Chapter 1

Introduction of Tin Can History

It was in the year 1810, when King George of England awarded a patent on the tin
can, which was a crucial turning point in the can making process. From this point on cans
were to be produced commercially, although the rudimentary technology of the time meant
that a person could only produce approximately ten per day.

Public Demand for Canned Foods Grows

The very first commercial canning operation was established in 1812 on the New York
waterfront, to can and market oysters. However; it wasn't until the discovery of the California
gold fields in the 1840's when public demand for canned foods exploded. This unprecedented
demand for canned foods spurned on inventors to develop faster and more efficient means of
producing cans.

More Developments

Simple, yet effective early technological developments increased the production

level of commercially produced cans up to 60+ per day, per worker. One event that was to
permanently change the design of the modern can was the development of the "folded seem"
in Europe, in 1900. However; it wasn't until the industrial revolution of the 1920's that the
first commercial machinery was developed that could effectively mass produce cans.

The Aluminum Can is Born

During the 1940's, beverage manufacturers began exploring the concept of canning
and distributing carbonated drinks in cans and it wasn't long before they were readily
available on store shelves. However; it wasn't until the mid 1960's that the aluminum can, as
we know it today was introduced to the public. Due to its numerous positive manufacturing
and user attributes, the aluminum can quickly replaced steel cans as the container of choice
for beverages.

1
Evolution of the Pop Top

The original aluminum drink can had a pop top that was completely dis-attached
from the can when it was opened. It was the drinking publics penchant for carelessly
discarding this pop top, or stuffing it back in the can that sowed the seeds for another
technological change. This is because, all too often the pop tops were either carelessly gulped
down by enthusiastic drinkers or stepped on, leading to nasty gashes on the foot.

Thousands per Minute

So, a newer style of aluminum drink can soon made its debut in the later half of the
1960's that implemented a pop-top that remained safely attached to the drink can. Today’s
technology allows for cans to be commercial produced at a rate that renders them only a
"blur" as that speed past the eye on the assembly line and one can only wonder what new
technological innovations are in the cans future.

Near Perfection in Form and Function

One thing is for certain though and that is that the humble hermetically sealed can
has serviced mankind well and most likely will continue to do so for many years to come.
Even if changes do come to the can, there can be no doubt that the simple perfection in its
shape and function will remain unchanged. For, while the technology that goes into the
production of the can has changed much over the centuries, the can itself has remained true
to its form and function.

2
 Chapter 2

INTRODUCTION OF PACKAGING
Packaging is among the high growth industries in India. A high degree of potential
exists for almost all user segments which are expanding appreciably - Processessed foods,
hard and soft drinks, fruit and marine products, cosmetics and personal care, office stationary
and accessories, fabrics and garments, white goods and other durables, electrical appliances
and equipments, entertainment and other electronics, shoes and leather ware, gems and
jewellery, toys and sports goods, chemicals and fertilizers. Due to lower manufacturing costs,
India is fast becoming a preferred hub for packaging production. The Indian packaging
industry has made a mark with its exports that comprise flattened cans, printed sheets and
components, plastic film laminates, craft paper, paper board and packaging machinery, while
the imports include tinplate, coating and lining compounds and others. In India, the fastest
growing packaging segments are laminates and flexible packaging, especially PET and
woven sacks.
The market size for packaging materials & systems for food, pharmaceuticals,
cosmetics, toiletries, Ind. products, textiles, handicrafts, etc. accounts for  4%, while rigid &
semi-rigid  plastic containers is about 9%.The metal and tin containers accounts for 10%,
glass containers 10% , corrugated board & boxes 23%, paper & paper board 36% and other
ancillary materials  like tapes straps, labels, adhesives, etc. - 8%.
Upgradation, both of functionality and aesthetics, characterizes the recent trends in the
industry. Elaborate and more expensive packaging is penetrating deeper into marketing of
industrial products and even agro-based products, like food and personal care products, drugs
and pharmaceuticals, consumer durables and electronic products, especially entertainment
products.
Packaging market size in India is about Rs 65,000 crore is growing at the rate of 15
per cent per annum. Currently rigid packaging enjoys more than 65% market share but the
traditional rigid packaging users are migrating to flexible packaging in a big way. Market
size of PET/BOPP and other flexible film-based manufacturing segment is estimated at
around Rs 25 billion. The overall growth rate of the industry has tapered off to around 9%.
The flexible packaging industry is expected to grow at about 10-15% per annum in the
coming years. The laminated products are growing at around 30% p.a. There are about 600-
700 packaging machinery manufacturers, 95% of which are in the small and medium sector
located all over India.

3
The top  packaging companies of India includes Parksons Packaging System , ITC Limited ,
Hindalco , Tata Tinplate Company of India , Moldtek Technologies Limited , Gujarat Glass
Ltd , Advance Packaging , AMAC Plastic Packaging,  E C Packaging Pvt. Ltd, The Paper
Products Limited.etc.
The large and fast growing Indian middle class population and the growth of
organized retail sector are the catalysts to growth in packaging. Packaging of essential
products like food, beverage, milk, vegetable, food grains and pharma are the key driving
segments because of the huge domestic consumption.

There are two types of packaging as:

1. Metal Packaging – Tin plate, TFS (Tin free steel), Black plate, aluminum is used for
packaging purpose.
2. Non Metal Packaging –Plastic, Paper are the material used for packaging purpose.

Metal packaging:
 Products like food & Beverage
 OTS (Open Top Sanitary)
 Paints, Pesticides, coffee, milk foods
Types of Metal Packaging
1. Two Piece Can Packaging
a. DRD – Drowned and Re-drowned
b. DWI – Drowned and Walled Ironed
2. Three Piece Can Packaging
a. Round
b. Irregular

4
 Chapter 3

COMPANY PROFILE AND PRODUCT

PETROX PACKGING (INDIA) PVT. LTD

Petrox is one of the oldest manufacturers of Metal cans in India since last 40 years. We were
one of the first private companies after Multinationals - Metal Box and Poysha (American
Can) to start manufacturing metal cans in India.

