures are:

Weekend/holiday storage 67 ±3 psi for at 35.6°C ±1°C (96°F ±1.8°F)

24-hour storage 70 ±3 psi at 36.8°C ±1°C (98.2°F ±1.8°F) 15. Open and two-thirds empty remaining bottles, leaving bottles

one-third full of water and uncapped during “empty” bottle storage. Upon opening bottles, look for lack of venting which could indicate improper sealing or small stress crack leakage. On the 24-hour cycle only, remove all closures by hand at normal opening speed and note any closure releases or unusual closure performance.



16. Pour out remaining water immediately prior to wash. Moisture in the bottle is necessary to simulate stress crack patterns of this shortened cycle time.

NOTE To achieve target opening temperatures for all bottles may require addition of significantly more air flow around bottles. To achieve target opening unshaken pressure may require placing nucleation particle in bottle just before cap is applied to speed-up CO2 equilibration time for 24-hour storage.

17. At the completion of every fifth cycle, record the condition of each bottle with respect to breaking, cloudiness, stress cracking, or any other noticeable changes in appearance. Record the severity of stress cracks at each location on the bottle using the stress crack reference photographs in the Appendix or the following scale:

Stress crack Severity Quantity

A = Minor, very shallow cracks = 1 to 10

B = Moderate, shallow cracks = 11 to 100

C = Major, moderately deep cracks = 101 to 500

D = Major, deep cracks = 500+ 18. Record on Data Form III “Stress Crack Severity” the stress

crack severity and quantity of cracks at the following: a. bottom bearing surface b. inside radius of the bottom bearing surface c. sprue d. area between the sprue and the inside radius e. finish f. neck g. top flute h. bottom flute i. heel

19. Record all bottle failures by bottle location and cycle. Save all bottles. If bottle has two different conditions of stress cracking at any location, then note both, for example B4, D1 on bearing surface.



20. Return empty bottles to the environmental chamber at 37.8°C ±1°C (100°F ±1.8°F) and 40% +10% until the next filling (typically about 20 hours), unless the test is interrupted, then store at 72°F.

21. Repeat steps 5 through 20 for 24 complete cycles. At every fifth cycle, pull one typical reference sample from bottles numbered 11 through 123. Mark test request number and cycle pulled on the bottle.

22. Repeat steps 5 through 8 for one more cycle (cycle 25). 23. After 25 washings (not complete cycles) choose 18 cycled

bottles and six new bottles (for air and temperature checks) for conducting carbonation retention testing using REFPET Bottle Carbonation Retention Test, PK-PR-219.

24. After 25 washings conduct the following tests: a. PK-PR-247, Appearance and Color Evaluation b. PK-PR-207, Dimensions Evaluation—Exterior c. PK-PR-270, Perpendicularity Test d. PK-PR-223, Empty Weight and “As-Delivered” Capacity

Test e. PK-PR-218, Capacity Change (Shrinkage) Test f. PK-PR-225, Internal Pressure Test g. PK-PR-229, Vertical Load Test—Empty h. PK-PR-228, Thermal Stability Test i. PK-PR-224, Fill Point Variation Test j. PK-PR-220, Drop Impact Test k. PK-PR-227, Support Ledge Test

25. Conduct foaming tests using control samples numbered 145 to 154 from step 2 and select 10 samples after 25 washings. Control samples should be washed once prior to filling. All samples should be wet before filling. a. Fill all samples with Coca-Cola and note foaming/snift

characteristics. Store filled and capped overnight. b. Open bottles and note foaming characteristics by

measuring distance from top of finish to top of foam or amount of foam-over. Empty the bottles and rinse thoroughly. Repeat foaming procedure using diet Coke.



26. In addition, after 25 washes, conduct a storage test on remaining bottles. Fill these with 4.2 volumes ±0.2 volumes carbonated water and store at 37.8°C (100°F) and 30% relative humidity for one week. Each day check each bottle and note any bottle failures, such as leakers, and note location and other details concerning the failure.

