Geen diatitel

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Crossing Borders with Polymer Coated Steels
David Jones Jan Kleijn
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Corus Group Plc - The Future in Metal

• Corus Group plc created in 1999 through the
  merger of Koninklijke Hoogovens and British Steel
• A multi-metal product portfolio including Carbon
  Steels, Stainless Steels and Aluminium
• 24 business units, with major production plants
  in the UK, The Netherlands, Germany, USA and
  Canada
• Total group turnover Euro 15 billion
• Employees approx. 55,000 world wide
• Carbon Steel production 20 million tonnes 7th
  largest in the world

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Corus Group - turnover per region and sector
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Corus Packaging Plus - Providing Solutions

• Corus Packaging Plus part of Corus Group.
  Formed through merger of Hoogovens Packaging
  Steel and British Steel Tinplate
• Production sites in the UK, The Netherlands,
  Norway and Belgium
• Commercial HQ IJmuiden, The Netherlands
• Employees 3500
• Annual turnover approximately 1 billion Euro
• Annual production 1.5 million tonnes of light
  gauge steel largest in the world

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Corus Packaging Plus - markets by region and
application
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Aerosol Market Comparison - USA v Europe
SourceFEA
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European aerosol production by segment

• Personal care is the largest and also a
  continuously growing segment
• Household segment picking up again after a
  decline in 1997
• Others 1995 level has been achieved again and
  seems to have stabilized at 1 billion

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European Personal Care Market 1998/1999 -
Product Split
SourceFEA
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European Aerosols - Major Markets(1999)
SourceFEA
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Why Polymer Coated Materials?
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Polymer Coated Steels - Benefits(1)

• Coil Coating Process
• Both surfaces can be coated simultaneously
• Consistent quality and no thickness limitation (
  lt 0.12mm possible)
• Versatility
• Can combine properties of several polymers. Clear
  or pigmented coatings, different thicknesses.
• Formability
• Excellent for severe deep drawing operations.
  Complex shapes and designs can be formed without
  damage to the coating
• Manufacturability
• Excellent forming properties, higher production
  speeds
• Less process steps, no lacquering

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Polymer Coated Steels - Benefits (2)

• Improved Performance
• Corrosion protection
• Excellent abrasion resistance
• Appearance
• Range of colours available and surface finishes
• Good printability
• Environmental Advantages
• No VOC emissions
• Food compliant, no issues like BADGE etc.
• Recyclability
• Easily recovered by magnetic means from the waste
  stream, or by consumer collection schemes. Can be
  directly charged into the steelmaking process

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Corus Packaging PlusTwo routes for polymer
coatings

• Film coating Ferrolite Promica
  
• Direct extrusion Protact

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The Processes

• Film Coating
• Ferrolite Promica

• Direct Extrusion
• Protact

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Ferrolite - What is it?

• Ferrolite is basically a very simple system
  produced by applying polymer films onto a steel
  based substrate under closely controlled
  conditions.
• Substrate can be tinplate, ECCS or blackplate.
• Range of different polymer films available (e.g.
  PET, PPN) - also dissimilar films can be applied
  simultaneously.
• No solvent emissions resulting from the process.

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Ferrolite - The Product

• Two layer system
• top layer color printability adhesion
• bonding layer adhesion
• steel substrate tinned ECCS

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Ferrolite - The Applications

• Lower volume specialty applications
• Aerosol components
• Bottoms
• Tops
• Valve cups
• Drawn food cans
• Food can components
• Full aperture easy open ends
• Peel off lids
• Drawn beer beverage cans (RBS)

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Promica - The Product

• Wide variety of polymer coatings technology
• Coating with multi layered prefabricated films
• Typically 3 to 5 layers
• Eye catching appearance
• Steel substrate tinned ECCS

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Promica -The Applications

• Range of high added value products developed,
  e.g.
• Promica Pristine high gloss for appliances
• Promica Lumiforme high reflectivity for light
  fixtures
• Promica Chimera Holographic for eye-catching
  effects

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Protact The Product
Exterior
top layer compound adhesion
printability etc.
main layer colour barrier
forming
contact layer adhesion
Interior
steel substrate ECCS
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Protact - The Applications
Higher volume applications

• Aerosol tops bottoms

• Twist Off Caps

• Full Aperture Easy Open Ends

• Peelable ends

• Plain ends

• Drawn food cans

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Corus Capabilities
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Protact vs. Ferrolite within Corus Packaging
Plus
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Polymer Coated Steels for Aerosol Applications

• Already widely used for aerosol components mainly
  for personal care markets- domes,cones, valve
  cups
• Process route developed for welded bodies
• New 2-piece draw-redraw can making technology
  developed for hard to hold packs

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Polymer Coated Steel - Aerosol Components
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Polymer Coated SteelAerosol Components