The Group companies are:

 Petrox Pvt. Ltd., Petrox Containers,

 Petrox Packaging (India) Pvt. Ltd.
 Sun Extrusions Pvt. Ltd.

The Head Office of the company is located in Wadala.

Our Group companies are engaged in manufacture and sale of metal cans and aluminum
collapsible tubes catering to Pharmaceuticals, Ink industry, Food Processors, etc. Our major
customers are multinational companies.

Our Company is run by experienced professionals in the field of manufacture, marketing and
after sales service.

Services

 Contract packing
 Designing metal packaging & caps/closures to customers requirement
 Packaging consultant
 Developing / innovating new packaging as per customer requirement.
 Providing technical support to customers-

Products

 2 pc drawn food can

 2 pc drawn pesticide & chemical can

5
  2 pc drawn paint can
 Brake oil metal can with plastic inner liner & induction seal plastic cap
 2 pc drawn ink can
 Easy open ends/Peel off easy open lids
 Fancy & decorative can
 Components & closures for metal cans
 Aluminum - collapsible tubes/cans/bottles
 Printed and coated metal sheets

Aerosol Cans

2 Pc. Aerosol Cans

SALIENT FEATURES OF THIS CAN:

 No side and bottom seam - 1 pc. Seam less can body.

 Stackable
 Aesthetically attractive Can
 Robust & Sturdy Can
 Attractive multicolour heat shrink labels can be fixed. Multicolour printing can be
done on 4/6 colour printing machines on the entire surface of the Cans as there is no
side seam weld
 It is a relatively rustproof and leak proof Can compared to 3Pc. Welded Can

Available sizes: 211 & 300

6
7
Brake Oil Metal Can
AN INNOVATIVE CREATION OF A UNIQUE CAN FOR BRAKE
FLUID/AGGRESSIVE CHEMICALS.

Petrox developed a new type of can with a novel idea to make it leak proof and rust proof can
for filling Brake Fluid and aggressive chemicals. . The can is made up of two layers – inner
layer is a plastic sleeve and outer layer with fully printed metal sheet duly seamed at the
bottom and side.

The new invention is to eradicate the problem currently being faced by the Manufacturers of
Brake oil and aggressive chemicals as they often complain about the leakage and rusting of
the can. The leakage is being developed due to development of pin holes due to uneven flow
of electric current during welding, As a result the costly product packed is leaked which is a
great loss to the packer and consumer. Further, rust develops at the welded portion even
though protective lacquer is applied.

UNIQUE FEATURES OF THIS CAN ARE AS FOLLOWS:

 The inside plastic layer is having an in-built plastic neck and a plastic cap with
induction sealing wad for on line sealing of the can to prevent pilferage and
adulteration.

8
  The outer layer is a fully printed metal sheet and side seamed at the joint. Since there
is no welding on the can, there is no chances of rusting at the joint of the can.
 Leak proof – It has one piece internal plastic sleeve along with inbuilt plastic neck.
The advantage is that the can will not leak at any point of time and can withstand the
riggers of handling and transportation even at the terrain places.
 It is a very attractive and appealing can compared to other cans as printing is done
throughout the can.

Available in 3 sizes 5lts. 500ml, 250ml

DRD Conical Pail

 Conical Special press fit tight lid

 wide mouth
 Lid is curled for pilfer proof sealing
 Plastic handles are fixed without welding

SALIENT FEATURES OF THIS CAN:

 No side and bottom seam - 1 pc. Seamless can body.

 Stackable
 Aesthetically attractive Can
 Robust & Sturdy Can
 Attractive multicolour heat shrink labels can be fixed. Multicolour printing can be
done on 4/6 colour printing machines on the entire surface of the Cans as there is no
side seam weld

9
  It is a relatively rustproof and leak proof Can compared to 3Pc. Welded Can

Available in 4 lts. size

Peel Off easy open Lids

In the past cans could only be opened by mechanical means like can openers. More recently
innovative designs of closures EASY PEEL OF LIDS (EPOL) are making a big difference in
the ease of opening a can for the consumers. Today the can has taken a quantum leap forward
with Easy-Peel-Off-Lids (EPOLs) giving this pack form new opportunities for optimum
convenience and refreshing the appearance. By not having to use the can opener the
consumer is also offered a much safer and easy way of opening the can.

It demonstrates that new closure is capable of growing the market and of driving the
business. It is not just a substitution for added service for the consumer, but becomes a
marketing tool that gives real added value to the product packed.

With an EPOL we can make the can appealing and can generate interest in the can. By
refreshing the appearance of the can with EPOL, the image of the product that is packed in
the EPOL containers can get enhanced. EPOL can convey freshness and thus it opens the
market for a whole new range of products. New ways of containing and preserving food
safely and securely which have always been a challenge to the packaging industry. In order
to attract the consumers, convenience of opening a can will play a major role which is
exhibited in the Peel of Lid.

Another critical factor for growth of the can is the cost of it. Considering the advantage of the

10
Peel of lid can consumer does not mind switching over to it though it will be a substitution
market and not a new market.

Customer by and large is looking at the image of the package which in turn will induce the
customer to go in for the goods packed in it. Brand is all important.

This New closure (EPOL) has the potential to enhance the image of the can. Today, the
EPOL is all set to unlock the potential of the can and all its benefits for the consumer and
parties in the supply chain, conveying the message of quality and freshness.
The first experience that consumers have of packaging is when they see the can and the
second is when they open it. In today's world, the ease of opening any package is extremely
important to the consumer and is crucial in achieving a positive view of the brand. Looking
at the can from this view point, a real convenient closure such as Easy Peel Off lid can work
wonders with the appearance of the can and give it a fresher look.

