An interactive newsletter publication of the International Metal Decorating and Packaging Association.
A newsletter publication of the International Metal Decorating and Packaging Association | 2023
Q1
Future Market Growth: Canned Food Market to reach $31.31 billion by 2029. Aluminum Can Market to reach $76 billion by 2030
Inside:
Market Insights: Food & Beverage Cans
Market Insights: Food & Beverage Cans
Market Insights: Food&BeverageCans. . . . . . . . . . . . . . . . 2 President’s Message . . . . . . . . . . . . . . . . . 3 CMI: Mardi Gras Recycling . . . . . . . . . . . . 6 Roundtable: Addressing Industry Challenges . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tech: Can Washer Process . . . . . . . . . . . 10 Exclusive Members Only Access . . . . . . 14 New Officers . . . . . . . . . . . . . . . . . . . . . . .16 MembershipBrief...................17 U S Aluminum’s Economic Impact . . . . 18 Resource Directory . . . . . . . . . . . . . . . . . 20
Technical Article: Can Washer Process Aluminium formed products must be chemically cleaned to remove residual aluminium swarf, oil, smut, surface oxides the near-surface disturbed layer as to provide a uniform surface to receive further treatment Andy Raynor from Stolle walks readers through the can washing process this year, what do you see as the most pressing challenge? What has been your solution? Roundtable: Addressing Industry Challenges Industry leaders were asked the following question With an eye on 2023 challenges, of all the potential threats facing your business Two new research reports review total world Steel Canned Food & Beverage Packaging sales in 2022 providing a comprehensive analysis by region and market sector of projected Canned Food & Beverage Packaging sales through 2029 and 2030
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www metaldecorators org/newsletter
Market Insights: Food & Beverage Cans Report by Proficient Market Insights The global canned food market size is projected to grow from $23.72 billion in 2022 to $31.31 billion in 2029, according to a new report by Proficient Market Insights. What is Canning? Canning is a method used to preserve foods for long periods of time by packing them in airtight containers. This allows food to be shelf-stable and safe to eat for 1 to 5 years or longer. Canning was first developed in the late 18th century as a way to provide a stable food source for soldiers and sailors at war. Common canned foods include fruits, vegetables, beans, soups, meats and seafood. The Market The global Canned Food market size is projected to grow from US $23.72 billion in 2022 to US $31.31 billion in 2029; it is expected to grow at a CAGR of 4.05% from 2023 to 2029. Global Canned Food key players include Conagra Brands, Campbell Soup, Kraft Heinz, etc. Global top three manufacturers hold a share over 30%. Europe is the largest market, with a share about 30%, followed by North America and China, both have a share over 40%. In terms of product, Canned Vegetables is the largest segment, with a share about 20%. And in terms of application, the largest application is Supermarkets/Hypermarkets, followed by Independent Retailers. To learn more about the canned food marketing including a comprehensive overview, market shares, and growth opportunities of Canned Food market by product type, application, key manufacturers and key regions and countries contact Proficient Market Insights at proficientmarketinsights.com Continued on page 4
Officers and Directors
President John Clark Heraeus Vice President Tim Duca** Canpack Secretary Treasurer Kyle Hurla** INX International Ink Co. Executive Director Michael Masenior** IMDPA
John Hrdlick INX International Ink Co. . Art Hurley Silgan Closures Sarah Jacks** INX International Ink Co. Jack Knight INX International Ink Co. Andy Layden Stolle Machinery Carl Martel Coral Chemical Ted Nevins Sonoco Allan Sayers The Canmaker Renee Schouten** INX International Ink Co. Mark Von Bokel SGS International Elena West** Ohio Art Michael Yavorski** Sherwin-Williams Co.
Bob Blandford Miltec UV Levi Boss Ball Corp. Sam Courtney VN Graphics
Craig Eberts* ** Paul Fennessy Crown Cork & Seal Mark Finch Silgan Containers John Friedman Northern Container Eugene Furey* ** Nick Hammer** Trivium Packaging Bill Hoyle Hoyle Consulting
* Honorary Member ** Committee Chair
FUNDAMETALS Newsletter
[2] Q1 2023
The Conference Committee chaired by Tim Duca is assembling a team to put on another great Conference which will be held again at the Eaglewood Resort in Itasca IL. Sept. 26-28, 2023. If you have suggestions for topics to be presented or wish to present at the Conference, please contact Tim, Tim.Duca@canpack.com or Mike Masenior, info@metaldecorators.org The Technical Resources Committee is already working on providing additional content for the Website, Webinars, Newsletter and Conference Topics. We have begun to gather training videos and technical information to be made available for adding to the value of membership. We also ask that if you have any technical or training material, either video or articles that you are able to share, please send them to Mike Masenior, info@metaldecorators.org The Webinar Committee is compiling a schedule for 2023 presentations and is looking for volunteers to help with the administrative and presentation tasks involved. If you have previous experience or if your company can assist, please contact Elena West, weste@ohioart.com The Website is in the process of being refreshed with a stronger focus on providing valuable technical content designed to enhance your knowledge of the industry. If you would like to be part of this new creative team, contact Mike Masenior, info@metaldecorators.org The Membership Committee is seeking new committee members who can help to craft our increased member value message and join in on the steps being taken to enhance our reach across the industry. If interested in joining this most valuable committee please email nick.hammer@ triviumpackaging.com 2023 promises to be rewarding as travel is resuming with more face to face interaction with our colleagues. Having said that, we are looking forward to another great Conference this September 26-28 (Mark your Calendar). We are looking forward to the challenges of what this year brings and we are confident that this will be a rewarding year for the IMDPA membership. Stay Tuned.