NOTE To better understand stress crack results on wash

test, evaluate the material distribution in the base as outlined in REFPET Bottle Plastic Distribution Test, PK-PR-226.



Test Figure. Finish Measurements



FORM I—WASH CONDITIONS Test Request Number:

Date of Wash Cycle

No. of Bottles

Time Wash

Started

Time Wash

Compl.

Total Wash Time

(Mins.)

Time Rinse

Compl.

Total Rinse Time

(Mins.) % Caustic

Conc. % Additive

Conc.

°C (°F) Caustic Temp.

Caustic Carry-over



FORM II—FILLING AND STORAGE CONDITIONS Test Request Number:

Date of Filling Cycle

Bottle Order

Filling Temp., °C (°F)

Filling Pressure,

Bars (psig)Vols.

Carbonation

Storage Chamber Temp., °C

(°F)

Time Storage Started

Time Storage

Completed

Total Storage

Time (Hrs./ Mins.)

Bottle Storage

Location*Product Temp.**

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

Start T

Middle M

Last

S

*T = Top stack corner M = Middle stack corner S = Bottom stack opposite corner to top

**Measure temperature is 1 bottle for each location from storage chamber



FORM III—STRESS CRACK SEVERITY T. R. #: Manuf.: Package: Test Type: Bottom Lube: Sample Size:

Stress crack Severity A = Minor, very shallow cracks B = Moderate, shallow cracks C = Major, moderate deep cracks D = Major, deep cracks

Quantity 1 = 1-10 2 = 10-100 3 = 100-500 4 = 500+

Cycle Bottle

Broken Finish Neck Top Flute

Bottom Flute

Top Heel

Middle Heel

Bearing Surface

Inside Radius Push-Up Sprue

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25



Appendix. Stress Crack Photographs






REFPET Bottle Empty Weight and “As-Delivered” Capacity Test


Purpose Controlling empty bottle weight at manufacture is the first step in achieving consistent container properties. Bottle capacity affects the container’s ability to meet correct volume requirements without overfilling.


REFPET Bottle Specifications, Empty Weight and Capacity “As-Delivered,” PK-SP-045

Test Equipment

Mettler PC4000 scale or equivalent Fill-height syringe assembly

Procedure

1. Select at random 10 samples previously inspected for visual defects. Mark each sample with an identification number in a continuous sequence.

2. Weigh each bottle and record the weight to the nearest 0.1 grams. Report each bottle weight and the maximum, average, minimum, and standard deviation for the sample group.

3. Place each bottle on a digital scale and tare the weight so that the readout is at 0.0.

4. Fill the bottle with water at a known temperature to a level above the fill-point.

5. With a preset fill-height syringe, remove the excess water down to the proper fill-point.

6. Record the weight and water temperature. 7. Use the Density Conversion Table found in RF-PK-108 to

adjust to milliliters. 8. With the bottle still on the scale, add water until the level is just

above the finish. 9. Record the weight and water temperature. 10. Use the Density Conversion Table found in RF-PK-108 to

convert to milliliters. 11. Report the weight of the water, temperature of the water, and

milliliters for each bottle and the maximum, average, minimum, and standard deviation for the sample group.

REFPET Bottle Empty Weight and “As-Delivered” Capacity Test



REFPET Bottle Fill-Point Variation Test


Purpose These test procedures address the ability of a plastic container to maintain adequate fill-height variation, under pressure, between containers in the same lot.


REFPET Bottle Specifications, Fill-Point Variation, PK-SP-045

Test Equipment

Carbon dioxide source Hypodermic needle/pressure transducer assembly Height gauge Fill-height syringe assembly Thomas septums (fitted) Capper

Procedure

1. Select 10 samples which provide the best representation of all mold numbers that have previously been inspected for visual defects.

2. Fill each container with tap water at 22.2°C (72°F) and syringe each to the proper fill-point. Cap each sample with a closure that has been fitted with a septum.