Peel of Lid can have one more added advantage that one can put the hand upto the bottom of
the can without hurting the hand as the edges are rounded and made smooth unlike in the
conventional end or easy open end or RLT (ring lid tagger) closures where the edges are
sharp.

SALIENT FEATURES OF THIS CAN:

 These closures make the can easier to open and more appealing to the consumer.
 Offer brand owners an exciting new tool to attract and satisfy consumes.
 Easy open End is a good example of the added value that closure can give to a can.
 It demonstrates that a new closure is capable of growing the market and of driving the
business.
 It is not just a substitution for added service for the consumer. It becomes a marketing
tool that gives real added value.

Petrox is constantly innovating to improve and develop new and unique packaging concepts
for our customers as per their needs / products. Contact us for assistance...
Creative Solutions Creative Solutions for your closure needs for your closure needs
Size Available: 101 (99mm) & 603 (153mm)

11
Fancy can

 For greater consumer appeal & to Enhance brand image of the product
 Available in attractive shape and sizes

SALIENT FEATURES OF THIS CAN:

 No side and bottom seam - 1 pc. seamless can body.

 Stackable
 Aesthetically attractive Can
 Robust & Sturdy Can
 Attractive multicolour heat shrink lables can be fixed. Multicolour printing can be
done on 4/6 colour printing machines on the entire surface of the Cans as there is no
side seam weld
 It is a relatively rustproof and leak proof Can compared to 3Pc. Welded Can

12
2 PC FOOD CAN

Discarding Conventional 3 Pc Can And Switching Over To Non-Welded 2 Pc Drawn Can

For Product Safety And Preventing Contamination Of Product With Rust

Whenever food items have been packed in 3 pc conventional welded can. It is often noticed
that rusting takes place at the welded portion inside and outside the can - in spite of applying
protective lacquer at the welded portion. Further, due to uneven flow of electric current
during welding, pin holes develop at the welded portion resulting into leakage of can. As a
result the product packed is contaminated with the rust with the result the consumer is
hesitant to consume it and complains to the dealer/manufacturer about the quality. In order to
avoid this problem, the world over, packaging industry after research over a period time
witnessed a revolutionary change and found that 2 pc drawn can is the answer to avoid the
above problem since 2 pc can does not have welding and packing in these can is safer to
prevent contamination with rust.

2 Pc cans are manufactured by drawing and redrawing The 2 pc can have greater consumer
appeal and have the potential to enhance the image of the can. The consumers will be
attracted on looking at the image of the can which in turn will induce them to go in for the
goods packed in it thus benefiting the manufacturers/dealers by increased sale.

As explained earlier, the can is manufactured by drawing and redrawing the metal sheet.
Hence there is no welding at the side or seaming at the bottom of the can. In other words it is
a single piece body can. In the absence of joint/seam, there is no chance of rusting the can.

13
The product packed in the 2 pc can have a longer shelf life since it does not have any weld.
Special type material is used for drawing the can and the body is a rigid single piece one and
hence there is better handling convenience.

Since 2 pc can is a single body can, this is going to be the next generation can replacing the
conventional welded can.

Another critical factor which the consumer look for is the cost of the can. The cost of the 2
pc can will be in the range of the welded can and hence there will not be any additional cost
incurred by the Brand owners in packing their goods in 2 pc cans which is having an
overriding advantage than the welded can as it has got greater consumer appeal.

The 2 pc can is capable of growing the market and boosting the business. These can are
easily available from Petrox Containers.

SALIENT FEATURES:-

 Greater consumer appeal

 There is no leakage of the can since there is no joint/seam.
 Longer shelf life
 Better handling convenience
 Increased image of pack
 Next generation can
 Enhance the image of the product packed in it
 Capable of growing the market and boosting the business.

14
2 PC Drawn Ink Can

A drawn & redrawn, stackable, conical, two piece container for filling / packaging of printing
inks.

Being manufactured in India by Petrox – a pioneer in the manufacture of industrial &

Consumer Packaging Products, on machinery imported from Europe, using the latest
Technology currently adopted worldwide, ideally suited for vacuum packed printing inks.

SALIENT FEATURES:-

 No skin formation on ink layer

 Tamper & Leak proof
 Longer shelf life of inks
 Aesthetic looks
 Stackable
 Saves storage space
 Saves Transport freight
 International Size & Design

15
Paint Can

 Special press fit tight lid

 wide mouth
 Lid is curled for pilfer proof sealing
 Plastic handles are fixed without welding

SALIENT FEATURES OF THIS CAN:

 No side and bottom seam - 1 pc. Seamless can body.

 Stackable
 Aesthetically attractive Can
 Robust & Sturdy Can
 Attractive multicolour heat shrink lables can be fixed. Multicolour printing can be
done on 4/6 colour printing machines on the entire surface of the Cans as there is no
side seam weld
 It is a relatively rustproof and leak proof Can compared to 3Pc. Welded Can

Available in 1lts., 500ml, 250ml, 4 / 5 lts. Sizes

16
2 PC Drawn Pesticides Can
A REVOLUTIONARY CAN FOR FILLING PESTICIDES/CHEMICALS

A new type of 2 pc can is developed by us to solve the problem of leakage currently being
faced by the Pesticide manufacturers who are filling their costly products in 3 pc welded can
as these welded can is getting pin hole at the welded portion due to uneven flow of current
and losing their costly products at the time of filling/storage/at customers premises.

The can is manufactured by drawing and redrawing the metal sheet. Hence there is no
welding at the side or seaming at the bottom of the can. In other words it is a single piece
body can. In the absence of any joint/seam on body of the can, there is no chance of rusting
or leaking of the can.