Greetings All, We are rolling into 2023 in big way with a lot of focus on improving the value of the IMDPA for our Membership. Much of the emphasis on the work done thus far in 2023 is building a strong Committee base with defined goals and accountability. We are working to align our committees with our strategic plan going forward. This is important to keep us focused on growing the association and keeping it relative for the future. We have established a great Team of leadership heading up our committees and are always looking for more help with volunteers to help on the Committees. If you are able to join one of the committees listed below please contact myself, john.clark@heraeus.com, Mike Masenior, info@ metaldecorators.org or the Committee Chairs for more information. • CONFERENCE - Chair: Tim Duca, Canpack Tim.Duca@canpack.com • TECHNICAL RESOURCES – Chairs: Carl Thomsen INX carl.thomsen@inkintl.com, Eric Kuhns, Henkel eric.kuhns@henkel.com • WEBINAR – Chair: Elena West, Ohio Art weste@ohioart.com • MEMBERSHIP – Chairs: Nick Hammer, Trivium Packaging nick.hammer@triviumpackaging.com , Paul Dounian, Miltec UV pdounian@miltec.com • EDUCATION & OUTREACH – Chair: Sarah Jacks, INX sarah.jacks@inxintl.com • WEBSITE – Chair: Mike Masenior, IMDPA info@metaldecorators.org • COMMUNICATIONS (Newsletter, Social Media) – Mike Masenior, IMDPA info@metaldecorators.org Sarah Jacks, INX sarah.jacks@inxintl.com
John Clark IMDPA President
FUNDAMETALS Newsletter
Q1 2023 [ 3 ]
Aluminum Can Market to Grow to $76 Billion by 2030 Report by Custom Market Insights The aluminum can market is expected to grow worldwide to approximately $76 billion by 2030, with a compound annual growth rate (CAGR) of 4.5 percent between 2022 and 2030, according to a new report from Custom Market Insights, a market research and advisory company.. Pegged at $53.3 billion in 2021, the market shows increased consumption of various types of beverages, which is expected to be one of the major contributors to its growth during the forecast period. Increasing demand for sustainable packaging options that can maintain product authenticity is helping the aluminum cans market show a tremendous boost. Aluminum cans provide an economical option for packaging food and beverages, the report notes, as they are easily recycled multiple times and reused. Scrap collectors emerged as a major collection source where aluminum cans are gathered and then sent for the process of recycling. Read the report: www custommarketinsights com/report/aluminum-can-market
HandyCoat ®
The breakthrough for beverage can coating
Patented system: EU: PCT EP2005/010302 / US: 8,075,465.B2
Improved Ergonomics Cost Savings Time Savings Longer Lifetime
ALUMINUM CAN MARKET CAGR 4.5% Size by Capacity, 2020-2030 (USD Billion)
Up to 200 ml 201 to 450 ml 451 to 700 ml 701 to 1000 ml more than 1000 ml
76B
56.2B
53.3B
51.3B
2020 2021 2022 2023
2024 2025
2026 2027 2028 2029 2030
BARBERTON, OHIO • 330-753-8458
Source: www.custommarketinsights.com
FUNDAMETALS Newsletter
[4] Q1 2023
3rd Annual Can Design Contest for Brand Owners, Graphic Designers, and Metal Decorators
Honoring the Best Beverage Can Designs From Across the World
Can Design Contest for brand owners, graphic designers, and metal decorators
Was your can design made possible with INX Color Perfection? Don’t miss this opportunity to showcase your best work by entering the Colored by INX Can Design Contest. Your outstanding brand design deserves a lot of recognition and we at INX are proud to be part of the process.
2022 CONTEST DATES
CONTEST KICKOFF February 15 SUBMISSION ENTRIES BEGIN February 15
CAN ENTRY DEADLINE April 29 2022 Contest Winners GREAT LAKES BREWING CO. TropiCoastal Triopical IPA
FINALIST JUDGING PERIOD April 30 – May 9 FINALIST ANNOUNCED website and social media May 10
Adam Ritterspach Marissa DeSantis Jameson Campbell Megan Monsman
WINNER ANNOUNCED May 18
Enter your design today!
Accepting entries for the 2023 Can Design Contest
ENTER TODAY inxcancontest.com
Visit coloredbyinx.com for more information and to submit your can design!!
1700 Martingale Drive • Suite 700 • Schaumburg, IL 60173 • inxinternational.com
INX-CC-Q1-Can-Contest2-28-23.indd 1
2/28/23 1:43 PM Q1 2023 [5]
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CMI: Mardi Gras Recycling
A luminum Beverage Can Recycling Effort at Mardi Gras Provides Money for Charity, Diverts Aluminum from Landfill and Into New Cans By Scott Breen, CMI Can Manufacturers Institute (CMI) catalyzed a partnership with a variety of local organizations to recycle more aluminum beverage cans during Mardi Gras 2023. Instead of going to landfill, many thousands of aluminum beverage cans were sold for revenue that CMI doubled and was given to three charitable partners, and the aluminum in those cans will now be available to be turned into new cans. In total, 142,974 used beverage cans (UBC) were recycled and $3,854 (UBC market value of $1,927 plus CMI financial match) was generated from the sale of these cans to a New Orleans metal recycling facility run by EMR . Since 93 percent of recycled UBCs become new cans, these cans will almost certainly be turned into new cans. Further, more recycled aluminum in beverage cans means the industry can build on its average 73 percent recycled content and lower its greenhouse gas emissions. “In fact, the carbon emission savings from recycling the cans collected in this initiative is equivalent to the emissions from driving a car a little more than 35,000 miles.”
