Aerosol Overcaps 101 March 10 2011 Aerosol 101

Aerosol Overcaps 101 March 10, 2011 Aerosol 101 Faye Haber e. Style Caps and Closures, Inc. Midwest Aerosol Association March 11, 2010

Why are caps important? ? 1. 2. 3. 4. 5. 6. March 10, 2011 Dust Cover Prevents accidental discharge Aesthetics Load Factor Can deliver a message “Green” Factor Aerosol 101 Slide 2

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”. March 10, 2011 Aerosol 101 Slide 3

Injection Molding Machine March 10, 2011 Aerosol 101 Slide 4

How does it work? March 10, 2011 Aerosol 101 Slide 5

Mold (Cavity) March 10, 2011 Aerosol 101 Slide 6

To layer pack or not to layer pack…. . March 10, 2011 Aerosol 101 Slide 7

Material Properties March 10, 2011 Aerosol 101 Slide 8

Materials • • • Polyethylene (HDPE) Polypropylene (PP) Clarified Polypropylene (CPP) Copolymers (Blended) Styrolux/K-Resin Non-Antistat Polypropylene (NAPP) March 10, 2011 Aerosol 101 Slide 9

Polypropylene 1. 2. 3. 4. 5. 6. Lightweight High compressive strength (top load) Scuff Resistant Retains stiffness and flex Clearer than PE Higher anti-stat levels March 10, 2011 Aerosol 101 Slide 10

Polyethylene 1. 2. 3. 4. 5. Softer material – more crack resistant Does not hold it’s shape when bent Cloudier Faster cycle times Scuffs easily March 10, 2011 Aerosol 101 Slide 11

Other materials § Clarified PP ØUse when more clarity is needed § Styrolux ØBest clarity, lowest shrinkage § Non-antistat PP ØUse when painting, printing or metallizing caps March 10, 2011 Aerosol 101 Slide 12

Can Styles üAluminum üStraight Walled üNecked In üDS Container üSexton Can March 10, 2011 Aerosol 101 Slide 13

Aluminum March 10, 2011 Aerosol 101 Slide 14

DS Container March 10, 2011 Aerosol 101 Slide 15

Sexton Cans March 10, 2011 Aerosol 101 Slide 16

Cap Styles March 10, 2011 Aerosol 101 Slide 17

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. March 10, 2011 Aerosol 101 Slide 18

Straight Side/Necked In March 10, 2011 Aerosol 101 Slide 19

Straight Sided • 202 • 211 • 300 March 10, 2011 • • • Aerosol 101 High Stacker Caps Double Shell Tamper Resistant DS Tamper Proof Snap Lock Rim Snaps Slide 20

Necked In • • • 112/45 mm 202/52 mm 205/57 mm 211/65 mm 300/70 mm March 10, 2011 • • Stacker Type Double Shell Single Shell Tamper Resistant/Child Proof • Spray Thru Aerosol 101 Slide 21

Aluminum • • 38 mm 45 mm 49 mm 50 mm 53 mm 59 mm 66 mm March 10, 2011 • Caps to fit over valve cover • Double Shell Caps • Caps to fit over actuators Aerosol 101 Slide 22

Single Shell/Double Shell March 10, 2011 Aerosol 101 Slide 23

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 March 10, 2011 Aerosol 101 Slide 24

…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) March 10, 2011 Aerosol 101 Slide 25

Functional Caps (or caps that work for a living) • • • Spray Thru Child Resistant/Elderly Friendly Tamper Resistant Tamper Proof Accessory Holder (Tube Clip) Interactive March 10, 2011 Aerosol 101 Slide 26

Spray Thru March 10, 2011 Aerosol 101 Slide 27

Tamper Resistant March 10, 2011 Aerosol 101 Slide 28

Interactive Cap March 10, 2011 Aerosol 101 Slide 29

Tube Clip March 10, 2011 Aerosol 101 Slide 30

Value Added Printing March 10, 2011 Embossing Aerosol 101 Slide 31

More value added…. Metallized Cap March 10, 2011 Stickers/Labels Aerosol 101 Slide 32

Marketing March 10, 2011 Aerosol 101 Slide 33

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 March 10, 2011 Aerosol 101 Slide 34

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? March 10, 2011 Aerosol 101 Slide 35

Resources • Caps – – – March 10, 2011 www. cobraplastics. com www. berryplastics. com www. estylecaps. com www. dubuqueplastics. com www. rackowpolymers. com http: //underwoodmold. com Aerosol 101 Slide 36

THE END Thank you! Please email any questions to: Faye Haber e. Style Caps & Closures faye@estylecaps. com Phone: 815. 861. 2967 Fax: 847. 387. 3911 March 10, 2011 Aerosol 101 Slide 37

March 10, 2011 Aerosol 101 Slide 38

Aerosol Overcaps 201 April 19, 2012 Aerosol 201 Faye Haber e. Style Caps and Closures, Inc. Midwest Aerosol Association April 19, 2012

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” April 19, 2012 Aerosol 201 Slide 40

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? April 19, 2012 Aerosol 201 Slide 41

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… April 19, 2012 Aerosol 201 Slide 42

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? April 19, 2012 Aerosol 201 Slide 43

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 April 19, 2012 Aerosol 201 Slide 44

Commercializing a CAP Rapid Prototype (SLA or Polyjet) vs Molded Prototype • SLA or 3 D 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 3 D CAD Model to be used for commercializing your design April 19, 2012 Aerosol 201 Slide 45

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) April 19, 2012 Aerosol 201 Slide 46

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 April 19, 2012 Aerosol 201 Slide 47

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 April 19, 2012 Aerosol 201 Slide 48

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 March 10, 2011 Aerosol 101 Slide 49

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 April 19, 2012 Aerosol 201 Slide 50

Commercializing a CAP • Rule of Thumb for a cap is to multiply cavitation by 2. 5 million to get annual capacity (on 5 day work week) • Of course, that can change because of cycle time April 19, 2012 Aerosol 201 Slide 51

Commercializing a CAP Production Molds • Use ‘Best Value’ method to determine cavitation • Use Annual Piece Part Cost + Annual Mold Amortization Cost to compare cavitation options April 19, 2012 Aerosol 201 Slide 52

Commercializing a CAP Production Molds • Cavitation choices are recommended to be 1, 2, 4, 8, 16 or 32 • to ensure a balanced runner system (improves cavity to cavity variation). March 10, 2011 Aerosol 101 Slide 53

March 10, 2011 Aerosol 101 Slide 54

Commercializing a CAP Production Molds • Lead time for tooling and process validation typically takes from 4 weeks to 20 weeks • Depending on cavitation and mechanical complexity April 19, 2012 Aerosol 201 Slide 55

Producing a CAP Quality Considerations • Sources of size variation • Changes in base resin • PP shrinks less than HDPE April 19, 2012 Aerosol 201 Slide 56

Producing a CAP – Quality Considerations • Sources of size variation • Changes in color • Blues shrink more than white April 19, 2012 Aerosol 201 Slide 57

Producing a CAP – Quality Considerations • Sources of size variation • Changes in Process • Faster cycle time results in smaller cap March 10, 2011 Aerosol 101 Slide 58

Commercializing a CAP Cavitation Considerations 250 200 150 Molding SG&A 100 RM + PKG 50 0 1 April 19, 2012 2 4 8 Aerosol 201 16 32 Slide 59

Resources • Caps – – – www. cobraplastics. com www. berryplastics. com www. estylecaps. com www. dubuqueplastics. com www. rackowpolymers. com http: //underwoodmold. com April 19, 2012 Aerosol 201

Thank you! Please email any questions to: Faye Haber e. Style Caps & Closures faye@estylecaps. com Phone: 815. 861. 2967 Fax: 847. 387. 3911 March 10, 2011 Aerosol 101 Slide 61