3. Measure the liquid fill height from the top of each container to the bottom of the meniscus. Record this value.

4. Inject carbon dioxide gas through the septum at a rate of 4.1 bar gauge (10 psig) per second to a level of 4.1 bar gauge (60 psig). Hold this pressure for one minute and then remove the hypodermic needle/pressure transducer from the septum.

5. Repeat step 3. 6. Increase the pressure in the same manner as in step 4 to a

level of 5.5 bar gauge (80 psig). Hold this pressure for one minute and then remove the hypodermic needle/pressure transducer from the septum.

7. Repeat step 3. 8. The fill-point variation is the difference between the minimum

and maximum fill-points for each pressure.

REFPET Bottle Fill-Point Variation Test



REFPET Bottle Internal Pressure Test


Purpose The internal pressure strength of a plastic container varies due to its method of manufacture and conditions it may encounter in its normal life cycle. This test presents a means of measuring internal pressure strength to determine whether it meets minimum performance requirements.


REFPET Bottle Specifications, Internal Pressure, PK-SP-045

Test Equipment

AGR internal pressure tester or equivalent

Procedure

1. Select at random 10 samples previously inspected for visual defects. Mark each sample with an identification number in a continuous sequence.

2. Fill each bottle completely with water. 3. Place in a suitable apparatus that will build internal pressure

hydraulically. Pressure should be increased steadily until bottle failure.

4. Record the pressure at which the bottle failed, along with the location of failure.

5. Report each failing pressure and location of failure, maximum, average, minimum, and standard deviation for the sample group.


REFPET Bottle Perpendicularity Test


Purpose Use this test to ensure that REFPET plastic bottles stand upright in an orientation that is completely perpendicular to the bearing surface on which they stand.


REFPET Bottle Specifications, PK-SP-045, Perpendicularity—Empty and Filled Uncapped Bottles

Test Equipment

Perpendicularity gauge assembly or equivalent

Procedure 1. Using 108 randomly-selected sample bottles as a source, select a subgroup of 12 Perpendicularity samples.

2. Fill each sample bottle approximately half full with tap water and place it in the measuring apparatus. Be sure that the base of each bottle is held securely in the support fixture.

3. Adjust the dial indicator contact so that it rests on the locking ring of the bottle finish. Set the dial indicator to zero.

4. Rotate the bottle through at least 360 degrees and note the maximum and minimum deviation on the gauge on either side of vertical. Set the zero mark of the gauge at that position.

5. Repeat steps 3 and 4 for the remaining samples. 6. Record all measurements.


REFPET Bottle Plastic Distribution Test


Purpose Controlling plastic distribution is a basic requirement for maintaining properties of all plastic containers. This test provides a means to judge this aspect of bottle manufacture.


REFPET Bottle Specifications, Plastic Distribution, PK-SP-045

Test Equipment

Electronic sensing probe Mettler PC4000 scale or equivalent

Procedure

1. Select 10 samples previously inspected for visual defects. 2. Measure the plastic sidewall thickness every 30° around the

bottle at the specified heights. 3. Report the maximum height for each bottle, and then the

maximum, average, minimum, and standard deviation height for the sample.

4. Measure the neck thickness every 90° around the bottle at 10 mm, 20 mm, 30 mm, and 40 mm down from the support ring for all bottles. For bottles larger than 1 liter, also measure at 50 mm.

5. Report each reading for each bottle along with the maximum average, minimum, and standard deviation for each location for the sample.

6. Measure bottom thickness around the base at five locations according to the test figure. Rotate the bottle 360° to obtain the minimum and maximum thickness for each location.

7. Report the individual measurements for each bottle. Indicate where the mold seam is in relation to the thickness measurements. Report the maximum, average, minimum, and standard deviation for each location.