The Mardi Gras pilot recycling initiative, Recycle Dat, collected UBCs in two ways:
1. Having 4 recycling hubs and 10 can-only receptacles at strategic points along the most-used parade route during the daytime parades for the two weekends before Mardi Gras Tuesday. Volunteers staffed these strategic points, as well as used a variety of mechanisms to get empty beverage cans from paradegoers in the crowd. These mechanisms included specially designed backpacks for people to directly insert their used cans for recycling, over-sized shopping carts, and grabbers to easily pick up UBCs off the ground. 2. Encouraging people to directly drop off UBCs at the centrally located EMR metal recycling facility in Mid-City New Orleans. UBC collection during the initiative supported local charities and allowed people to earn extra cash. CMI doubled all the revenue generated from selling the UBCs collected along the parade route. The money raised was split between three local charities—Coalition to Restore Coastal Louisiana, Louisiana SPCA, and New Orleans Area Habitat for Humanity. CMI also doubled the market rate payout for UBCs brought directly to EMR, and redeemers could either put the money toward the three local charities or keep it. The structure of Recycle Dat’s can recycling component leveraged something that only aluminum beverage cans are able to support given its relatively high economic value.
Scott Breen of Can Manufacturers Institute and Brett Davis of Grounds Krewe with the used beverage cans collected during the first weekend of operation at one recycling hub along the Uptown Mardi Gras parade route.
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[6] Q1 2023
CMI is excited to collaborate with local partners again next year to increase the amount of beverage cans recycled, generate more money for charity and local residents, and turn more used beverage cans into new cans. CMI was proud to collaborate closely with many local partners on the recycling effort. These partners included the sustainable events non-profit Grounds Krewe, the City of New Orleans, the local tourism group New Orleans & Company, EMR and a variety of local breweries. A full list of partners is on the Recycle Dat website (ready.nola.gov/mardi-gras/ recycling/). The effort has attracted media attention. The Washington Post covered the recycling effort and also CMI’s Vice President of Sustainability Scott Breen appeared in a segment on the New Orleans NBC affiliate WDSU’s morning news show. This effort is one of many activities that CMI is undertaking to make progress toward the ambitious aluminum beverage can recycling rate targets set by CMI beverage can manufacturer members (Ardagh Metal Packaging, Canpack, Crown Holdings, and Envases) and aluminum can sheet producer members (Constellium, Kaiser Aluminum, Novelis, and Tri-Arrows Aluminum). The targets involve going from a 45 percent recycling rate in 2020 to a 70 percent rate by 2030, 80 percent by 2040, and 90 percent or more by 2050. CMI published an Aluminum Beverage Can Recycling Primer and Roadmap that details how the can industry got to the leading position as most recycled beverage container the United States, and how via four pillars of action it’s going to achieve the new heights it set. The Mardi Gras effort fits with the pillar to increase and improve household and away from home recycling. The other pillars are new, well-designed deposit systems, improving proper sortation at material recovery facilities, and more people understanding the can’s sustainability advantages.
Scott Breen of Can Manufacturers Institute promoting the Mardi Gras recycling initiative on the NBC affiliate WDSU morning show.
Two volunteers with the specially designed backpacks where paradegoers could insert their empty used beverage cans for recycling.
Two volunteers with the used beverage cans and beads collected from engaging volunteers using an oversized shopping cart.
Scott Breen is vice president of sustainability at the Can Manufacturers Institute (CMI). CMI represents U.S. metal can manufacturers and their suppliers. His responsibilities include promoting the can as a sustainable/circular package, advocating for federal and state legislation and regulation that reflect the can’s sustainability advantages, and leading the industry’s efforts to build upon the can industry’s leading recycling rates. Scott’s roles prior to CMI were associate manager of the Sustainability and Circular Economy Program at the U.S. Chamber of Commerce Foundation and attorney-adviser at the National Oceanic and Atmospheric Administration. Along with his position at CMI, Scott also explores various aspects of sustainability as creator and co-host of the podcast Sustainability Defined. Sustainability Defined has monthly episodes that reach thousands of listeners across more than 100 countries and all 50 states.
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Q1 2023 [7]
Round Table Round Table Discussion
Addressing Industry Challenges Advice from Industry Experts
Peter Lockley INX Europe
We are entering another challenging year made even more opaque by world events and domestic politics. Recession threats, inflation, continued staffing hurdles and a general feeling of malaise throughout most of the population is adding to the uncertainty. With these challenges in mind, we asked leaders in our industry what they will be focusing on in 2023. IMDPA: With an eye on 2023 challenges, of all the potential threats facing your business this year, what do you see as the most pressing challenge? What has been your solution? Peter Lockley, INX Europe It’s a very uncertain time. It seems that the world is still feeling the after-effects of the Covid pandemic, just as war in Ukraine and tension between China and US threaten everyone’s attempts to create a sustained recovery. I think that the most pressing challenge we face is to try to balance cost optimisation with the need to ensure strong supply chains and a capable & motivated workforce. As growth slows down and consumers feel less affluent, all of our businesses look to pressures on short term profitability, but we also need to remember the lessons we learned in 2021/22. At INX, we are continuing to emphasise the importance of Business Continuity Planning whilst engaging with our workforce and external supply chain partners to create an emphasis on creating value, not simply saving costs. Paul Fennessy, Crown Cork & Seal In essence, most pressing challenge: Strained supply chain and customers in need—no room for error ever, but especially these days.
