Pira Consulting Report

Logistics, Distribution & Operations Group

Evaluation of fitness for

purpose of new aerosol
products

S013572

Prepared for Alessandro Algozzino of Colgate Palmolive

By Brian McHale, Laboratory Technical Specialist

January 2009

Private and confidential

Pira International Limited

Registered office: Cleeve Road, Leatherhead, Surrey, KT22 7RU, United Kingdom
Main line +44 (0)1372 802000 Facsimile +44 (0)1372 802241
Registered number: 3858209 England
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Evaluation of fitness for purpose for new aerosol products

1. Introduction
In March 2007 Pira undertook testing to evaluate the fitness for purpose of a
new 150ml deodorant aerosol can against a benchmark aerosol on the market
(Pira ref S002294). Colgate Palmolive has since made modifications to the new
can and wishes to assess the fitness for purpose of this can. In addition to this,
Colgate Palmolive wishes to assess the performance of a larger 250ml can in
the new format.

This report details the work conducted by Pira International in assessing the new
and current aerosol products with respect to distribution.

2. Objective
To evaluate the fitness for purpose of distribution of 2 products through
laboratory based testing as per previous Pira testing and the Colgate Palmolive
G EU Ship Testing Grid. Results will be compared to the previous testing results
to draw conclusions on the fitness for purpose of distribution.

3. Pira International
Pira International is recognised world wide as a leading centre of excellence
specialising in technical, commercial and strategic aspects of packaging and the
application of packaging within logistics and the supply chain. Pira has over 50
years experience in testing of packaging materials and packaged products,
packaging technical investigations, evaluating the hazards of distribution and in
undertaking improvement projects relating to packaging performance and
specification. Pira also has a world class state-of-the-art distribution packaging
test laboratory facility.

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Evaluation of fitness for purpose for new aerosol products

4. Scope
This report covers elements of unit load distribution and individual collation
distribution from point of manufacture through to retailer, via distribution centre,
based on testing using a limited number of packs. The testing is to give an early
indication of new cap design field performance. Pallet stability is not covered.
Investigatory side impacts representing hazards associated with rail distribution
(applicable to some European countries) are not covered by this report.

5. Samples tested
Collations of aerosols sufficient for each test condition were delivered to Pira for
testing:

Table 1 Samples delivered for testing

Sample Number of collation packs

150ml aerosol 20

250ml aerosol 20

Individual collation pack specifications/stacking heights and pallet stacking

heights are presented in Table 2.

Table 2 Sample specification, weight and stacking details

Sample 150ml aerosol 250ml aerosol

Contents 2 x 3 array of aerosols 2 x 3 array of aerosols

Corrugated base tray with Corrugated base tray with

Outer collation pack specification
shrink wrap shrink wrap

0.813kg 1.281kg
Total collation weight/ dimensions
140x92x195mm 160x102x234mm

No. of layers on a pallet 4 4

No. of pallets stacked in warehouse 2 2

No. of pallets stacked in transit 2 2

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Evaluation of fitness for purpose for new aerosol products

6. Work undertaken
Testing was conducted based on previous Pira testing, in accordance with the
‘Preliminary Colgate Palmolive Greater Europe Region Package Performance
Test’ (V.0.2 03/20/2007) comprising:

• Sample conditioning at +38ºC 85%RH and -29ºC

• Pallet base drop simulation
• Pallet warehouse stacking simulation (2 high)
• Vibration simulating road transport of palletised loads
• Manual handling simulation
• Vibration simulating road transport of mixed loads
• Mixed load stacking simulation.

6.1 Inspections

Pira conducted an inspection of all collation packs for damage prior to testing (2
packs of each can size were opened up for detailed inspections, these packs
were not tested). All packs were opened for a detailed inspection on completion
of testing. The external condition of the outer packs, and where possible the
internal condition, was monitored throughout testing. See Diagram 1 for
individual aerosol identification. Photographs of packs and any issues that arose
can be found in Appendix A.

