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Aerosol Overcaps 101

Aerosol Overcaps 101. Why are caps important??. Dust Cover Prevents accidental discharge Aesthetics Load Factor Can deliver a message “Green” Factor. How are they made?.

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Aerosol Overcaps 101

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  1. AerosolOvercaps101 Aerosol 101

  2. Why are caps important?? • Dust Cover • Prevents accidental discharge • Aesthetics • Load Factor • Can deliver a message • “Green” Factor Aerosol 101

  3. How are they made? • Caps are made via an injection molding machine – the machine is known as the “press” and the tool that makes the caps is the “mold”. Aerosol 101

  4. Injection Molding Machine Aerosol 101

  5. How does it work? Aerosol 101

  6. Mold (Cavity) Aerosol 101

  7. To layer pack or not to layer pack….. Aerosol 101

  8. Material Properties Aerosol 101

  9. Materials • Polyethylene (HDPE) • Polypropylene (PP) • Clarified Polypropylene (CPP) • Copolymers (Blended) • Styrolux/K-Resin • Non-Antistat Polypropylene  (NAPP) Aerosol 101

  10. Polypropylene • Lightweight • High compressive strength (top load) • Scuff Resistant • Retains stiffness and flex • Clearer than PE • Higher anti-stat levels Aerosol 101

  11. Polyethylene • Softer material – more crack resistant • Does not hold it’s shape when bent • Cloudier • Faster cycle times • Scuffs easily Aerosol 101

  12. Other materials • Clarified PP • Use when more clarity is needed • Styrolux • Best clarity, lowest shrinkage • Non-antistat PP • Use when painting, printing or metallizing caps Aerosol 101

  13. Can Styles • Aluminum • Straight Walled • Necked In • DS Container • Sexton Can Aerosol 101

  14. Aluminum Aerosol 101

  15. DS Container Aerosol 101

  16. Sexton Cans Aerosol 101

  17. Cap Styles Aerosol 101

  18. Styles • Generic designs are mass produced and lower priced. Provides a standard look. • Custom designs are developed with marketing for a distinctive look to complement the package and product. Aerosol 101

  19. Straight Side/Necked In Aerosol 101

  20. Straight Sided • 202 • 211 • 300 • High Stacker Caps • Double Shell • Tamper Resistant DS • Tamper Proof • Snap Lock • Rim Snaps Aerosol 101

  21. Necked In • 112/45mm • 202/52mm • 205/57mm • 211/65mm • 300/70mm • Stacker Type • Double Shell • Single Shell • Tamper Resistant/Child Proof • Spray Thru Aerosol 101

  22. Aluminum • 38mm • 45mm • 49mm • 50mm • 53mm • 59mm • 66mm • Caps to fit over valve cover • Double Shell Caps • Caps to fit over actuators Aerosol 101

  23. Single Shell/Double Shell Aerosol 101

  24. Why use a single shell cap? • Will fit a larger actuator – one that is larger than the valve cup • May use less plastic than a double shell Aerosol 101

  25. …and WHY NOT? • Caps are more size critical with regard to fitment on the can – double shells lock onto the valve cup so are not as critical • Top load strength is diminished because caps rests on the shoulder radius • Do not mold as fast as double shells which will affect cycle time (cost) Aerosol 101

  26. Functional Caps (or caps that work for a living) • Spray Thru • Child Resistant/Elderly Friendly • Tamper Resistant • Tamper Proof • Accessory Holder (Tube Clip) • Interactive Aerosol 101

  27. Spray Thru Aerosol 101

  28. Tamper Resistant Aerosol 101

  29. Interactive Cap Aerosol 101

  30. Tube Clip Aerosol 101

  31. Value Added Printing Embossing Aerosol 101

  32. More value added…. Metallized Cap Stickers/Labels Aerosol 101

  33. Marketing Aerosol 101

  34. Marketing Questions • What is your customer’s business - filler, manufacturer or end product user? • Does your customer have specific requirements for an overcap - tamper resistant, functional, spray through? • Convenience vs. cost – large cavitation vs. small, short leadtimes, uniqueness or inventory requirements Aerosol 101

  35. More questions…. • What is your competitive edge – a unique feature, distinctive look, low cost? • What size do you need – can size, double or single shell? • Premium product or market driven? Aerosol 101

  36. Resources • Caps • www.cobraplastics.com • www.berryplastics.com • www.estylecaps.com • www.dubuqueplastics.com • www.rackowpolymers.com • http://underwoodmold.com Aerosol 101

  37. THE END Thank you! Please email any questions to: Faye Haber eStyle Caps & Closures faye@estylecaps.com Phone: 815.861.2967 Fax: 847.387.3911 Aerosol 101

  38. Aerosol 101

  39. AerosolOvercaps201 Aerosol 201

  40. Importance of the CAP Dust Cover Protects Actuator Prevents Actuation During Shipping Communicates a ‘BRAND’ image Provides additional real estate for stickers and printing “Green Factor” Aerosol 201

  41. Choosing a CAP Check First for Stock Caps at Suppliers Websites (see end of presentation for supplier websites)… Determine if you want your product to blend in with existing product or present a different look. Should you use a Round Cylinder Stock Cap or design a Custom Shape? Aerosol 201

  42. Choosing a CAP (cont) • Do you want to compliment the shoulder radius on the can or hide it? • Is there a special function required? CR/EF, Spray, Tamper Resistant, Brush… • If the cap you seek is not available, work with your supplier to develop a cap that meets your needs… Aerosol 201

  43. A Few Other Considerations to keep in mind when choosing CAP • Double Shell or Single Shell • Actuator Height • Special Actuator? • Cap to fit directly on Can or Actuator? • Do you want the cap to fit on a collar? Aerosol 201

  44. Keep in Mind the CAP’s Impact On the Filler • Will it need to be Hand Capped (extra cost) or Automatic Capping • Orientability • Will Capper Need to Be Modified Aerosol 201

  45. Commercializing a CAP Rapid Prototype (SLA or Polyjet) vs Molded Prototype SLA or 3D Printing provides a cap to be used for confirmation of aesthetics and some function Model can be painted but will not be exact color as molded part Cap Supplier or Outside Design Firm will design a 3D CAD Model to be used for commercializing your design Aerosol 201

  46. More on SLA Models • SLA’s cost between $50 - $500 each depending on size and complexity so cost for line trials and sales samples are prohibitive • Models tend to be brittle and are easily broken • They will also warp if left in the heat (or during shipping) Aerosol 201

  47. Commercializing a CAP Rapid Prototype vs Molded Prototype If larger numbers of caps are needed for line trials and sales samples, a single cavity prototype is advised Single cavity mold will cost between $3,000 (est) and $30,000 dependent upon complexity Aerosol 201

  48. Commercializing a CAP • A prototype tool will provide a plastic cap that will be representative of final production • During this stage, any changes to surface finish or sizes can be made • Prototype can be used for sales samples and actual production • Should the cap design need modification, then it is best to find it before you build the production tool Aerosol 201

  49. Commercializing a CAP • Color matches can be done in exact cap in preparation of the production mold • The prototype can be used for line trials and prequalification while the production tool is being built • Should the volume only warrant a single cavity – then the prototype can be used for production purposes Aerosol 101

  50. Commercializing a CAP Production Molds Choosing mold cavitation is important to overall project cost The higher the cavitation, the more expensive the mold The higher the cavitation, the bigger the mold, and therefore it needs to run in a bigger injection molding machine which increases the machine hour rate Aerosol 201

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