The top lid of the can is made up of integrated neck in one piece thus there is no separate
crimping of neck on the top lid. Hence, leaking at the neck portion is also ruled out.

The top lid of the can is seamed with a wire handle with a new process i.e. without welding.
Since there is no welding of the handle on the lid, there is no rust or leak at the point of
handle unlike in the welded portion of handle. In the conventional type handle, lacquer is
applied on the welded portion which used to contaminate the product, but the same will not
happen in this case.

The 2 pc can have greater consumer appeal and have the potential to enhance the image of

17
the can. The consumers will be attracted on looking at the image of the can which in turn will
induce them to go in for the goods packed in it thus benefiting the manufacturers/dealers by
increased sale.

SALIENT FEATURES OF THIS CAN:

 This can is manufactured without any welding or soldering.

 Body of the can is in one piece
 Wire handle is not soldered/welded or riveted on the can.
 Bottom of the can does not have seaming as in the case of conventional welded can as
bottom is an integral part of single piece drawn body can.
 There is no threading on the integrated metal neck due to which there are no chances
of coating coming out/peeling off during threading operation - We have smooth
plastic deep threaded neck which is strong and also makes the cap fit tight because of
strong grip due to deep thread and makes it leak proof.
 Printed/decoration of the can - Attractive eye catching multicolour heat shrink labels
can be fixed on the can.
 Superior can in terms of performance and looks compared to conventional welded
cans available in the market.
 It has longer shelf life compared to conventional welded can.

Available in 3 sizes 5lts. 500ml, 250ml

18
19
 Chapter 4
TIN CAN MANUFACTURING PROCESS
Overview of Tin can making procedure:

1. Firstly, tin-plate (steel coated with tin) arrives in the factory.

2. The next machine cuts out a precise shape from the tinplate to make a body blanks.
3. A ‘body rounding’ machine then takes this body blanks undergoes through rolling
operation.
4. Next operation is side seam welding operation.
5. The cans are passed through a machine that a special protective coating is then
sprayed on the inside of the cans to stop them from rusting when the food is put
inside. The cans are heated in a special oven to about 210 degrees Celcius to make
sure the coating attaches to the can. This heat also makes sure that there are no germs
in the can that could go into the food.
6. Once the coating has dried, the next operation is Die flanging. This machine curls the
sharp top edge to make a safe, smooth surface. This will also allow a lid to be fitted
on later. The can is now described as a ‘flanged’ can.
7. The ‘flanged’ can then moves onto the next machine, which is the ‘beading’ machine.
This adds the rings that we see around the sides of the can. These strengthen the can.
Without them, the can is easily squashable!
8. Finally, the cans move onto a huge conveyor belt that lines them up ready to be
packaged to go to the factory. The lids are sent to the factory separately and when the
food has been put inside the can, the lid is sealed on top. A label is added and it’s off
to the shops!

Tin can making machine

Tin can making machinery has wide applications. This Tin can making machinery
inherits all the merits of Tin can making machinery, enhanced by new technology. Compared
with other Tin can making machinery.
Tin can making machinery enjoys many advantages including:
1. More reasonable structure,
2. More compact appearance,
3. Smoother operating,

20
 4. Higher efficiency and is easy to operate and maintain.

Characteristics :-
1. Equipped with human-computer-interface and PLC
2. Adopt quantitative control means.
3. Main drive and copper wire adopt inverter for speed regulation.
4. New digital inverter for power supply.
5. Widely useful range.

Specification :-

Specifications of the series Full Automatic Body welders

 Type SLBA04-50/220-RT
 Welding speed 7-24m/min
 Welding point distance 0.5-0.9mm
 Production capacity Max 300cans/min
 Overlap 0.4mm
 Can diameter 52-155mm
 Can height 70-250mm
 Sheet thickness 0.16-0.3mm
 Material Tinplate, Ni plate
 Copper wire 1.38mm, 1.5mm
Three phase Voltage:380V
 Power Frequency:50Hz
Electric comsumpt:22KVA
 Welding frequency 50 Hz
 Cooling water 392-490kpa, 12-18, 20L/min
 Compressed air 490kpa, 800L/min

CAN MAKING PROCESS

21
STEP INVOLVED
1. PRINTING
2. SLITTER(SHEET CUTTING ALONG AND ACROSS)
3. BODY ROUNDING
4. SIDE SIM WELDING
5. DIE FLANING
6. END SIMMING
7. BIDDING
8. TOP SIMMING

4.1] PRINTING
1. TIN PLATE DECORATION SYSTEM(PRINTING)
2. PRINTING LINE CONSIST OF
a. SHEET FEEDER
b. PRINTING MACHINE
c. COATING MACHINE
d. DRYING CURING OVEN

Printing :
It is also called as offset printing.

Principle:
Printing machine works on the principle that water and oil or water and Grease does
not get mixed.
Printing line consisting of:
1. Sheet feeder
 The sheets are uploaded for the printing
2. Printing machine
 The printing machine consist of 3 cylinder
1. Plate cylinder
 The printing ink is supplied in this cylinder and it
directs the ink towards blanket cylinder.
2. Blanket cylinder

22
  This cylinder transfer the image on the sheet
3. Impression cylinder
 This cylinder holds the sheet while operation
3. Coating machine
 Varnishing
4. Drying curing oven
 Temperature specification
1. For white coating 140-160 °c
2. For colour printing 120-135 °c
3. For epoxy phenolic lacquer 190-200 °c
Time for the Tin sheet in the drying curing oven about 20 minutes.