Diagram 1 Aerosol and drop orientation identification

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Evaluation of fitness for purpose for new aerosol products

6.2 Elevated temperature and humidity testing

The following testing sequence was conducted for each can size format by Pira,
on collations detailed below :

6.2.1 Conditioning of samples – ramp up temperature from +23°C, 50% RH to +38°C,

85% RH over 12 hours. Hold temperature at +38°C, 85% RH for a minimum of
12 hours

6.2.2 Subject columns of collations to a 6” base drop simulating pallet drop hazards
likely to be encountered during normal handling, performed on collations 1, 2, 3
and 4

6.2.3 Subject packs to an apply and release compression test simulating double
stacking of pallets in a warehouse; using a safety factor of 4.9 (based on Colgate
Palmolive internal protocol), performed on collations 1, 2, 3 and 4

6.2.4 Re-conditioning of samples – as per 6.2.1

6.2.5 Subject columns of collations to the random vibration profiles (between 1 and
200Hz) generated by Pira; 2.5 hours with a Grms of 0.37, followed by 0.5 hours
with a Grms of 0.65, simulating unitised load transport of identical products by
road, performed on collations 1, 2, 3 and 4

6.2.6 Re-conditioning of samples – as per 6.2.1

6.2.7 Subject individual collations to a drop sequence simulating manual handling of

packs in the RDC/retailer environment, performed on collations 6, 7, 8 and 9

• 9” base drop sequence comprising the following drops:

Flat base, base long edge, base short edge, 2 opposite base corners

• 9” top drop sequence comprising the following drops:

Short top edge, short vertical side, long vertical side

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Evaluation of fitness for purpose for new aerosol products

6.2.8 Subject a column of collations (mixed orientation) to the random vibration profiles
(between 1 and 200Hz) generated by Pira; 15 minutes with a Grms of 0.37,
followed by 1 minute with a Grms of 0.65 (see Diagram 2 for orientations),
simulating mixed load transport of similar products by road, performed on
collations 1, 2, 3, 4, 6 and 7

6.2.9 Subject individual collations to compressive tests simulating stacking of mixed

loads in vehicles, based on Pira ‘Retail Supply Chain’ test method (see Appendix
B), performed on collations 1, 2, 3, 4, 6, 7, 10, 11, 12 and 13.

6.3 Reduced temperature testing

The following testing sequence was conducted for each can size format by Pira,
on collations detailed below :

6.3.1 Conditioning of samples – ramp down temperature from +23°C, to -29°C, over
12 hours. Hold temperature at -29°C for a minimum of 12 hours

6.3.2 Subject columns of collations to a 6” base drop simulating pallet drop hazards
likely to be encountered during normal handling, performed on collations 10, 11,
12 and 13

6.3.3 Subject packs to an apply and release compression test simulating double
stacking of pallets in a warehouse; using a safety factor of 4.9 (based on Colgate
Palmolive internal protocol), performed on collations 10, 11, 12 and 13

6.3.4 Re-conditioning of samples – as per 6.3.1

6.3.5 Subject columns of collations to the random vibration profiles (between 1 and
200Hz) generated by Pira; 2.5 hours with a Grms of 0.37, followed by 0.5 hours
with a Grms of 0.65, simulating unitised load transport of identical products by
road, performed on collations 10, 11, 12 and 13

6.3.6 Re-conditioning of samples – as per 6.3.1

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Evaluation of fitness for purpose for new aerosol products

6.3.7 Subject individual collations to a drop sequence simulating manual handling of

packs in the RDC/retailer environment, performed on collations 15,16, 17 and 18

• 9” base drop sequence comprising the following drops:

Flat base, base long edge, base short edge, 2 opposite base corners

• 9” top drop sequence comprising the following drops:

Short top edge, short vertical side, long vertical side

6.3.8 Subject a column of collations (mixed orientation) to the random vibration profiles
(between 1 and 200Hz) generated by Pira; 15 minutes with a Grms of 0.37,
followed by 1 minute with a Grms of 0.65 (see Diagram 2 for pack orientations),
simulating mixed load transport of similar products by road, performed on
collations 10, 11, 12, 13, 15 and 16

6.3.9 Subject individual collations to compressive tests simulating stacking of mixed

loads in vehicles, based on Pira ‘Retail Supply Chain’ test method (see Appendix
B).