Paul Fennessy Crown Cork & Seal
Levi Boss Director, Graphics CoE Leader, Ball Corporation
Tim Feaver CEO, CANIMAL
Martin Killgallon
Our contributors have decades of experience addressing crisis downtime for the metal printing industry. All agree that with routine maintenance, most issues can be avoided.. President, The Ohio Art Company
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[8] Q1 2023
attractive ZombieCans with quality as good or better than the originals. With feedback and support from industry partners, we are building progressively more capable hardware integrations based on cutting-edge automation products in a step-wise development plan that will produce millions of ZombieCans per month. This will make it easier to attract and retain a qualified labor force by reducing hand labor, improving work conditions, and increasing per-person productivity. Martin Killgallon, The Ohio Art Company The events of the past few years have sped up reshoring efforts of manufactured goods and components. This represents both an opportunity and a challenge for our industry. Ohio Art is focusing on re-positioning the company for this opportunity through investments in our people, new equipment and renewed focus on our supply chain including developing new relationships, cultivating existing relationships and working to ensure we have reliable secondary suppliers in place. Developing the most dynamic manufacturing sector in the world is exciting – as a country, we have done it before and can do it again!
Our solution: Investing in capacity regionally where it best supports customers but continuing to back their projects with design/deco guidance from our global team of experts. Levi Boss, Director, Ball Corporation First, education and workforce development. Second, addressing the skills gap by collaborating with industry experts to identify the skills and knowledge required for deco jobs. We will increase access to job training and career development recourses, especially in the deco communities. Tim Feaver, CANIMAL What do you see as the most pressing challenge? As is commonly said: when people are happy, they drink; when people are sad, they drink. In that respect, our go-to-market plan of initially targeting brewers helps to recession-proof CANIMAL and our ZombieCans™ product ramp up. Also, the need for brewers and can decorators to go greener isn’t being dampened, so a product that saves more than 95% of the energy and water (like ours) is still in high demand. That said, we are also making sure brewers know that the right can-packaging strategy doesn’t just save money - it can generate revenue! A green, innovative product like ZombieCans™ offers new profits to canmakers, an attractive product differentiator to packagers and supply chains, and a superior platform for digital direct-to-can printing. Our biggest challenge now is ramping our pilot production capacity rapidly enough to meet demand - both from customers and from canmakers looking to process their unused but unsellable printed “orphan” cans. Plus, attracting and retaining production operators (aka staffing) is a continuing challenge. What has been your solution? We continue to double down on communicating the message that innovation = increased revenue potential. This is more than a savings platform, it’s a revenue producing platform. On the production side, CANIMAL designed and built a pilot production line with modest capacity, proving that we can convert printed unused “orphan” cans into
The Canmaker Gold Club
The gateway to business intelligence and networking opportunities for metal packaging professionals
Join the club: canmaker.com/goldclub
FUNDAMETALS Newsletter
Q1 2023 [9]
Technical Resources
Can Washer Process By Andy Raynor, Stolle Why do we clean the cans? We must chemically clean aluminium formed products. The aluminium cleaning is to remove residual aluminium swarf, oil, smut, surface oxides and, most importantly, the near-surface disturbed layer as to provide a uniform surface to receive further treatment. The metal forming processes create the near-surface disturbed layer. This is due to the severe shear strain in the near-surface region from the interaction between the aluminium surface and the steel surfaces.
The disturbed layer nano-sized grains with grain boundaries decorated and pinned by oxide particles and lubricant residues. The removal of the near-surface disturbed layer is critical for the pre-treatment to be successful.
Where does the can washer sit in the line? The beverage can washer and dryer systems sits in the can making line between the Body Makers and the lacquer sprays and/or Basecoater. The washer has a number of tasks, the first is to clean the loose residues off the can following the metal forming processes. These residues include swarf and organic oils which are applied to keep the metal surfaces lubricated and cool during the intense mechanical pressures used to form the aluminum sheet into containers. The washer also prepares the aluminum
cans using acidic washing processes and rinsing to produce a bright shinny can that is dried prior to the cans being presented to the lacquer sprays/basecoater and decorating processes down stream. It is very important that the washer processes, both mechanical and chemical, are fully understood to ensure that the ever increasing production demands are satisfied. The washer system is a complex integration of mechanical spraying technology and chemical control to ensure the washer is as efficient as possible therefore reducing the cost of can manufacture.
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History of can washing The beverage can washing process was created from the areo industry, used to prepare aircraft flying surfaces The washing process was developed with the aluminum two piece can manufacturing developments in the 1950/60’s, but it has not significantly changed for many years. There have been developments over the last few years to improve efficiency and reduce water usages.
How is good cleaning achieved? To achieve cleaning with the utmost excellence, a simple way is to consider the following important variable factors. Chemical Action – It is very important to understand the chemistry which is summarized as follows:- The acid cleaning processes (Stages 1 & 2) are usually based on sulphuric (H2SO4) or phosphoric (H3PO4) acid solutions and surfactants. However, hydrofluoric acid (HF) is added as an activator. Surfactants are also added to prevent re-attachment of contaminants. A number of washer systems include a treatment stage (Stage 4) which is designed to apply a Zirconium coating to the cans to prevent corrosion during the sterilization process prior to filling the cans. There is a final stage (Stage 7) which has been included in the last few years. This process applies a Mobility Enhancer (M.E.) coating to the outside surface of the cans to reduce surface friction to improve the mechanical can handling at the higher throughput speeds now being demanded. Mechanical action – The cans are transported through the washer tunnel on an open mesh conveyor belt. The cans are transported through a number of separate stages which contain a duplicity of spray nozzles. The different spray systems are designed to create spray pattern that provides a mechanical cleaning action to create liquid forces to remove residues, to create an even distribution of chemicals in and around the can. There are spray systems which create an even water distribution pattern to rinse the cans after each chemical treatment stage with clean water.