RAW MATERIAL: TIN PLATE

 1 TIN SHEET : COST 300 Rs. AND WEIGHT 1.9 Kg
 SIZE : 0.28*910*971
 1 TIN SHEET BOX:-
o 1699 Kg
o 603 Body

4.2] SLITTER OPERATION:-

For harder material such as sheet metal, blades cannot
be used Two cylindrical rolls of shearing is use. Two
cylindrical rolls with matching ribs and grooves are
used to cut a large sheet into multiple no. of sheets.
This continuous production process is very economical
yet precise usually more precise than most other
cutting process. However the occurrence of rough or
irregular edges known as burrs are commonplace on
slit edges.

23
4.3] ROLLING MACHINE
It provides curl to the body blanks.

4.4] WELDING OPERATION:

Side Seam Welding Machines:-

Side Seam Welding Machines are one of the most

common yet essential machines in steel drum
manufacturing units. These machines are used for full
length side seam welding in steel drum making units
where entire 36” seam weld is formed to make a perfect
circular leak proof shell. Fabricated from high strength
steel and completely digitally control makes our Side
Seam Welding Machine completely safe from all
hazards. We offer these machines in standard
specifications of 200 KVA for 205 Ltr Steel Drums and
100 KVA for 15 Ltr to 165 Ltr Steel Drums.
Customization of these machines is also possible

Spot Welding Machines

High quality Spot Welding Machines that are

to spot weld the side edges of the drum body
to make them ready for further side seam
welding. Normally four spots are created on
the side edge to maintain the circular shell
shape. Normally 30 KVA is used for 205
Ltr steel Drums and 15 KVA for 15 Ltr to
165 Ltr Steel Drums.  The Spot Welding
Machines offered by us are available in
standard and customized specifications.

24
Various types of side seam

Various types of Weld Operation

25
% Overlap = BH+CH+1.1te – SL * 100

SL – (1.1tb + 2.2te)
Where,
tb – Body thickness
te – End thickness
BH – Body Hook
CH – Cover Hook
SL – Seam Length

4.5] LACQUER COATING

The cans are passed through a machine that a special protective coating is then sprayed
on the inside of the cans to stop them from rusting when the food is put inside. Epoxy
Phenol Lacquer which is acid resistance in nature is used. For food cans, which will
ultimately receive a paper label, the external coating is applied by passing them under a
series of waterfalls of clear lacquer which protects the surface against corrosion.

4.6] COMBUSTION CHAMBER

The cans are heated in a special oven to about 210 degrees Celsius to make sure the
coating attaches to the can. This heat also makes sure that there are no germs in the can
that could go into the food.

4.7] FLANGING
Types of flanging:
◦ Rotary flanging
◦ Die flanging
◦ Spin flanging
Once the coating has dried, the next operation is Die flanging. This machine curls the
sharp top edge to make a safe, smooth surface. This will also allow a lid to be fitted on
later. The can is now described as a ‘flanged’ can.

26
4.8] BEADING
The ‘flanged’ can then moves onto the next machine,
which is the ‘beading’ machine. This adds the rings
that we see around the sides of the can.These
strengthen the can. Without them, the can is easily
squash able!

4.9] BOTTOM SEAM

Automatic sealing and bottoming

combining machine

measure 1700x1100x1400mm
weight 4 ton
Can diameter 50-155mm
Can height 40-200mm
capacity 100 cans/min

27
 Chapter 5
QUALITY MEASUREMENT
Various Test During Quality Checking:
1. Visual check
o Through observation method we found out if error is present or not. Most of
the time external appearance is the main defect.
2. Before seam check
3. After seam check(about thickness of material)
4. Weight and Height check
o There are certain specified guidelines are given by the customer about it’s
demanded product
o E.g. Asian paint

Height Weight Weight of lids

Sr. Item Min Max Min Max Min Max

no. (mm) (mm) (mm (mm (mm) (mm)
) )

1 500 ml 107 109 66 86 11 15

2 1 Ltr 132 134 106 132 19 25
3 4 Ltr 196 198 285 352 57 74
4 5 Ltr 233 236 362 428 2 2
5. Pressure test
A. Water testing
o We allow the certain pressure into the can and then sink the can into
the filled water tank and observe that any bubble coming out of the
tank or not.
B. Bursting test
o We allow the certain pressure limits into the can sample to understand
it’s pressure handling capability to avoiding the can from bursting
o Pressure limits
 Up to 1 Kg 30 pound
 Below 1 Kg 20 pounds
 Above 1 Kg 40 pounds

28
 If can sample withstand for above pressure then we passed the sample
6. Drop test
o In this test we drop the product from certain height if the product gets damage
or if lids get opened up then we reject the sample
Testing of welding surface with Lacquer coating
1. Take a piece of lacquer coated welding material from tin body then keep it in copper
sulphate for 2 min. Take an observation,
a. If material coating displaced from the surface then lacquer coating is not
proper.
b. If material coating sustains it’s position on the surface then lacquer coating is
good.
2. Take a piece of lacquer coated welding material from tin body then rubbed the
acetone on the surface of coating around 20 times. Afterwards put copper sulphate on
strip and then broke the strip in between middle then take an observation,
a. If material coating disturbed then lacquer coating is not proper.
b. If material coating sustains it’s position on the surface then lacquer coating is
good.
Reference of detail TIN container in PETROX
Sr. Heights Weights
Min (mm) Max (mm) Min (gms.) Max (gms)
No. Items
1 500 ml 107 109 66 86
2 1 Ltr 132 134 106 132
3 4 Ltr 196 198 285 352
4 5 Ltr 233 236 362 428

Weights of Lids

Sr. No. Items Min (gms.) Max (gms)

1 500 ml 11 15
2 1 Ltr 19 25
3 4 Ltr 57 74
4 5 Ltr 2 2
Chapter 6
Normal Can Range: A Guide To Principal Food Can Sizes
Diameter 52

52 52

202*308 202*504 29
170 ml (6 0z) 265 ml (8 0z)
89
133
Diameter 65
65
65

211*109
100 ml (3 ½ 0z) 40 102
211*400
No. 1
310 ml (10 0z)

