1/2 Gallon Blue/White HDPE Plastic Round Jug, 38mm 38-400
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Paneling occurs when the pressure inside a plastic bottle becomes less than the ambient air pressure outside, causing the walls of the bottle to partially collapse inward. The result is an aesthetically unappealing product package with a distorted shape and badly puckered or wrinkled labels. This is most noticeable in the case of bottles that are hot filled and sealed before cooling. This negative pressure can cause the side panels to suck in to compensate for the loss of product volume.
Increase the structural integrity of the bottle walls through design mechanics means such as ribbing or vacuum panels - think Gatorade bottle. Ensure your bottle is of proper gram weight and consistent wall thickness to combat paneling. One of the most effective solutions to combat panel sink is to improve the structural integrity of the bottle by slightly changing the shape, from a cylinder to an oval for example.
The design change adds structural integrity by replacing flat areas with a more rigid surface that can resist the pressure. Since oxygen comprises about 16 percent of the volume of air, reducing its concentration can significantly reduce the bottle's internal pressure, leading to bottle paneling. Cause 3 - Gas Permeation through Bottle Walls It is possible that the walls of the bottle may be permeable to the vapor of one or more of the ingredients in the product.
PET, on the other hand, is an excellent oxygen barrier but not a great water vapor barrier. Any vapor permeation through the bottle walls can result in unequal pressure and paneling. Change to a resin with barrier properties that match the requirements of the ingredient s causing the problem.
Consider utilizing a barrier, such as fluorination or a multi-layer barrier resin in the design of the bottle. Fluorination also reduces the chemical permeation, weight loss, odor emission, and flavor or fragrance loss. The liners allow gas and moisture to pass in or out of the container. Remember, any change in resin would require elevated stability and compatibility studies in order to ensure there will be no adverse reactions between the product and container resin.
Cause 4 - Fill Processing In some cases, machinery used to package to the product may pinch or compress the bottle before capping, reducing the volume and the pressure inside the container. If the packaging machinery cannot be economically replaced, the solution may lie in redesigning the container itself. Effective design changes could include:. Fillers should review their manufacturing and production processes for any possible mechanical situations that may be causing panel compression i.
Cause 5 - Environmental Conditions To avoid paneling issues, environmental conditions, such as altitude, temperature and relative humidity, also need to be taken into account. When a product is packaged at an elevation of over 5, feet, for example, its internal pressure will be equal to the external atmospheric pressure, which is considerably lower than that at sea level. If the product is later sold at sea level, the difference in internal and external pressures can cause paneling — and this just one example of how environmental conditions can affect this issue.
This can be an excellent solution for containers that fill product at high altitude and then ship to distribution at lower geographic elevations. Pressurize the bottle slightly during filling to compensate for the drop in atmospheric pressure. Consider treating both the bottle and cap with a fluoration process that will serve as a barrier against the problem ingredient s. If your current containers are experiencing paneling or any other difficulties, give the packaging professionals at O.
We ready to help identify the causes and find the cures. Containers Containers Glass containers, plastic containers, metal containers, thousands of selections, limitless possibilites.
Fortunately, the causes of paneling are easy to identify and just as easy to avoid. Here are five common causes and their cures: Conversely, when air inside a closed container is cooled, it contracts, reducing the internal pressure and triggering the conditions that can cause paneling. Five Helpful Solutions Allow the hot filled bottle to cool before sealing it. Reduce the headspace in the bottle by increasing the fill level. Three Helpful Solutions Reformulate the product to remove ingredients with which oxygen is reacting.
Purge the headspace with liquid nitrogen in order to remove oxygen before the bottle is sealed. Increase the fill level of the product to reduce the size of the headspace and minimize the effect of oxygen absorption. Four Helpful Solutions Reformulate the product to eliminate the problem ingredient s. Effective design changes could include:
