Hazmat Documentation Life Cycle

January 14, 2015

Gary asks;

I have a question regarding record keeping for running hazmat items.

How long do we have to keep the signed production order (factory ticket) that verifies our compliance to the test requirements?

My question is not about the certifying lab and the copy of the original hazmat test…..it is about keeping records of a production order that went through our plant and the verification process that we do to be sure it is following the requirements of the certified test.

We have a pretty good handle on our process to run hazmat packaging for our customers. The one question that we are struggling to get a good answer on is how long we have to keep our production copies where we verified the board combination and that the spec was followed and signed off by our operator.

We order board specific to our hazmat test – receive the board in and sign off that the order is ready to be processed based on the testing done and submitted to us by our board supplier. We then send the factory ticket out to production with our signature that the board was correct and production can now process the order. Our operator of the last operation signs off on the factory ticket to indicate that the spec was followed for this hazmat item. We then turn those signed factory tickets back in to the office for filing away.

After a while, we get quite a file full of old factory tickets. I have heard that we need to keep the factory tickets for 1 year, 3 years, etc.

According to our own Hazardous Materials Guide for Corrugated Packaging Manufacturers, on page 26 it states that test reports, and other data, must be maintained as long as the packaging is produced and for at least two years thereafter.

— Ralph

Carrier Starch Standards

December 17, 2014

Ruel asks,

Is there a standard testing method for a modified carrier starch? Just like the caustic sensitivity for the pearl starch. I am looking for such test for our basis of acceptance for carrier starch samples. What we have now is just the pilot mixing/formulation at the lab and get the gel point and viscosity of the resulting mixture. However, I believe this can be misleading in some cases, because we may be getting our desired gel point and viscosity at the lab but not be able to determine the other important character of the adhesive which is the green bond.

Ruel –

Roman Skuratowicz from Ingredion Incorporated contributed the information below. I hope this provide the information you were looking for.

— Ralph.

There are a variety of different modified starches used in the industry, and many are distinct from each other. There are viscosity adjusted starches (both stabilized and not stabilized), high amylose starches, non-corn starches, derivatized starches, and custom mixtures. Depending on the type of modified starch used, one of several viscosity, fluidity, or rheology tests would be used for quality control. These are run on the starch similar to the alkali sensitivity and viscosity analyses currently used for unmodified starch. There is no specific test to determine modified starch performance in an adhesive, as the performance is subject to formulation, application conditions, and desired performance attributes.

What has traditionally been done in the field is running a production trial with the modified carrier starch formulated by the adhesive supplier, thus giving them an opportunity to demonstrate product performance as well as their formulation proficiency. Performance is measured by machine speed, bond strength, and quality of board against total consumption (application level) of adhesive. There is no standard method that can predict all of these attributes and conditions.

Ideal moisture content to prevent score cracking on doublewall

December 5, 2014

John asks:

Could you tell me the acceptable level of moister in 90# liners after they have been converted? We have an issue with 600# B/C converted boxes that crack at the scores. Our customer will not accept them and the corrugator that supplies us states that they have to apply enough heat to acquire the correct bond and that sometimes that allows the liner to crack. They say that they ran a moisture test and the moisture is 6.48%, but it does not affect the strength of the container. Is this correct?

Interesting that you bring this question forward now as I am creating a white paper on warp, bonding, and paper and board moistures.

However for a more immediate answer I would ask your supplier three questions. First , how they measure combined board moisture? Second, I would ask what their moisture targets are and if they experience any variations in the containerboards they purchase? Finally, I would ask what their pin adhesion values? Your sheet supplier, especially if it is an integrated, should be able to provide an internal expert on scoring to visit you operation.

Corrugators operate on a delicate balance between running an ideal seven percent combined board moisture and achieving the proper bond. Combiners with the proper process controls can control paper temperatures through the manufacturing phase, but cannot measure moisture with economically available controls.

Once you know what moisture contact you are working with, I would suggest that you contact one of the industry suppliers of creasing profiles to see if they can help you determine the best profiles given the moisture content of the combined board.

— Ralph

Tearing Glue Joints

October 31, 2014

Will asks;

We have recently had a slew of customer concerns in regards to glue joints. Our customers are saying that it is “tearing too easily.” This is for both hot melt and soft white glued boxes, (generally larger boxes that are NOT run through a flexo folder, but rather a Bahmuller or similar piece of equipment). Is there any way to baseline what poundage a glue joint should hold? Does it depend on what liner the board has and what material it is? If so how do you recommend measuring it?

Thank you for the question. First let me point you to an AICC resource, Key Characteristics of Linerboard and Medium and Their Impact on Combined Corrugated Board.  In that brochure you will learn what linerboard physical properties impact glue joint adhesion. Have you reviewed the FBA Handbook?  There is also a TAPPI Test Method for testing adhesives used in glue lap joints.

The strength of the glue bond is dependent on board moisture, relative humidity, slide angle, fibre type, surface strength and internal bond.

The type and location of the fibre tear, rather than an actual physical property value, will provide better information for identifying the source of the issue. Do you have any pictures to share? Is this a recycled linerboard?  Do you have any Dennison wax pick strips? Do you have containerboard mill specifications from the paper suppliers?

Where I am headed is that while it may be the adhesive, the environment, the process, the amount of coverage, it is usually a board and liner issue. Can you provide more information that will help us dig further into the issue?


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