The spray systems comprise plurality of spray bars which are populated with proprietary nozzles. The sprayed liquid is contained in a tank and pumped to the nozzles via a complex series of pipes and valves. The pressures and flows are accurately controlled to ensure efficient operation and good can coverage. Temperature – Temperature of the chemical stages is very important to ensure the chemical reaction with the aluminum takes place effectively. The correct temperatures also prevent unwanted effects such as foaming. The typical acid cleaning Stages are designed to operate in a temperatureof 50 – 70 °C. The Chemical Treatment, Stage 4, operates at a temperature of 45 °C. The Rinse Stages and the M.E. stages are not heated but generally acquire a temperature of about 20—40 °C depending upon ambient conditions. Time / Impacts – The time and frequency of the cans being exposed to the sprays within the chemical stages has a direct effect on the efficacy of the cleaning and treatment processes. If the cans are exposed to the chemical spray for a short time the chemical will be reactive when it is being sprayed onto the cans. The chemical quickly becomes non-reactive when no spray is being applied. It is proven that if the cans are continuously exposed to sprayed liquid the cleaning becomes more effective. Stolle have developed modern spraying systems that maximise the number of spray impacts that can be applied to the cans and this has been proven to provide good clean cans at the higher speeds and the design has reduced chemical usage and therefore costs. Typical residence times used have been between 5 and 60 seconds, but these are under review.
Continued on page 12
Andy Raynor is Product Director for Stolle’s Can Washer & Thermal Process Product Lines based out of Altham Offices in the UK. He has over the 19 years’ experience in the can making industry specialising originally in thermodynamics and was responsible for the design and manufacture of 2 Pc Can Making Ovens, before moving into fluid dynamics and applying his experience in Can Washing and Drying. Andy is now involved in implementing sustainability strategies across both the Washer & Ovens Products. He has held numerous roles throughout his career prior to joining Stolle in 2017, from Design Engineer, through to Service Engineer/Manager onto Operations and then Technical Director. Andy is a time served Mechanical Engineer serving his apprenticeship originally in the car industry before moving into can making back in 2003.
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Typical Washing Process Sequence
Can Movement Stages 3A, B & C- First Multiple Rinses
The Can Washer Stage 0 - Initial Rinse
The liquid in Stage 2 is highly acidic; if a small quantity of this liquid from Stage 2 enters the Stage 4 tank, the acidity in this tank would plumet causing the chemical control system in stage 4 to close down. The chemical imbalance would cause exception failures as the cans pass through the quality control processes. The impact of these can failures would mean that large numbers of cans would be scrapped causing financial loss. Residual chemicals are removed by passing the cans through a number of separate rinse stages where treated water, supplied from a ’Reverse Osmosis’ process, is sprayed onto the cans. How can we tell if the rinsing is working? The effectiveness of the rinsing processes are managed using a technology called conductivity. Conductivity is how much electrical current will pass through the liquid. The small electric current is measured in micro Siemens. The principal is that acid content in the allows more current to flow therefore producing a higher number of micro Siemens, shown on the ‘Y Scale’. The graph below indicates how the conductivity is like to fall as the cans pass through the rinsing processes. Rinse 1
The purpose of Stage 0 is to re-wet and remove loosely bound organic “soils” i.e. soluble lubricants from the cupper and body making operation, rolling oils, tramp oil and general dirt and aluminum swarf from the can surfaces. An air blowdown nozzle is fitted across the full width of the washer. This is designed to move liquid from the inverted can dome because the rim of the cans sit on the conveyor. Can Washing Stage 1 - Pre Wash The purpose of stage 1 is to chemically remove the organic “soils” that are chemically attached to the can after the Stage 0-Initial Rise Stage. This stage is a heated stage designed to spray diluted Sulphuric Acid onto the can surfaces using spray nozzles at pressure (~ 2.5 bar). These nozzles produce high impact forces which would lift the cans and disturb the can pack; to prevent this a Hold Down conveyor is installed to hold the cans in place. The organic soils removed from the cans can cause a build- up of oil in the supply tank. To keep the liquid system clean, a coalescer (i.e. oil/water separator) is fitted to remove excess oil. Stage 2 - Wash The purpose of stage 2 is designed to chemically remove any remaining organic soils and surface inorganics (i.e. aluminum “fines” and oxides). The liquid sprayed onto the can surfaces is a ‘cocktail’ of diluted chemicals to clean and etch the surface, removing the Disturbed Layer producing a bright, chemically clean can ready for further treatment in stage 4. This stage is also a heated stage with high pressure nozzles, hold down conveyor and coalescer.
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Stage 4 - Treatment The purpose of this stage is to treat the can to a coating of Zirconium which is a chemically applied to the aluminum in order to achieve a thin, electrically-conductive conversion coating that will provide corrosion resistance. The corrosion resistance is to prevent discoloration of the base when the decorated cans are passed through the ‘FILLERS’ retort sterilization process prior to filling the cans with the consumer liquids. There are some requirements that do not require the cans to be treated. The can maker will request that the washer is fitted with a treatment stage or not as determined by their customers requirements. The treatment stage is a heated process where a chemical cocktail containing Zirconium Phosphate is diluted and sprayed onto the cans to deposit a microscopically thin layer of Zirconium onto the can surfaces. Can Washing Stages 5 & 6 - Second Multiple Rinses It is important that all residual chemical salts are removed from the cans surfaces by passing the cans through a number of separate rinse stages where demineralized or Deionized water is sprayed onto the cans. The graph below indicates how the conductivity is likely to fall as the cans pass through the four rinsing processes.