8. Conduct sectional weight evaluation of the bottle as follows: a. entire bottle b. neck weight (50 mm from top) c. base weight (25 mm from bottom) d. panel weight (remaining midsection)

REFPET Bottle Plastic Distribution Test


Test Figure. Measuring Bottom Thickness


REFPET Bottle Support Ledge Strength Test


Purpose The topload strength of a plastic container support ledge varies to the profile design and load conditions encountered during its normal cycle life. This test presents a means of measuring support ledge strength to determine whether it meets minimum requirements. This testing is normally conducted only in conjunction with a retest after caustic wash cycling.


REFPET Bottle Specifications, Support Ledge Strength, PK-SP-045

Test Equipment

Tensile/compression tester Fixture (to represent support ledges in capper)

Procedure

1. Select 10 samples that provide the best representation of all preform mold numbers that have previously been inspected for visual defects.

2. Cut off the finish of the container about 6.3 mm (1/4 inch) below the ledge support. Place each finish into the fixture in the compression test apparatus at room temperature.

3. Position the load platen approximately 50 mm (2 inches) above the top of the container and zero the load gauge readout if necessary.

4. Apply the load at a rate of 5 cm (0.2 inches) per minute and record the resulting curve.

5. Report the first failure peak of the ledge support in pounds or kilograms of force. Also, report the maximum, average, minimum, and standard deviation for the peak loads.


REFPET Bottle Thermal Stability Test


Purpose The thermal stability of a plastic container varies due to its method of manufacture and the environmental conditions it may have to withstand in its normal life cycle. This test presents a means of measuring its axial and hoop strength to determine whether it meets minimum performance requirements.


REFPET Bottle Specifications, Thermal Stability, PK-SP-045

Test Equipment

Tensile/compression tester Carbonator Capper Environmental control chamber Perpendicularity gauge assembly Fill-height syringe assembly Pi-Tape or equivalent circumferential tape Dial caliper with base Depth gauge

Procedure

1. Use the same 10 bottles previously tested for empty dimensions and perpendicularity. Randomly select 2 new additional samples. Mark the additional samples as 11 and 12 (the first 10 bottles are already marked 1 through 10).

2. Rinse each sample prior to filling to eliminate dust or dirt particles from the inside surface of the bottle.

3. Fill all samples and controls on Meyer filler, or equivalent, to the proper fill-point with carbonated water to achieve 4.0 ±0.2 volumes apparent carbonation when measured at 22.2°C (72°F). Deaerated water should be used if possible to minimize air content in headspace of the bottle. High air content can significantly affect the test results. Samples should be immediately capped after filling.

4. After completion of step 3, immediately measure and record the fill height of samples 1 through 10 within one minute of capping. Measure fill-point from top of closure to bottom of liquid meniscus.



5. Store all samples at 22.2°C (72°F) for 24 hours. Measure and record carbonation level and oxygen content of samples 11 and 12. Maximum allowable air is 4 psi. Now measure and record the following for samples 1 through 10: a. Overall height b. Diameters c. Perpendicularity d. Fill height e. Dome depth

NOTE Any rocker bottoms, burst samples or any objectionable appearance (stress, whitening, localized expansion and the like).

6. Reclose bottles 11 and 12, then store all 12 samples at 37.8°C ±1°C (100°F ±1.8°F) and 40% ±10% relative humidity for 24 hours ±1 hour. All bottles are to achieve 36.7°C ±1°C (98°F ±1.8°F). Measure temperature of samples 11 and 12 then recap. Measure samples 1 through 10 as in part 5. Record all findings.

7. Place the samples that haven’t burst or developed rocker bottoms back into the oven at 37.8°C (100°F) and store them for six more days. Continue to measure and record temperature of controls and relative humidity daily.

8. Test as per 5 above. In addition, measure and record temperature in samples numbered 11 and 12. All bottles are to achieve 37.8°C ±1°C (100°F ±1.8°F).

9. Randomly divide the remaining intact samples into two groups and designate them as groups I and II.

10. Perform a drop impact test (PK-PR-220) at 37.8°C (100°F) on group I (drop from one meter or approximately three feet onto a smooth concrete floor and note any failures).

