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Private Company
Material and process improvements for eliminating metal particulates in manufacturing
  • Background
  • What we're looking for
  • What we can offer you
  • Q&A
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Background

Fibre drums are cylindrical containers used for the transportation and storage of dry, semi-liquid and liquid products, ranging from 1 to 78 gallons. They play a crucial role in our portfolio by offering sustainable, versatile, and cost-effective packaging solutions. 

 

The current methods for the production of fibre drums utilize materials and processes that inherently generate particulate matter, which can enter the packaging (fibre drum) during manufacturing. 

 

Metal particulates can be introduced into fibre drum packaging from several mechanical forming processes: precurling/hemming, mechanical crimping, steel metering and welding. These processes are essential for manufacturing and attaching chimes - metal hoops or bands at the top and bottom edges of the drum - which provide structural reinforcement and maintain the drum's integrity. 

 

Precurling or hemming involves shaping the edges of the drum’s components to create a smooth, rounded edge, ensuring secure fitting with lids or closures. During this process, metal particulates can be generated from the tools and machinery used. 

 

Mechanical crimping, a process used to attach the chimes to the drum body, involves pressing or bending the metal to secure it tightly around the drum. This process also produces metal particulates from the crimping tools and the metal chimes themselves. 

 

Metering and welding are used to decoil and cut chime band materials and weld them to the final chime size. This process also produces metal particulates from the cut-to-length shearing, and potential slag from welding. 

 

If not properly managed, particulates generated in the processes described above can enter the interior of the fibre drum.

What we're looking for

We are looking for technologies to either modify the materials used for chimes or to improve or replace the methods of production, such as precurling/hemming and mechanical crimping, to help eliminate the production of debris in the manufacturing process or prevent the debris from entering into the packaging.

Solutions of interest include:
  • Encapsulation technologies that provide protective coatings to prevent the release of particulates.
  • Alternative materials for chimes to reduce particulate generation.
  • Redesign of production methods to minimize debris.
  • Deburring processes that remove unwanted material from metal components (e.g. abrasive blasting, vibratory tumbling, automated deburring machinery).
Our must-have requirements are:
  • Any new materials or processing aid in contact with the interior package/lading surface must meet FDA and EU 10/2011 regulations for direct food contact application to packaging.
  • Solutions must eventually achieve a reduction or elimination of particulates by 35% or more, measured by size and count, using standard wipe, vacuum or swish test.
Acceptable technology readiness levels (TRL):
Levels 1-9
What we can offer you
Eligible partnership models:
Sponsored researchCo-developmentEquity investmentSupply/purchaseLicensing
Benefits:
Sponsored Research
Up to 100k in funding provided in increments based on the achievement of specific milestones and progress checkpoints.
Expertise
Partners will be assigned a company mentor to champion and connect other functional resources such as engineering, quality, continuous improvement, EHS, product managers, and other technical support.
Data
Will work with partners in gathering any data needed for the assessment and development, such as obtaining physical samples, photos, drawings (tooling and others), videos needed.
Facilities and Services
Partners can visit the facility in person and or send samples for on-site processing. Will work with partners to establish production trials.
Q&A with the company

The Q&A is now closed.

Sort by:
Q.
Is the process improvement that is desired specific to a single location & production line? What is the approximate throughput or production for the drum line(s)?
1
A.
Hi Ron- This is across several sites and several lines that operate in the 300-700 unit/hr range.
Team Member, Reviewer, Private Company
September 23, 2024
Is this response helpful?
1
0
Q.
I noticed the particulate data for each process isn’t included, which makes it difficult to identify the main sources of debris. Could you share this data to help focus on the most critical areas for improvement?
1
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