Stage 7 - Mobility Enhancer (M.E.) As the throughput of the can making lines have increased and the cans travel at higher speeds have caused mechanical handling problems because the uncoated cans are prone to sticking together. The purpose of this stage is to spray a chemical known as a Mobility Enhancer (M.E.) onto the can external surfaces. M.E. reduces the surface tensions between the cans preventing them sticking together as they travel to the downstream to the lacquer and decoration processes. Can Drying The cans leave the Washer and presented to a Vacuum Transfer Unit which transfers the cans, using vacuum technology, to the can dryer. The cans are placed onto the dryer conveyor belt which transfers the cans into the Washer Dryer cavity. Hot air is blown onto the cans which elevates the temperature of the can and any moisture that is on the surface of the can. As the temperature of the can rises, the thermal energy, the water evaporates and is removed and discharged to atmosphere. The dried cans are conveyed past a quality control station where sample cans are removed and tested. If the quality of the bulk can pack is acceptable the cans proceed on a conveyor belt to the internal spray stage where the cans are internally sprayed with lacquer. Prior to being dried and then decorated. Recent Developments For many years deionized water has been used as the main source of water to finally rinse the cans prior to drying However, the De-Ionizing process is capital intensive and the operating costs are expensive Over the last few years the Reverse Osmosis (R O) process has been used to produce de-mineralized water to rinse the cans The R O process is proving to be a cost effective option The Stolle washers have developed innovative technology in conjunction with the can makers to provide significant water saving.
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Webinars
EXCLUSIVE MEMBER ONLY ACCESS The IMDPA provides educational webinars that deliver focused content and programming for our membership delivered by industry experts. If you don’t catch it live, they are recorded and available on-demand for members. Did you know?
Members can log into Growth Zone App access this exclusive content
Troubleshooting Common Ink Issues Presenters Carl Thomsen and Shawn Swinden from INX Int’l take an expert deep-dive into how to diagnose and address the most common ink issues plaguing metal decorators today. With over 22 years in the metal decorating arena, Carl and Shawn will share their knowledge and experience as well as his tips and tricks on how to identify, diagnose and remedy the most common ink issues facing today’s metal decorators. Troubleshooting Common Coating Issues We take an expert deep-dive in to the most prevalent coating issues for metal decorators. The team reviews common problems, their causes and their remedies. With over 85 years of hands-on experience and training between them, there isn’t a coating issue or challenge they haven’t seen and conquered. Curing 101 Pt 1 by Jeff Robinson of ES&T An in-depth look into the history, operation and future of oven curing and oxidizers for the flat sheet litho industry. Jeffrey Robinson, President of Environmental Services & Technology, an expert in all things relating to flat sheet curing, will be presenting this seminar. With over 55 years in this business, Jeff will share his expertise and anecdotes from a life-time of helping our industry keep their ovens running efficiently and consistently. Curing 101 Pt 2 by John Clark of Heraeus An informative in depth review of UV Curing Technology including Microwave, Arc, and UV LED platforms. Topics for discussion will include UV Applications and Fundamentals, Benefits, UV System Hardware Designs and Best Maintenance Practices. John has over 30 years experience in the UV Technology and Metal Packaging Industries.
Demystifying Global Regulatory Requirements for the Metal Decorating and Packaging Industry The regulatory landscape is shifting rapidly in our industry and metal packaging professionals are often caught off guard by new regulations, codes and classifications. Rebecca Lipscomb, INX’s Director of Global Affairs, takes us on a tour of the most recent changes in global regulatory requirements for metal printing and packaging. She’ll cover the latest changes in GHS classifications as well as provide a glimpse into what we can expect to see in the next 12 months. Inks 101 by Alex Folloso of INX International Alex Folloso, Director of Metal Deco Technology for INX International takes in depth look at the ink chemistries used today for metal decorating. The history of the inks used in metal packaging goes back more than a century when the first lithography machines began using color to distinguish brands on grocery shelves. During this webinar we will present an overview of the ink making process, review different ink chemistries and their applications, and provide an update on industry trends and regulations.
Coatings 101 by James Robinson of Sherwin Williams
James Robinson, Technical Director Global Food, Sherwin- Williams, takes a deep dive into the chemistry of coatings used today in the metal decorating industry. Coatings are the key to the versatility, longevity and dependability of metal packaging. During this webinar, you’ll learn about the history and future of the coating industry from tried and true options, to new coating development for improved performance and more environmentally sound options.
FUNDAMETALS Newsletter
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FUNDAMETALS Newsletter
Q1 2023 [ 15 ]
New Officers
O ur team of volunteers works diligently to provide the membership valuable services that foster and encourage improvements and advances in the art of metal decorating and packaging The collective efforts from our committee members are led by the leadership team of the Board of Directors. IMDPA Officers serve 2-year terms in each of three positions – President, Vice President and Secretary/Treasurer If you would like to take a more active role in the association please reach out to any of our officers below.