Diameter 73

38 73
73

300*108 38 300*108 300*201 52

44
120 ml (4 0z) 145 ml 180 ml

73 73 73

300*407
300*103 ¾ 1 pound 30
300*401
305 ml 440 ml (15 0z)
395 ml
 82
103
Diameter 83 113

83 83
83

307*113
No. 1/2 46
90
210 ml (6 ½ oz)

116
307*309
450 ml (15 ½ 0z)
307*409
No. 2
580 ml (20 oz)

Diameter 99

99 99

401*206
401*212 70
No. 1 flat 60
400 ml (13 oz) 465 ml

99
99

401*700
1300 ml
178
401*206
No. 2 ½ 31
850 ml (30 oz)
 119

153
Diameter 153
153

178
603*700
No. 10
114 3100 ml (108 oz)
603*408
4 lb Tuna
1935 ml (66 ½ oz)

Beer & Beverages

65/63

211/209 *408¾ 114

330 ml

Diameter 211
211 211

Fish, meat, cream, variety Veg, variety

108 201
85 gm (3 oz) 110 gm (4 oz)

32
 211 211

Pineapple, variety 301 Variety

225 gm (8 oz) 225 gm (8 oz) 309

211 211

Beer, Beverage
Pineapple, Veg.
330 gm (12 oz)
310 gm (11 oz)
400 410 ½

Diameter 300

300 300

Meat, fish, Cream, Veg. Skimmed S.C.M

201 215
170 gm (6 oz) 280 gm (10 oz)

33

Pineapple
 300 300

Meat, Veg.
(Army ratios)
Full cream S.C.M 303 ¼ 305
400 gm (14 oz)
400 gm (14 oz)

Pineapple

300 300

401
Evaporated milk Veg. beans, soups, variety 410
410 gm (14 ½ oz) 450 gm (16 oz)

Diameter 301
301 301

Pineapple, meat, variety

No. 1 tall
450 gm (16 oz)

Pineapple, Jam 309 409

34
450 gm (1. L .B.)
Diameter 307

307 307

Fish Tuna 113 Margarine 203

200 gm (7 oz) 250 gm (9 oz)

307 307

Margarine, motor oil Fruit, Veg. Variety

403 408
450 gm (16 oz) 570 gm (20 oz)A2

Diameter 401

401 401

Margarine Butter, meat

450 gm (1.L.B.) 215 330 gm (12 oz) 201

35
 401
401

Butter, pineapple, puddings, meat 411

450 gm (16 oz) 212 Fruit, Veg. Variety
850 gm (30 oz)A2 ½

401

401

Margarine, Fats
510
1000 gm (36 oz)A2 ½
1 Jam, Pineapple
411
900 gm (2 L.B)

Fruit, Veg. Variety

(Catering Packs)
3100 gm (109 oz) A10
Mango Pulp
Diameter 603 4500 gm (159 oz) A12
603
603

36
 912

700

Diameter 700

700

Mango Pulp (Bulk) 900

5250 gm (185 oz) A79

Chapter 7
ANALYSIS OF PRODUCTION
Daily production analysis (Dt. 13/05/2010)

Period (hr.) Start End Total Production per Hr

37
 9.00 t0 10 0001 3800 3800
10.00 to 11 3801 8000 4200
11 .00 to 12 8001 12800 4800
12 .00 t0 1.00 12801 16800 4000
01.30 to 2.30 16801 20300 3500
02.30 to 3.30 20301 24600 4300
03.30 to 4.30 24601 27900 3300
04.30 t0 5.30 27901 32646 4746

6000

5000

4000

3000

Column2
2000

1000

0
10 11 12 t0
1 30 30 30 30
t0 to to 2. 3. 4. 5.
9 10 11 12 to to to t0
30 30 30 30
1. 2. 3. 4.

 Efficiency of machine:

In thermodynamics and the theory of machines, the ratio of the useful work
derived from a machine to the energy put into it. The mechanical efficiency of a
machine is always less than 100%, some energy being lost as heat in friction.

Here the efficiency of machine is 85%

 Scrap value % - 0.5%

Chapter 8

DIFFERENT PROCESS IMPROVEMENT TECHNIQUES

SMED: Single Minute Exchange of Dies

38
“Reduce your setup and adjustment times from hours to minutes”

In this paper we will talk about a lean tool, which will increase your OEE (Overall
Equipment Effectiveness), but also your flexibility.

This tool is called SMED ( Single Minute Exchange of Dies), or Quick Changeover.

Changeover losses are one of the 6 big losses that have been defined within the TPM method.

First some definations.

 Changeover the total process of changing a production line from mining one product
to another.
 Changeover time elapsed time between the last good previous product, and first good
next product at the right speed.
 Setup time : the time to adjust or replace machine parts to accommodate the new
product.
 Startup time : the time to bring the process up to the right speed and quality
 Change over time = setup time + startup time

SMED stands for single minute exchange of die, and covers the techniques for obtaining a
changeover time of less than 10 minutes ( single digit number of minutes). The SMED
method, and also Poka Yoke, was introduced by Dr. Shigeo Shingo, one of the world’s
leading experts in improving manufacturing process.

There are three stages to the SMED technique. The first stage, which he developed in 1950,
enabled Shingo to reduce the averaged time for changing set-up on large still presses from
four hours to less than ninety minutes. The second and third stages, introduced in 1969, led to
these same set up changes being reduced to less than ten minutes. Because Shingo developed
his ideas mainly on still presses and plastic molding and extrusion machinery. He called the
technique ‘Single Minute Exchange of Dies”. However, the same techniques can be applied
to virtually any type of manufacturing process where changes of set up occur.

There are 2 key elements in any change over.