Diagram 2 Mixed orientation column used for 150ml product and 250ml product

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Evaluation of fitness for purpose for new aerosol products

7. Results
Results and observations for the testing are summarised in Tables 3 to 7.

Table 3 Results from pre-test inspections

150ml pack observations 250ml pack observations

Pack Observations Pack Observations

1 – 18 No apparent damage to cans 1 – 18 No apparent damage to cans

Minor indentations to base and main body Minor indentations to shoulder, main body
19 of several cans, minor defect to cap apex 19 and base of several cans, scuff to main

on several caps. body of several cans.

Minor indentations to base and main body

Minor indentations to main body and base
of several cans, scuff to main body of
20 20 of several cans, scuff to main body of
cans, minor defect to cap apex on several
several cans.
caps.

Note: Packs 1-18 remained unopened, whilst packs 19 and 20 for each can size were opened for
inspection (not tested).

Table 4 Results from elevated temperature and humidity testing

Test 150ml pack observations 250ml pack observations

Base drop No damage observed to packs No damage observed to packs

Each pack withstood the top load of Each pack withstood the top load of
Compression
274N with no damage observed 431N with no damage observed

Vibration No damage observed to packs No damage observed to packs

Base drop sequence No damage observed to packs No damage observed to packs

Top drop sequence No damage observed to packs No damage observed to packs

Mixed orientation
No damage observed to packs No damage observed to packs
vibration

Mixed load
No damage observed to packs No damage observed to packs
compression

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Evaluation of fitness for purpose for new aerosol products

Table 5 Results from reduced temperature testing

Test 150ml pack observations 250ml pack observations

Base drop No damage observed to packs No damage observed to packs

Each pack withstood the top load of Each pack withstood the top load of
Compression
274N with no damage observed 431N with no damage observed

Vibration No damage observed to packs No damage observed to packs

Base drop sequence No damage observed to packs No damage observed to packs

Top drop sequence No damage observed to packs No damage observed to packs

Mixed orientation
No damage observed to packs No damage observed to packs
vibration

Mixed load
No damage observed to packs No damage observed to packs
compression

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Evaluation of fitness for purpose for new aerosol products

The damage count data for 150ml aerosols inspected after testing is presented
in Table 6 below (number of cans exhibiting damage, cap rotation was monitored
at the request of Colgate Palmolive).

Table 6 Results from post-test inspections - 150ml cans

Cap
Pack Shoulder Main Body Base
Rotation Cap Defect
number Indentation Indentation Indentation
(<3mm)
1H 0 0 1 3 4
2H 0 0 0 6 1
3H 1 0 1 1 2
4H 0 0 0 4 0
6H 0 4 2 4 3*
7H 0 5 3 6 3
8H 0 6 0 5 3
9H 1 6 0 6 2
10 C 0 1 2 4 4
11 C 1 3 2 0 3
12 C 0 1 0 0 0
13 C 1 2 1 5 0
15 C 0 6 1 6 4*
16 C 0 6 1 5 3
17 C 0 6 4 6 5
18 C 0 6 1 6 5**

Total cans 4 52 19 67 42

Note:
H - packs conditioned at +38°C 85% RH
C - packs conditioned at -29°C
One faulty actuator was detected on completion of testing from Pack 3H
* 1 can exhibiting severe cracking to cap apex
** 2 cans exhibiting severe cracking to cap apex.

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Evaluation of fitness for purpose for new aerosol products

The damage count data for 250ml aerosols inspected after testing is presented
in Table 7 below (number of cans exhibiting damage, cap rotation was monitored
at the request of Colgate Palmolive).

Table 7 Results from post-test inspections - 250ml cans

Cap
Pack Shoulder Main Body Base
Rotation Cap Defect
number Indentation Indentation Indentation
(<3mm)

1H 0 1 5 5 0
2H 0 2 1 5 0
3H 0 1 4 4 0
4H 1 5 2 6 0
6H 0 6 2 6 0
7H 0 6 4 6 0
8H 0 6 3 6 0
9H 0 6 4 6 0
10 C 0 4 4 6 0
11 C 0 5 3 5 0
12 C 0 4 5 5 0
13 C 0 5 3 6 0
15 C 0 5 2 6 0
16 C 0 5 5 6 0
17 C 0 6 3 6 0
18 C 0 6 5 6 0

Total cans 1 73 55 90 0

Note:
H - packs conditioned at +38°C 85% RH
C - packs conditioned at -29°C
One faulty actuator was detected on completion of testing from Pack 4H

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Evaluation of fitness for purpose for new aerosol products

8. Discussion
On completion of testing no significant issues were observed with the overall
appearance of the collation for both can sizes. Can observations are discussed
below.

150ml can

Noticeable defect to the cap apex for a large number of cans was observed prior
to and on completion of testing from both +38°C and -29°C conditions (see
photograph 15). This was not an issue with the “loop” cans tested previously and
is likely to be attributable to an issue with the manufacture of the 150ml cap. The
marking appeared to be most prevalent on cap manufactured from injection
cavity ‘II 11.’

The cap apex from a total of 4 cans exhibited cracking on completion of testing
(again not seen during previous testing – or during 250ml can testing). On
further inspection, the cracked caps appeared to be from two injection cavities ‘II
11’ and ‘II 15.’

2 cans from both +38°C and -29°C conditions exhibited between approximately 1
and 2 mm cap rotation (4 cans in total) on completion of testing, however this did
not appear to impact product actuation.

The shoulder and base area of the cans exhibited denting on completion of
testing as observed during previous testing. The number of cans exhibiting
damage was no greater than for the 150ml benchmark tested previously. In fact
the number of cans with indentations to the shoulder area was actually lower for
this 150ml can tested.

All cans actuated without issue on completion of testing, with the exception of 1
can from +38°C, where the actuator under the elastomer cover appeared to be
out of position – on further investigation this issue appears to have occurred
during production as the actuator button was not correctly located on the can
actuator mechanism.

250ml can

1 can from the +38°C condition exhibited approximately 2 mm cap rotation on

completion of testing, this did not appear to impact product actuation.

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Evaluation of fitness for purpose for new aerosol products

The shoulder and base area of the cans exhibited denting on completion of
testing as observed during previous testing. The number of cans exhibiting base
damage was marginally greater than for the 150ml benchmark tested previously.
However the number of cans with indentations to the shoulder area was
marginally lower for this 250ml can tested.

All cans actuated without issue on completion of testing with the exception of 1
can from the +38°C condition, where the actuator under the elastomer cover
appeared to be out of position – on further investigation this issue appears to
have occurred during production as the actuator button was not correctly located
on the can actuator mechanism (similarly to 150ml can).

9. Conclusions
150ml can
With respect to the can body - in comparison to the 150ml benchmark can
previously tested (see Pira report S002294), the 150ml pack tested is regarded
as having marginally improved performance characteristics under the simulated
distribution conditions tested.

However with respect to the moulded cap – there appear to be manufacturing

issues present which are likely to result in significant cap damage during
distribution. Possible issues with the polymer used, the surface of the injection
cavity and knit line should be investigated further to identify the specific problem.

Although an actuator was identified to be out of position on completion of testing

– it is most likely that this was attributable to a production issue which Colgate
Palmolive should investigate further.

With the exception of the cap apex (defects/cracking), performance is

comparable to the 150ml benchmark can previously tested. Subject to resolving
the cap apex issue, this pack would be expected to offer acceptable field
performance.

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Evaluation of fitness for purpose for new aerosol products

250ml can

In comparison to the 150ml benchmark can previously tested (see Pira report
S002294), the 250ml pack tested is regarded as having equivalent performance
characteristics under the simulated distribution conditions tested.

Although an actuator was identified to be out of position on completion of testing

– it is most likely that this was attributable to a production issue which Colgate
Palmolive should investigate further.

The performance of the 250ml can is comparable to the current 150ml

benchmark can previously tested. Given that the current 150ml can has
acceptable field performance, the new 250ml pack could also be expected to
also offer acceptable field performance.

10. Recommendations
• Investigate 150ml cap apex manufacturing issues

• Observe early live shipments of 250ml cans (and 150ml cans when cap apex
issue resolved) for pallet stability issues where product is shipped as full
pallets.

Prepared by Checked by

Brian McHale Henry Goodband

Laboratory Technical Specialist Senior Consultant

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Appendix A

Photographs

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Evaluation of fitness for purpose for new aerosol products

Photograph 1 Example of 150ml pack Photograph 2 Example of 250ml pack

Photograph 3 Example of column base drop Photograph 4 Pack during compression

Photograph 5 Example of individual base drop Photograph 6 Pack during mixed orientation
vibration

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Evaluation of fitness for purpose for new aerosol products

Photograph 7 Packs during vibration testing Photograph 8 Rotation of 150ml cap (post-
test)

Photograph 9 Flattening of shoulder (post-test) Photograph 10 Severe indentation to base

(post-test)

Photograph 11 Minor indentation to base Photograph 12 Severe crack to 150ml cap

(post-test) (post-test)

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Photograph 13 Crack to apex of 150ml cap Photograph 14 Faulty actuator (post-test)

(post-test)

Photograph 15 Cap apex defects on untested

can (pre-test)

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Evaluation of fitness for purpose for new aerosol products

Appendix B

Pira ‘Retail Supply Chain’ test method –

Mixed load distribution compression tests

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Evaluation of fitness for purpose for new aerosol products

Local Top Load

Set up a test pack in its normal orientation with one standard 2-piece food can
(typically 415 to 420g) placed centrally on top of it. Stabilise with a spreader board
as shown in Figure B1.

Apply a dead-weight load centrally placed over the can for 24 hours, with load
applied according to the formula:

load (kg) = 0.25 * (1.6 – 2h) * a * d for d > 400, OR

load (kg) = 0.25 * (1.6 – 2h) * a * d * 1.2 for d ≤ 400

where h is the vertical dimension of the test pack in the test orientation (in metres), a
is the area of the top face of the test pack in the test orientation (in square metres)
and d is the density of the test unit in kg / m3

Load

Test pack

Figure B1: Localised top-load test

NOTE: The support on the left of the diagram is to stabilise the test assembly
only – it should not be too close to the test pack or may affect the loading of the
test pack.

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Bridge Load

Set up one test pack centrally on top of 2 further test packs (with all three packs in their
normal orientation), with the lower packs separated by half their longer dimension (see
Figure B2).

Apply a dead-weight load centrally via a spreader board half the width of the longer
dimension, with load applied according to the formula:

load (kg) = 0.5 * (1.6 – 2h) * a * d for d > 400, OR

load (kg) = 0.5 * (1.6 – 2h) * a * d * 1.2 for d ≤ 400

Note: The spreader board should be at least the full width of the upper pack in its
shorter horizontal axis.

Figure B2: Bridge-load test

Diamond Load

Reproduce the bridge-load test described above, but with the entire test on a slope of
7.5° and with the left hand pack raised on a wooden block so that the top pack is
nominally level – see Figure B3. Ensure the spreader board and load are stable.

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Figure B3: Diamond load test

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