Group 6:

Anjali shrikant
Basuki Nath dubey
Debasish Padhy
Kushal roy
Mona kumari
Richa daruka
Sonam keshari
Sumit khandelwal

 Introduction to bubble wrap packaging

Raw material used
Manufacturing Process
Poka yoke mechanism
managing by product/ waste
Use of single minute exchange of die mechanism
Future improvements

Name Bubble wrap is registered by Sealed Air Corporation of Saddle Brook,

New Jersey
It is a packing material consisting of two plastic sheets laminated together in a
way that traps air bubbles in small, uniform pockets
Its Flexible cushion helps in protecting fragile objects during storage or
shipping

Plastic resin

Polyethylene and polypropylene as they perform well and are relatively inexpensive
Can be cast into strong, flexible films, which have the ability to hold air without
leaking
These are thermoplastic materials
Other additives
Polypropylene or polyethylene films are formed with a variety of additives mixed
with the base polymers in order to modify their properties and to facilitate processing
Lubricants and plasticizers which control the flexibility of the resin blend
Coupling agents and strength modifiers which improve the bond between the
polymer and the filler
Antistatic agents are added to reduce buildup of static electricity
Biocides may be included to inhibit microbial growth.

As the molten resin is squeezed through the die, it is shaped into a sheet
which is then processed further. After being extruded, the sheet passes through a
series of stainless steel rollers, known as a three roll finisher or a three roll stack.

Polyethylene resin is heated and mixed with the additives

Mixture is then melted and formed into small pellets 0.125 in (0.3175 cm) in
diameter
These pellets are introduced into a molding machine, known as an extruder
At one end of the extruder is a hopper into which the pellets are dumped
Hopper feeds the pellets into a long heated barrel
Barrel is equipped with a screw mechanism, which pushes the plastic forward
The resin melts as it moves along the heated barrel, and by the time it reaches
the end, it can be easily forced out through the opening in the die
After being extruded the sheet passes through a series of stainless steel rollers,
known as a three roll finisher or a three roll stack. These rollers are 10-16 in (25.441 cm) in diameter and are internally cooled with water

Lamination is the process used to seal the two sheets together in such a
way that traps air bubbles.

Resin and additives must be added carefully to ensure the formula components are
blended in the proper ratios
Finished resin may be analyzed to ensure its chemical and physical properties meet
specifications before sheet extrusion operations begin
Start of the extrusion process a small amount may be flushed through the barrel of
the extruder. This purging process cleans out the barrel and reveals any problems with
the molding systems.
It is critical that the resin is kept at the proper temperature
In certain methods of manufacturing it is important that top and bottom plastic
sheets respond to heat differently so that during the lamination process one sheet
distorts but the other does not. For this type of operation, it is critical that the heat
distortion of the two sheets differ by at least 77 F (25 C) or problems will occur
during lamination

The major waste product from cushioning laminate manufacturing is the

plastic resin. Resin that is contaminated, overheated, or otherwise ruined
Sheets that fail quality checks for reasons related to physical molding
problems can be reworked
This recycling process is known as regrinding and shredding the sheets, re
melting them, and re-extruding them as new sheets.
To ensure the plastic meets physical specifications, regrind may be mixed
with virgin resin. This can be done without loss of quality because of the
thermoplastic nature of polypropylene

Single minute Exchange of Die is one of the many lean production methods for
reducing waste in manufacturing process

Improved plastic compounds that are easier to process, provide better

cushioning ability, and are biodegradable
This process creates bubbles without the use of a forming surface. It remains
to be seen if this, or other new manufacturing methods, will be embraced by the
industry in the future.