I. Internal Activities:
Must be performed while the machine / process is stopped i.e. not making parts.
II. External Activities :

39
 Can be performed whilst the machine / process is running i.e making parts.

Examples of ‘internal activities are:

 Removing work from machine

 Removing tools dies etc.
 Cleaning down the work surface
 Fixing new tools n place
 Fixing the new work piece in place
 Trial run and adjusting the machine

Examples of external activities are:

 Getting instructions for the next job

 Getting material for the next job from stores
 Getting tools for the next job from tool stroes
 Returning tools from the last job to tool stores
 Returning tools from the last job to toll stores
 Arranging for lifting equipment to be available when required
 Arranging for a setter to be available when required

PDCA Cycle of Systematic Development

PDCA is an acronym for PLAN, DO, CHECK and ACT. It is very simple, easy-to-use and
highly effective means of managing anything and everything!

The PDCA cycle is also known as the Deming Cycle, the Deming wheel of continuous
improvement spiral. Another compelling reason is that it can be easily tried out (there is no
financial cost, only mental and physical efforts are required!) and practiced at any level and
magnitude and the obvious advantages can be tasted through a test-recipe before ordering the
full course!

PDCA has varied applications. A few are listed below:

1. For daily routine management-for the individual and/or the team.

2. For problem-solving process.

40
 3. For continuous development.
4. For vendor development.
5. For human resources development.

Indian examples of some companies using TQM and PDCA are:

1. MODI XEROX, Rampur.

2. Crompton Greaves, Mumbai.
3. TISCO, JamshedPur.

Kaizen

Kaizen (kai ‘ zen) is a Japanese term that means continuous improvement, taken from words
Kai, which means continuous and ‘zen’ which means improvement. Some translate Kai to
mean change and zen to mean good, or for better.

Kaizen is one of the most commonly used words in Japan. It is in the newspapers, on the
radio and TV. Japanese society is bombarded daily with statement regarding Kaizen of
almost anything. In business, the concept of kaizen is so deeply ingrained in the minds of
both managers and workers that they often do not even realize that they are thinking kaizen.

The key difference between how change is understood in Japan and how it is viewed in the
west lies in the Kaizen concept. This concept is so natural and obvious to many Japanese
managers that they often do not even realize that they possess it. This explain why companies
are constantly changing in Japan.

The kaizen concept is very weak in western companies, where it is often rejected without
knowing what it really entails. This explains why American and European factories may go
years without changing.

41
 Chapter 9

Future Suggestions and Recommendations

1] Proper Layout plan should implement.

Petrox is one of the leading industries in the Tin packaging business. So in order to
ensure sustainable growth it has to undergo prior changes to maximize its production level. I
have drawn the existing plant layout of the company as follow-

Exit Tin plate Tin

Exit For
2 cutting plate
Scrap Press shop dispatch Store
section store

(Slitter)
Admin

Manufacturing line 1
Tool
Finished product
store Manufacturing line 2 Room

Manufacturing line 3

Fig. Plant layout

From above plant layout we can clearly find the mistake in the distance between the finished
goods store and Exit for dispatch. Further the company doesn’t have automatic pallet through
which they can upload the truck. Due to this they are using manpower to upload the dispatch
vehicle so it leads to following problems:

1. The efficiency of manpower is too less compared to automatic pallet due to which it
takes more time for uploading dispatch material
2. Company doesn’t have their own dedicated labour for loading purpose. They use the
manpower through their production plant labour. Due to this they have to
compromise with their production speed
3. For uploading one whole Truck, labourers take one whole day because they are max
4 in no. and cartons are also too heavy (around 28 to 40 kg depending on material)
so they get easily exhausted.

42
 4. Most of the time the company hires external labour for uploading purpose giving
them high wages.

Suggestions to be taken into consideration are:

1. Make a proper change in plant layout if possible. For example you can widen the area
of exit2, so dispatch vehicle can easily enter into the plant and distance between the
finished product store and dispatch exit reduces.
2. Introduce automatic pallet machine.
3. Appoint dedicated labour for loading.

2] Adopt proper quality checking techniques

Every can must be tested by passing through a light tester which automatically rejects any
cans with pinholes or fractures. But in Petrox they are using random sample checking method
in which randomly cans are tested which is quite wrong because in this method there are
chances that the leak Can may pass through production.

End Micro Leak Tester (MLT)

Single head off-line MLT system. On and off line modules are
available.

 High Sensitivity
 High Sampling Rate
 Low Maintenance, Low Running Costs
 Class Leading Performance
 Low False Rejects
 Intelligent Sampling for Complete Protection
 Real Leakage Rates Displayed
 Flexible Installation and Modular Expansion

Fast, practical and effective sample testing for micro-leaks in

converted ends, with low maintenance and low running costs.

3-head on-line MLT sampling system. On and off line

modules are available.

Failure to detect leaks in lids leads to massive re-checking

jobs or customer complaint. 100% light testing with Sencon’s

43
on-press End Light Tester Package ELTP will find leaks that have a detectable light path
through the fault. However, faults such as rivet cracks or more complex fractures may not
allow light to pass and will therefore go unnoticed. An additional test is needed,using gas
flow to indicate the presence of these very small or hidden leaks.

MLT is a real time testing unit designed to detect what are commonly called ‘micro-leaks’.
The system works at the limit of dry seal capability, while at the same time avoiding product
damage. This means that a careful balance is maintained between applying sufficient
pressure to open up metal fractures, while ensuring the tested ends remain suitable to re-enter
production. Sencon believe that MLT achieves the best mix of sampling speed and test
sensitivity, offering the most practical and economic solution to detecting micro-leaks in can
lids.