Kyle Hurla, Secretary & Treasurer
John Clark, President
Tim began his career at Ball in the Golden Colorado plant as an operator in the end line in 1987. He spent 10 years at the Golden Plant prior to moving to the Corporate offices in Broomfield where he landed in the Quality and Graphics departments. From there, Tim went to Ardagh in California for 2 years for a line startup, then moved to Canpack in 2021 where he is currently the Regional Quality and Graphics Manager. “ The IMDPA is an organization that promotes the improvement of our industry and allows people world-wide an opportunity to meet, collaborate and learn from each other about the can making process. I believe this produces new ideas and partnerships that help suppliers promote their new ideas and products, and likewise allows can makers to improve their can making processes. As an officer, I am very much looking forward to furthering the mission of the IMPDA to help all members and their companies to not only be profitable and successful, but also companies that are recognized as responsible leaders in the can-making industry.” Tim Duca, Vice President
John began his career in the UV Curing Industry in 1988 working for AETEK UV Systems in Plainfield IL. In 1988 he went to work for Fusion UV Systems as a Regional Manager in 1993. It was there he worked with Crown and Akzo on the development of a UV Coating process to apply and cure a mobility coating to the bottom rim of 2 Piece Beverage Cans. While with Fusion he was also responsible for the Coors Beverage Can Account. Coors was the first to commercially use UV Inks and Coatings for the side wall decoration of 2 Piece Cans. He now works for Heraeus which purchased Fusion in 2013 and has a global presence around the world. “The IMDPA has always been a great organization to be a part of. For me, it provided great networking opportunities early in my career, educational information and connections to all facets of the metal packaging industry. I am absolutely looking forward my term as President to help continue the legacy this great organization has provided so many of us in the metal packaging industry.”
Kyle began his career with INX International in 1997 , first learning ink chemistry in the lab and then moving into a General Manager role in Utah and California. During his GM role he also began to take on account management of our INX 3pc metal customer base. In 2011 after learning about digital printing from INX Digital Hardware division he began managing digital metal ink projects. “I attended my first IMDPA conference in 2005. Shortly after that I began participating on the conference planning committee and became Golf Chair in 2014. I enjoy working with all the IMDPA volunteers from multiple companies that are the backbone of what makes up the IMDPA. I am looking forward to the challenges of being an officer on the executive committee. I look forward to helping the IMDPA grow memberships and grow the number of volunteers participating on sub committees.”
IMDPA Annual Conference and Exhibition EAGLEWOOD RESORT September 26–28, 2023 Itasca, IL
FUNDAMETALS Newsletter
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Membership Brief
Welcome New Members!
2023 Industry Events
MetPack May 2-6 Essen, Germany Craft Brewers Conference May 7-10 Nashville, TN
LatamCan Conference July 12-14, 2023 Mexico City IMDPA ANNUAL CONFERENCE September 26-28 Itasca, IL
Asia Can Tech October 30– November 1 Bangkok, Thailand Canmaker Summit October 11-12 Edinburgh, Scotland
We are pleased to have the following industry personnel as new members of our Association and look forward to many years of participation in membership activities:
Philip Burgess Ardagh Group Derek Swick Can manufacturers Institute Rex Learmouth Deco Technology Group Inc.
Jeanie Morris INX International Shawn Swinden INX International Matthew Peschisolido Phillips Brewing
Membership Dues Reminder
Stay up-to-date on social media For the latest news and event information, connect with IMPDA on Facebook, Twitter and LinkedIn While you’re at it don’t forget to like, share and comment on our posts! IMDPA Committees The IMDPA is constantly seeking active committee members and future association leaders If you want to get more involved please reach out to those officers and directors attending and express your wishes You can also email us at info@metaldecorators or contact us through metaldecorators org
2023 dues were sent out in January with a slight increase to 95 00 per year for 2023 Dues have not been increased in many years and after careful consideration, the Board decided that the increase was needed to keep our Association financially strong. Thank you for your continued support
Now accepting 2023 scholarship applications
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Luke Fassoth First Place $2,000
Since its inception the IMDPA has awarded nearly $100,000 in education grants which have been distributed to IMDPA family members as partial college scholarships to be used to offset some of the high costs of higher education. This year the Association awarded the following students with scholarship money. Learn more at: https://conta cc/3Xb1s3d
Membership Statistics (as of October 3, 2022)
Members 393; Honorary 21; Privileged 22; TOTAL: 436
Interested in becoming a member? Join us! www.metaldecorators.org/membership
FUNDAMETALS Newsletter
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U.S. Aluminum’s Economic Impact Report by Aluminum Association The U.S. aluminum industry is a key element of the nation’s manufacturing base. Strong, lightweight and recyclable, aluminum is a material uniquely suited to meet the needs and challenges of the 21st century. From increasing vehicle fuel efficiency to green building products to sustainable packaging, aluminum is well positioned in the U.S. and global markets. For nearly a decade, the Aluminum Association has worked with research firm John Dunham & Associates to produce economic impact impact studies that capture U.S. aluminum jobs, wages, output and other information on an ongoing basis. Today, the U.S. aluminum industry: • Directly employs more than 164,000 workers and indirectly supports an additional 470,000 workers. • Directly generates more than $73 billion in economic output and indirectly generates an additional $103 billion in economic output. • Supports more than 6 34,000 direct, indirect and induced jobs and more than $176 billion in economic output . • Committed or invested more than $7 billion in domestic manufacturing since 2013. The 2022 impact study highlights the importance of the aluminum industry to the U.S. economy. The aluminum industry is a dynamic part of the U.S. economy, accounting for about $176.32 billion in total economic output or roughly 0.73 percent of GDP.1 Aluminum manufacturers and wholesalers directly employ 164,402 Americans in 2022. These workers earn over $13.55 billion in wages and benefits. When supplier and induced impacts are taken into account, the aluminum industry is responsible for 634,419 jobs in the United States and $47.10 billion in wages; as well as $14.97 billion in direct federal, state and local taxes; not including state and local sales taxes imposed on aluminum products.
