Iranian Tulk Co. | Technical Information
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Technical Information

Can Making Industry:

The metal can is the single most effective packaging solution that has ever been invented. Since its introduction in the early 1800’s, it has enabled  generations  of  human  beings  to  preserve and  protect food  and  other supplies in a shelf – stable  form that does not require refrigeration,  and eliminates waste during shipping, storage and handling. Metal packaging has been the single most important factor in assuring the ready availability of a safe and plentiful supply of nutritious foods and beverages throughout the world.

Cans are classified into:

1-3 piece cans and 2 piece cans, depending on the structure.

2-Aluminum cans and steel cans, depending the material.

3-Pressurized cans and vacuum cans, depending on the degree of internal pressure.

2 Piece Cans and 3 Piece Cans

Major cans are classified into two types;   3 piece cans consisting of three components,   (1) a bottom lid,  (2) a cylindrical body and (3) a top lid (a lid with a lip [an opening] for a beverage can), and 2 piece cans consisting of two components, (1) a body integrated with a bottom lid and (2) a lid with a lip (an opening). Each component is attached by seaming so that the can-body and can-lids (top and bottom) are connected. Cans are sealed by seaming so to isolate their interior  from the outside environment.

3 piece cans are further classified depending on the body joining method (rolling and joining a rectangular flat plate into a cylindrical body) into welded cans (welding by thermal bonding) and soldered cans (bonding by soldering).

Welded cans dominate the market while soldered have almost all disappeared from the market.

2 piece cans are further classified depending on their body forming method;

҉   Drawn cans (drawn cans, draw and redraw cans [DRD cans])

҉   DWI cans (draw and wall ironing cans)

҉   TULC (stretch-draw-ironing cans)

Aluminum Cans and Steel Cans

Aluminum and steel are used as the materials for cans.   Cans are classified into either aluminum or steel,  depending by the can-body (a cylindrical portion) material. Aluminum cans include aTULC (aluminum TULC), ADWI (aluminum DWI) and DRD cans. Steel cans include :

TULC, SDWI (steel DWI), DRD, welded and soldered cans. Aluminum and steel cans are grouped as shown in the following figure:

Beverage can contents and containers

Products:

1-Beverages with milk ( tea, cofee, others).

2-Fruit Juices, Tea and others (Pressurized with Nitrogen gas).

3-Carbonated beverages, beer, Others (Contents include carbonated gas).

Filling Methods:

1-Vaccum Filling:

The pressure inside a can is lower than atmospheric pressure (Negative Pressure). But rigidity of can maintains its strength.

Technology suitable for assuring the safety of milk beverages, where bacteria can easily grow.

The remaining amount of oxygen in the can is low. That protects the content in the package. Oxygen has a property to degrade the quality of the contents.

  1. Pressure Filling:

By using gas, the can’s internal pressure is graeter than the atmospheric pressure ( Positive Pressure ). Even though the can’s body is weak, rigidity is maintained.

Reduction in weight and energy consumption.

Types of Cans:

3 Piece Can:

Welded Can (Steel) – 3 piece cans consist of three components : Body, End and Lid.

2 Piece Can:

Manufacturing Process of aTULC

aTULC (aluminum Toyo Ultimate Lightweight Can) is a 2 piece can which constitutes drastic improvements in environmental friendliness  through which were achieved by reviewing the fundamentals of materials properties and manufacturing processes. aTULC is a polyester laminated aluminum 2 piece can on the interior and exterior surfaces, is processed into cups, similar how DWI cans are processed. Then, it is drawn, stretched and ironed to reduce the thickness of the can-body side walls (stretch-draw-ironing process). However, unlike DWI cans, no coolant (lubricant) is used during the can-body forming process, thus eliminating the need for coolant rinsing, and waste water treatment.  Due to the internal layer of polyester, inside lacquer coating is not required, hence significantly reducing CO2 emissions, a byproduct of the internal lacquer curing process.