11. Store group II at 22.2°C (72°F) for 24 hours. Test as per 5 above.

12. Perform a drop impact test on group II (drop from one meter or approximately three feet onto a smooth concrete floor at a 30° angle) and note any failures.



13. Report all measurements and observations along with the bottle numbers. Report the maximum, average, minimum, and standard deviation for each measurement location, fill-point, and perpendicularity. Compare the averages and report the percent increase or decrease for each measurement location.


REFPET Bottle Vertical Load Test—Empty


Purpose The topload strength of a plastic container varies due to its method of manufacture and the load conditions it may have to withstand in its normal life cycle. This test presents a means of measuring column strength to determine whether it meets minimum performance requirements.


REFPET Bottle Specifications, Vertical Load, PK-SP-045

Test Equipment

Tensile/compression tester

Procedure

1. Select 10 samples which provide the best representation of all mold numbers that have previously been inspected for visual defects.

2. Place each empty container in the compression test apparatus at room temperature (approximately 22°C or 72°F).

3. Position the load platen approximately 50 mm ( 2 inches) above the top of the container and zero the load gauge readout if necessary.

4. Apply the load at the rate of 51 cm per minute and record the resulting curve.

5. The compression tester readout should be capable of indicating the minimum load between 1.59 mm and 4.76 mm (1/16 inch and 3/16 inch) bottle deflection, the peak load, and the bottle deflection at peak load.

6. Report the minimum load between 1.59 and 4.76 mm bottle deflection for each bottle in pounds or kilograms of force. Also, report the maximum, average, minimum, and standard deviation for these minimum loads.

7. Report the peak load in kilograms (pounds) of force and the bottle deflection at the peak load for each bottle. Also, report the maximum, average, minimum, and standard deviation for the peak loads.

REFPET Bottle Vertical Load Test—Empty



REFPET Bottle Line Trial


Purpose As part of New Package Authorization, PK-RQ-020, use this procedure as a general guide to performing a Line Trial for REFPET bottles. The line trail identifies areas within bottle handling, production and distribution that may contribute to scuffing. This document describes the procedure for performing a line trial and suggests corrective actions.


REFPET Bottle Specifications, PK-SP-045

Procedure

Bottling Line Test

Preparation 1. Obtain ten new REFPET bottles 2. Mark them with a caustic-proof adhesive tap around the bottle

neck

Operation 1. Select a pallet of REFPET bottle returns identified for immediate production

2. Place the ten new, marked bottles at locations within the pallet.

3. Pass the pallet through the bottling line. 4. Retrieve the ten bottles from the cases after the caser. 5. Empty the contents of the bottles 6. Record the line speed, stoppage information, amount of time

bottles are in washer. 7. Repeat for a total of 25 cycles or until bottles reach a scuff

level #4, whichever happens first.

NOTE To make sure no bottles are misplaced, gather the group of test bottles at the entrance to the washer and manually place the bottles in one row of washer pockets so that all the bottles in the sample come out at the same time and are easier to find. In addition, it may help to gather them after the filler and mark the closure top with black in felt marker. This makes collection mush easier after the caser.



Data Handling Record results. No action is necessary if 25 cycles are completed without bottles reaching scuff standard #4. Otherwise, isolate the source of abuse by the Bottling Machine Test, Route Truck Test, and Remote Sorting Test in this document, and take appropriate corrective action.

Bottling Machine Test

Preparation Obtain five new bottles for each piece of equipment: combiner, sniffer, decapper, washer and the like. Mark them with an adhesive tape and identify each bottle with a code for each machine.

Operation Pass each group of five bottles through the respective machines 25 times. See Loop Trial Desired Performance and Scuffing Scores section of this document for interpretation of results.

Route Truck Test

Preparation 1. Remove two cases from the line prior to the caser. 2. On only one of these cases, clean thoroughly all the inside

bottle contact surfaces. Put new filled REFPET bottles in each pocket, and wrap the case so it will keep clean through the test.

3. Put new filled bottles in the other case. 4. In a like manner two cases should be selected, one cleaned,

both filled with new, empty REFPET bottles, and the cleaned case should be wrapped to keep it clean.