To Download the Full Report, visit www.aluminum.org/economy
FUNDAMETALS Newsletter
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It’s time to enter The Canmaker Cans of the Year Awards Recognising and celebrating the best in metal packaging
the-canmaker-magazine-cans-of-the-year
cansoftheyear.com
Noblelight
Look to Heraeus Noblelight for: Expertise in metal packaging coating and decorating In-house/in-plant UV cure testing capabilities Reliable UV curing solutions Is UV Curing Right for Your Production?
UV Process Experts Heraeus Noblelight America LLC Gaithersburg, Maryland 20878, USA Phone: 301 527 2660
Info.hna.uvp@heraeus.com Heraeus-noblelight.com/uvbc
Explore the possibilities with the #1 can UV curing supplier.
FUNDAMETALS Newsletter
Q1 2023 [ 19 ]
IMDPA RESOURCES DIRECTORY
AIR POLLUTION CONTROL
COATING, PRESS 2-PIECE ROLLERS
John M Travis Ltd 27031 Trinity Heights San Antonio, TX 78261 Tel: +1 740-407-0685 travisltd com
Grace Davison Materials & Packaging 7500 Grace Drive Columbia, MD 21044 USA Tel: +1 410-531-4000 bryan t pugh@grace com Henkel Corporation 32100 Stephenson Hwy Madison Heights, MI 48071 Tel: +1 248-577-2243 henkelna com
Anguil Environmental Systems 8855 N 55th Street Milwaukee, WI 53211 USA Tel: +1 414-365-6400 anguil com Babcock & Wilcox Megtec Systems 830 Prosper Street De Pere, WI 54115 Tel: +1 920-337-1505 megtec com The CMM Group 2071-C Lawrence Drive De Pere, WI 54115 Tel: +1 920-336-9800 thecmmgroup com Catalytic Products International 980 Ensell Road Lake Zurich, IL 60047 Tel: +1 847-438-0334 cpilink com Environmental Services & Technologies 4941 41st Street Moline, IL 61265 USA Tel: +1 309-762-9551 envsrvcom Epcon Industrial Systems PO Box 7060 The Woodlands, TX 77387 Tel: +1 936-273-3300 epconlp com epcon@epconlp com Pro-Environmental, Inc 10134 6th Street, Suite K Rancho Cucamonga, CA 91730 Tel: +1 909-898-3010
Bottcher Systems 4600 Mercedes Drive Belcamp, MD 21017 USA Tel: +1 800-637-8120 bottcher com Finzer Roller, Inc 129 Rawls Road Des Plaines, IL 60018 USA finzerroller.com Hannecard Roller Coatings, Inc./ASB Industries 1031 Lambert Street Barberton, OH 44203 Tel: +1 330-753-8458 hannecard com asbindustries com Pacesetter Graphic Service Corp. 2672 Hickory Grove Road Rollercoat Industries 10135 Hwy 62 East Tampa, FL 33610 USA Tel: +1 800-248-4351 rollercoat com Urethane Roller Specialists 100 S Central Ave PO Box 566 Eureka, MO 63025 USA Tel: +1 800-367-1136 urethaneroller com Acworth, GA 30101 pacesetterusa com
BLANKETS
Continental Surface Solutions 4021 N 56th Street Lincoln, NE 68504
Tel: +1 800-235-4632 www continental com
COATINGS
DYC Supply 5740 Bay Side Road Virginia Beach, VA 23455 USA Tel: +1 800-446-8240 www d-y-c com
AkzoNobel Packaging Coatings 16651 Sprague Road Strongsville, OH 44136 USA Tel: +1 440-297-5589 akzonobel com Jamestown Coatings 108 Main Street Jamestown, PA 16134 Tel: +1 724-932-3101 jamestowncoatings com PPG Industries 500 TechneCenter Drive Milford, OH 45150 Tel: +1 513-576-3100 packagingcoatings com Prime Coatings 1002 Hickory Street Pewaukee, WI 53072 USA Tel: +1 262-691-1930 primecoatings net The Shewin-Williams Co. 2001 Tracy Street Pittsburgh, PA 15233 USA Tel: +1 412-766-9300 packaging@valspar com
Package Print Technology 1831 Niagara Street Buffalo, NY 14207 USA Tel: +1 800-382-8851 packageprinttech com
Trelleborg Printing Solutions 5680 Commerce Blvd Morristown, TN 37814 Tel: +1 339-236-5745 trelleborg com
BODYMAKER Spare Parts
Beckon Worldwide Inc 455 E Clinton Place St Louis, MO 63122 USA Tel: +1 314-965-0755 beckonworldwide com Stolle Machinery 6949 South Potomac Street
COIL LAMINATION SYSTEMS
Centennial, CO 80112 Tel: +1 303-708-9044 stollemachinery com
Can Components Corp. 201 South Biscayne Blvd 28th floor Miami, Florida 33131 Tel: +1 305-868-4343
ANILOX SYSTEMS
COATING APPLICATION SYSTEMS
CHEMICALS & MATERIALS
Art International 16745 Cagan Crossings Ste 102B-69 Clermont, FL 34714 Tel: +1 831-295-2969 anilox@me com
Nordson Corporation 300 Nordson Drive Amherst, OH 44001 Tel: +1 440-985-4000 nordson com/container
Coral Chemical Company (see Lubricants & Cleaners)
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