Manufacturing Process of 2 Piece Cans (TULC & aTULC)

Ironing of DWI Cans

Material ( in the form of a cup ) is punched, using a punch sleeve, through a set of ironing rings. Pushing the cup through the narrow gap between the punch sleeve and the ironing dies form the cup,  by ironing  the  cup  walls  into  thinner and further  extruded  walls,  into  the can-body. Coolant is sprayed in order to lubricate and cool the tools and materials during this process, thus rinsing is required after molding.

Stretching and Ironing of TULC

“Stretch-draw-ironing”, a molding method developed from the “tension and bending” process, is used to iron materials while applying a back tension. Polyester film laminate acts as lubricant to allow molding without the use of coolant, allowing for a decrease in material usage, and thus reducing environmental burdens.

Focusing on Environment and Society ( CSR ):

TU LC(Toyo Ultimate Lightweight Can)

Pursuit of  convenience  in  consumer  products  has  created  various problems  for  the environment,  which now  demands  a  production  system  that protects the environment  and make  the best possible use of ur resources.

In  the  packaging  industry , TU LC for  Toyo Ultimate Lightweight Can, is the answer to such needs.

TU LC comes  out  of  a manufacturing  process  that  does  not pollute  water  and dramatically  reduces industrial  water usage and CO2  emissions. A state-of-the-art technology in the areas of material and  forming  techniques developed  by Toyo Seikan Group over the course of its 90 years history gave birth to TU LC, truly an innovation package for new area.

aTU LC  ( Aluminum Toyo Ultimate Can )  is a polyester  –  laminated aluminum  can  based  on the  “TULC”  concept and is characterized by its high functionality and low environment impact.

TU LC THE PACKAGING FOR NEW ERA

  1. Technology that covers “Cradle-to-Grave”

Developed based on LCA (Life Cycle Assessment) The unprecedented   low  environmental   load   of   TULC  was   attained   by  the introduction of LCA procedures in the process of its development. For the life cycle; from raw material  processing  to recycling, one  TULC has reduced the production energy by 26% and the carbon dioxide emissions by 20% compared to one aluminum  DWI can.

  1. Technology that does not use water

New forming method that does not cause water pollution During the forming of aluminum DWI can, a large amount of water is consumed to rinse  out the coolant  required  for the ironing process,  reaching to as much as  9,000  m3 per  month for a single line.  In the contrast,  “TULC”  uses absolutely no water during its can forming  process because  it  employs  what is called  dry forming  that does not required Coolant.

  1. Technology that does not produce wastes

Ultimate reduction of industrial wastes

40 tons of solid waste per line is generated monthly from the treatment of waste water used for the forming of aluminum  DWI  cans.  On the other hand,  there is no waste water from the formin process of  “TULC” and it generates mere 120 kg of solid waste per month ( from waste lacquer ).

  1. Technology that is friendly to the atmosphere

Reduction of CO2 emissions to less than 1/3  Lamination of polyester  film  on both the internal and external surface of  “TULC” eliminates the need for coating   and   baking  processes  that  are essential with the conventional aluminum  DWI  can.  As a result, emission of carbon dioxide, a cause of global warming, from one  “TULC”  has been reduced to less than a third of what comes out one aluminum DWI can.

  1. Technology that encourages recycling

Remarkable recyclability In cause of laminated polyester films only consist of carbon, hydrogen  and  oxygen,   it discharges no toxic fumes when burned off for recycling.

Film Laminating Process

  1. Technology that retains deliciousness

Outstanding flavor retention

TULC has much better properties rather than the conventional cans  in  terms of  flavors retention because  its internal surface  is  laminated  with  polyester   film   that   absorbs   less  flavor  components  and  allows  significantly less migration of organic  substances over conventional lacquer coating.

Cans are an ideal choice for beverage packaging:

1. easy to handle and transport
2.     easy to open
3. unbreakable
4. cools quickly in the fridge
5. lightweight and volume efficient
6. protects content from light and air
7. long shelf life
8. environmentally friendly
9. easy to recycle
10. maintains fizz and freshness
11. compact – best cubic efficiency for carbonated drinks
12. fast and efficient filling
13. no labeling required
14. Polished surface.
15. No coating process needed.
16. It can reduce CO2 occurring in the coating process.
17. Laminated resin does not contain environmental hormones.
18. No cleaning process needed when used for beverage or food containers.