• First commercial use of Ferrolite. Use rapidly
  growing for aerosol domes, cones and valve cups
• The PET coatings offer superior coverage and
  abrasion resistance in the bottom double seam
  area and significantly reduces the risk of
  corrosion particularly where the aerosol is
  stored in a humid (e.g. bathroom) environment
• For cones, the PET coatings also give superior
  external appearance and protection
• In general, the internal coatings( normally PP)
  have been shown to give excellent internal
  protection for all components
• A thick internal coating of PP (e.g. 200µm) on
  valve cups has been shown to act as an effective
  sealant without the use of a separate gasket.
  Alternatively thinner coatings (e.g. 15 - 40µm)
  can be used whilst retaining the seaming gasket

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Aerosol ComponentsNew Developments

• New range of colours and finishes. Colour
  co-ordinated cones and domes
• Application of Promica Holographic for valve cups
• Protact commercialisation trials for valve cups,
  domes and cones

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Growth in Polymer Coated Steels for Aerosol
Components
Tonnes
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Polymer Coated SteelsWelded Aerosol Bodies

• Welded aerosol bodies can now be produced from
  polymer coated steels
• Feedstock is Ferrolite with a tinplate substrate
• The polymer film is removed from the weld margin
  by means of Freis metLam Peeler. This is a
  laser stripping device
• Powder coated side stripe repair

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Polymer Coated Welded Bodies- Features

• Existing line equipment can be utilised. No
  modifications to the welding machines are
  required. Can diameters down to 45mm pose no
  problems
• Finished can has superior packing performance
• Uniform thickness and consistent quality of the
  polymer coating
• Excellent flexibility for subsequent embossing
  and shaping operations
• Visually pleasing. Homogeneous surface. Special
  coating/effects are possible
• Excellent environmental profile compared to
  lacquering
• No overspray around the leading and trailing edge
  on the outside of the can

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Polymer Coated Steel 2- piece Aerosols

• Development based on existing CPPs beverage can
  technology.
• 2-piece deep drawn aerosols
• Feedstock is Ferrolite with improved coatings.
  Also option of coloured external coatings
• Substrate 0.22mm up 0.26mm DR depending on
  pressure requirements
• Wide range of can designs possible
• including high aspect ratio containers

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Draw Stretch Redraw Technology for Aerosol Can
Manufacture

• Key features
• Use of precoated Ferrolite feedstock
• Use of CPPs Tenform DR
• family of high strength steels with improved
  formability
• No internal lacquers or external base-coats
  required
• Decorated by U.V. techniques or by shrink wrap
  labels

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Draw Stretch Redraw Can-Making Technology

• Can making is based on an updated version of
  draw-redraw technology
• involves wall thinning
• new patents applied for
• Stretch redraw - what is it?

• Standard Redraw
• Can wall thickness is not reduced
• Stretch Redraw
• Tool profiles/clearances are designed to reduce
  can wall thickness

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Corus Packaging Pluss Tenform DR

• CPPs range of
  high strength, formable steels
• Strength range 500 - 660N/mm2
• Minimum earing quality
• To minimise wastage
• Specifically developed to give the can the
  required strength at light gauges whilst
  maximising the potential for shaping

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Stretch Redraw AerosolProcess Route
Trimmer
Washer
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DWI Aerosol- Process Route
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Ferrolite DRD Aerosols - Can Designs
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Environmental Profile - Ferrolite Aerosols

• Solvent emissions
• Process virtually eliminates solvent emissions.
• No solvent incineration required. All coatings
  PVC free.
• Very low level of can making waste products
• Energy efficiency
• Ferrolite manufacturing process has received an
  European Community award for energy savings.
• Recyclability
• Easily recovered by magnetic means from the waste
  stream, or by consumer collection systems. Can
  be directly charged into steelmaking process.
• Precoated, waxed feedstock
• no VOCs
• If UV cured decoration, then no process VOCs
• Simple washer required to remove wax

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Ferrolite Aerosols - Benefits

• Excellent appearance and aesthetic effect
• Major pack performance benefits
• specially developed coatings means that they can
  be used for hard to hold packs
• No weld, no separate dome (bottom)
• therefore, less likely to leak in the bottom
  seam.
• Major environmental benefits
• no VOC emissions
• reduced waste products/consumables.
• Higher production speeds/outputs
• Versatile system to compete with Al-monobloc
• Improved external corrosion benefits

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Polymer Coated Steels - The Future

• The last 10 years has seen growth in the
  application of polymer coated steels in the
  aerosol sector mainly for components
• CPP has pioneered the development of polymer
  coated steels and with new application systems,
  and a wider range of coatings now available
• In future, it is expected to see wider
  acceptance of these products because of the
  major benefits they offer.
• In parallel, additional production capability
  (with more planned) has been introduced which
  means that there is greater availability of the
  feedstock
• The development of new can-making technologies
  also means that polymer coated steels can now be
  used for the bodies as well
• In short, the future for polymer coated steel in
  the aerosol market is indeed bright