 On-line testing up to 2.4% of production

 Acceptable ends can re-enter production in stick form or take-away conveyor
 Easily adapted to test a wide range of end sizes
 Robust construction with low maintenance

Avoiding False Rejects - All lids rejected by a tester demand extra attention to confirm the
leak and initiate the appropriate action. False rejects therefore waste time through
unnecessary investigation. Based on detailed research, MLT is set by default to work at
realistic detection thresholds in order to avoid rejecting good product.

Intelligent Sampling of All Belt Pockets - Sampling from the line at regular fixed intervals
could mean that ends are tested from only one group of belt pockets, as the belt and the
sampler fall into synchronization. To avoid this, the on-line MLT has an option called “walk
the belt”, which monitors and varies the sampling rate to ensure that lids from every belt
pocket are sampled. In this mode, the average sample rate is 15 lids per minute, but overall
protection against faulty product is effectively greater.

3] Need of proper Inventory Management

Inventory is usually a distributor’s largest asset. But many distributors aren’t satisfied with
the contribution inventory makes towards the overall success of their business:

44
  The wrong quantities of the wrong items are often found on warehouse shelves. Even
though there may be a lot of surplus inventory and dead stock in their warehouse(s),
backorders and customer lost sales are common. The material a distributor has
committed to stock isn’t available when customers request it.
 Computer inventory records are not accurate. Inventory balance information in the
distributor’s expensive computer system does not accurately reflect what is available
for sale in the warehouse.
 The return on investment is not satisfactory. The company’s profit, considering its
substantial investment in inventory, is far less than what could be earned if the money
were invested elsewhere.

 Purpose of Inventory Management

INVENTORY MANAGEMENT must tie together the following objectives, to ensure that
there is continuity between functions:
• Company’s Strategic Goals
• Sales Forecasting
• Sales & Operations Planning
• Production & Materials Requirement Planning.

Inventory Management must be designed to meet the dictates of market place and support the
company’s Strategic Plan. The many changes in the market demand, new opportunities due
to worldwide marketing, global sourcing of materials and new manufacturing technology
means many companies need to change their Inventory Management approach and change
the process for Inventory Control .

Inventory Management system provides information to efficiently manage the flow of

materials, effectively utilize people and equipment, coordinate internal activities and
communicate with customers. Inventory Management does not make decisions or manage
operations; they provide the information to managers who make more accurate and timely
decisions to manage their operations.

Inventory is defined as the blocked Working Capital of an organization in the form of

materials. As this is the blocked Working Capital of organization, ideally it should be zero.

45
But we are maintaining Inventory. This Inventory is maintained to take care of fluctuations in
demand and lead time. In some cases it is maintained to take care of increasing price
tendency of commodities or rebate in bulk buying.

Traditional Supply Chain solutions such as Materials Requirement Planning, Inventory

Control, typically focuses on implementing more rapid and efficient systems to reduce the
cost of communicating information between and across the Inventory links in the SCM.COM
focuses in optimizing the total investment of materials cost and workload for every Inventory
item throughout the chain from procurement of raw materials to finished goods Inventory.
Optimization means providing a balance of supply to meet the demand at a minimum total
cost , Inventory level and workload to meet customers service goal for each items in the link
of Inventory Chain .

It is strategic in the sense that top management sets goals. These include deployment
strategies (Push versus Pull), control policies, the determination of the optimal levels of order
quantities and reorder points and setting safety stock levels. These levels are critical, since
they are primary determinants of customer service levels.

Keeping in view all concerns, the latest concept of Vendor Managed Inventory is used to
optimize the Inventory. We are entering into Vendor Managed Inventory, Annual Rate
Contracts with manufacturers or their authorized dealers, who maintain Inventory on our
behalf and supply the items as and when required.

VMI reduces stock-outs and optimize inventory in supply chain. Some features of VMI
include :
• Shortening of Supply Chain
• Centralized Forecasting
• Frequent communication of inventory, stock-outs and planned promotions
• Trucks are filled in a prioritized order , e.g. items that are expected to stock out have top
priority then items that are furthest below targeted stock levels then advance shipments of
promotional items

The Inventory Management system and the Inventory Control Process provides information

46
to efficiently manage the flow of materials, effectively utilize people and equipment,
coordinate internal activities, and communicate with customers. Inventory Management and
the activities of Inventory Control do not make decisions or manage operations; they provide
the information to Managers who make more accurate and timely decisions to manage their
operations.

The basic building blocks for the Inventory Management system and Inventory Control
activities are:

1] Sales Forecasting or Demand Management

2] Sales and Operations Planning
3] Production Planning
4] Material Requirements Planning
5] Inventory Reduction

The emphases on each area will vary depending on the company and how it operates, and
what requirements are placed on it due to market demands. Each of the areas above will need
to be addressed in some form or another to have a successful program of Inventory
Management and Inventory Control.

47
 Chapter 10

CONCLUSION

My experience in Petrox was an enriching one. I had the opportunity of learning many
things. I was able to implement everything that I had learnt theoretically.

I had hands on experience in handling machinery and understood the tin can
manufacturing process. I also had a chance to study the working of Tin Can manufacturing
company.

I also studied the problems faced by the production department while producing Tin
Can and how they tackle the same. Another important point that I learnt at this place was
Labour Management, optimum utilization of resources. However there were a few weak
points.

For instance –
 Material Management: The assembly table and racks of raw material are not
properly situated due to which there is increased material handling.
 Improper House Keeping

Accordingly I have given the suggestions for improvement which have been
considered for implementation.

Thus these two months of internship have been extremely fruitful. I did get a glimpse
of how exactly things work out in corporate and definitely this will have lifelong benefits.

48
 CHAPTER 11

BIBLIOGRAPHY

REFERENCE BOOK:
 HANDBOOK OF DIFFERENT PROCESS IMPROVEMENT TECHNIQUE
 JOURNAL OF OPERATION MANAGEMENT

WEBSITES:
WWW.GOOGLE.COM
WWW.PETROXCAN.COM

49