Operation Place the four cases on a route truck in the normal manner in which they are handled, and leave on the truck for ten days of deliveries. Compare the condition of bottles in the wrapped cases with the bottles in the unwrapped cases. If the bottles in the unwrapped cases are noticeably different, take appropriate action. For example, if the bottles are noticeably dirtier, then the covering for the truck is probably not adequate, or the truck bays might need cleaning. If the unwrapped bottles are more scuffed, the case washer is probably inadequate.



Remote Sorting Test

If sorting is done at a location other than the bottling plant, then carry out this test.

Preparation Obtain ten new bottles, mark and code them for easy identification.

Operation 1. Select a pallet to be sorted and replace ten bottles at random with the new marked bottles.

2. Retrieve the bottles after sorting. 3. Repeat for a total of 25 cycles.

Observations • While the bottles are running, inspect conveyor guide rails, infeed screws, star wheels, washer guides, washer pockets, and other bottle contact surfaces for sand, grit, and dirt.

• Where appropriate, use photographs and video tape to illustrate handling and storage conditions.

• Record the visual appearance of the test bottles after every five cycles. It may be found that on some pieces of equipment, the scuffing does not change markedly after reaching a certain level.

Loop Trial Desired Performance and Scuffing Scores

• After 25 trips the bottles should:

− show no stress cracks

− each have a scuff level 3 or less

• Calculate scuffing scores for each machine by adding the scuff level number for each bottle in the five bottle group after completing five additional cycles. These scores allow comparison of different machines’ scuffing action, or of the filling process VS distribution.

Corrective Action

1. Thoroughly clean all the bottle contact surfaces of the conveyors, guide rails, and individual pieces of equipment between the uncaser and the washer. Remove all accumulated dirt, sand, oil, or foreign substance of any kind.

2. Lightly rub guide, starwheels, and infeed screw body with a fine sandpaper and wipe off. Replace or repair any part to eliminate all rough spots, nicks, burns, and sharp edges.



3. Adjust top guides so they do not touch the upper part of the REFPET bottles.

4. Adjust conveyor speeds leading into combiners to avoid excessive bottle-to-bottle pressure.

5. Adjust infeed conveyor speeds at each piece of equipment slightly above the pitch speed to allow the infeed screw to merely separate the bottles rather than to accelerate them. The goal is to minimize the pressure between the infeed screws and bottles.

6. Adjust bottle handling parts of each piece of equipment to obtain smooth handling of bottles through the equipment from infeed to discharge.

7. Make sure there is at least 5 mm clearance between the bottles, the infeed screws and the back guides that are opposite the screws.

8. The conveyor guides leading in the infeed screw must be placed ahead of the solid bodies of the screws to avoid each bottle hitting the screw body instead of moving smoothly inside the screw pockets.

9. If after making all adjustments the plastic infeed screws still damage the bottles, replace them with screws made with stainless steel or cast in brass, polished and then chrome plated.

10. Replace roller belts and powered roller combinations, and adjust so that: a. only rollers are in contact with the bottle b. rollers are lubricated and cleaned with a water spray mist c. rollers do not touch the bottle pinches, and contact only

the major diameters at the bottle heels. 11. Install water sprays to provide bottle cleaning and lubrication.

a. in-case bottle pre-rinsing with high pressure water sprays prior to the uncaser—Minimize introduction of water spray into the uncapped bottles.

b. high-volume, low pressure spray on both sides of the single file conveyor after the uncaser, minimize introduction of water into the container.



c. low volume, high pressure water spray on the infeed screws of the machines between the uncaser and the washer. It should keep the screw as clean as possible while providing lubrication between the bottle and the screw.

d. low volume, high pressure water spray on the roller of powered roller combiners.

e. If after the changes there is still scuffing from the infeed screws, replace the plastic infeed screw with a stainless steel screw, or with brass cast screw, polished and chrome plated.


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Manual de Calidad 2006 Retornable

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