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Ill:munmill'l‘lilln‘lllflllll " I 3 1293 00763 5307 r \ LIBRARY Michigan Cute University I; A ‘fi— This is to certify that the thesis entitled A COMPARISON BETWEEN VARIOUS PACKAGE CUSHIONING MATERIALS BASED ON PERFORMANCE AND ENVIRONMENTAL CONCERNS presented by NOPPORN CHARNNARONG has been accepted towards fulfillment of the requirements for MASTER Jegree in W MW S. PAUL SINGH. H-D- Major professor Date JULY 9. L991 0‘7639 MS U is an Affirmative Action/Equal Opportunity Institution PLACE IN RETURN BOX to remove this checkout from your record. TO AVOID FINES return on or before date due. DATE-03E . DATE DUE DATE DUE ”1019;? Or {5"}‘3 U 7 1:54, 1 1'} ”3* '4 MSU Is An Affirmdlve Action/Equal Opportunity Institution dammit-o A COMPARISON BETWEEN VARIOUS PACKAGE CUSHIONING MATERIALS BASED ON PERFORMANCE AND ENVIRONMENTAL CONCERNS BY Nopporn Charnnarong A THESIS Submitted to Michigan State University In partial of fulfillment of the requirements for the degree of MASTER OF SCIENCE School of Packaging 1991 ABSTRACT A COMPARISON BETWEEN VARIOUS PACKAGE CUSHIONING MATERIALS BASED ON PERFORMANCE AND ENVIRONMENTAL CONCERNS BY Nopporn Charnnarong The solid waste problem associated with the increasing proportion of plastic packaging materials has become a serious public concern. Many innovative cushioning materials have been created with the intent to protect the environment from overpopulation of non biodegradable materials. In this study, ten cushioning materials were chosen to evaluate the performance euui develop " Environmental Cushion Curves " which describe the level of protection for Cushion Weight to Product Weight Ratios and Cushion Volume to Product Weight Ratios. Three different drop heights were used to evaluate each cushioning material. The results show that most of the polymer cushioning materials perform better with smaller percent weight usage than the paper-based cushioning materials. Copyright by NOPPORN CHARNNARONG 1991 ACKNOWLEDGMENTS I would like to express my sincere thanks to Dr. Paul Singh, who served as my major professor, for his time, assistance and guidance in the completion of this thesis. I would also like to thank Dr. Gary Burgess who took the time to discuss my concerns and whose guidance was invaluable in the completion of this thesis. I would also like to thank Dr. George E. Mase for his time, assistance and raising' some questions that I[ had. not considered. Last but the greatest of all, thank my parents for their love and support during both happy time and trying time. TABLE OF CONTENTS LIST OF TABLES ........................................ Vi LIST OF FIGURES ..................................... viii CHAPTER 1 : INTRODUCTION ............................... 1 CHAPTER 2 : MATERIALS AND TEST METHODS 2.1 MATERIALS 2.1.1 Arcel 310 ............................. 10 2.1.2 Arpak 4322 ............................ 12 2.1.3 Arsan 600 ............................ 12 2.1.4 Ethafoam 220 ......................... 13 2.1.5 Honeycomb ............................ 13 2.1.6 Instaflex ............................ 15 2.1.7 Pelaspan Mold-a—pac .................. 16 2.1.8 Polycap Plus PD 230 ................... 17 2.1.9 Popcorn .............................. 18 2.1.10 Quadrapak ............................ 19 2.2 TEST METHODS ................................ 21 CHAPTER 3 : DATA AND RESULTS .......................... 26 CHAPTER 4 : CONCLUSIONS ............................... 43 APPENDICES APPENDIX A : SHOCK TRANSMISSION DATA ............. 45 APPENDIX B : CUSHION CURVES ...................... 48 APPENDIX C : CALCULATED DATA .................... 58 REFERENCES ........................................... 68 LIST OF TABLES TABLE Page 1 Hierarchy for Solving Solid Waste Problems ............. 3 2 Cushioning Materials Evaluated in this Research ....... 11 3 Reference Documents for Cushion Curve Data ............ 22 4 Required Cushion Weight to Product .................... 27 Weight Ratio (%) at 24 inches drop height 5 Required Cushion Weight to Product .................... 28 Weight Ratio (%) at 30 inches drop height 6 Required Cushion Weight to Product .................... 29 Weight Ratio (%) at 36 inches drop height 7 Required Cushion Volume to Product .................... 31 Weight Ratio at 24 inches drop height 8 Required Cushion Volume to Product .................... 32 Weight Ratio at 30 inches drop height 9 Required Cushion Volume to Product .................... 33 Weight Ratio at 36 inches drop height A1 Shock Transmission Data of Honeycomb .................. 45 A2 Shock Transmission Data of Popcorn .................... 46 A3 Shock transmission data of Quadrapak .................. 47 Cl Arcel 310's Weight and Volume to Product .............. 58 Weight Ratio. vi Table Page C2 Arpak 4322's Weight and Volume to Product ............. 59 Weight Ratio. C3 Arsan 600's Weight and Volume to Product .............. 60 Weight Ratio. C4 Ethafoam 220's Weight and Volume to Product ........... 61 Weight Ratio. C5 Honeycomb's Weight and Volume to Product .............. 62 Weight Ratio. C6 Instaflex's Weight and Volume to Product .............. 63 Weight Ratio. C7 Pelaspan Mold-a-pac's Weight and Volume ............... 64 to Product Weight Ratio. C8 Polycap plus PD230's Weight and Volume ............... 65 to Product Weight Ratio. C9 Popcorn‘s Weight and Volume to Product ................ 66 Weight Ratio. C10 Quadrapak's Weight and Volume to Product .............. 67 Weight Ratio. vii LIST OF FIGURES FIGURE Page 1 Weight Percent of Materials in Solid Waste Stream ...... 2 2 Minimum and Maximum Static Stresses ................... 25 Were Obtained From Each Cushion Curve 3 Comparison of Level of Protection vs.Cushion .......... 35 Weight to Product Weight at 24 inches Drop Height 4 Comparison of Level of Protection vs.Cushion .......... 36 Weight to Product Weight at 30 inches Drop Height 5 Comparison of Level of Protection vs.Cushion .......... 37 Weight to Product Weight at 36 inches Drop Height 6 Comparison of Level of Protection vs.Cushion .......... 38 Volume to Product Weight at 24 inches Drop Height 7 Comparison of Level of Protection vs.Cushion .......... 39 Volume to Product Weight at 30 inches Drop Height 8 Comparison of Level of Protection vs.Cushion .......... 40 Volume to Product Weight at 36 inches Drop Height B1 Cushion Curve for Arcel 310 .......................... 48 BZ Cushion Curve for Arpak 4322 .......................... 49 B3 Cushion Curve for Arsan 600 ........................... 50 B4 Cushion Curve for Ethafoam 220 ........................ 51 B5 Cushion Curve for Honeycomb ........................... 52 B6 Cushion Curve for Instaflex's ......................... 53 B7 Cushion Curve for Pelaspan Mold-a—pac ................. 54 88 Cushion Curve for Polycap ............................. 55 B9 Cushion Curve for Popcorn ............................. 56 B10 Cushion Curve for Quadrapak ........................... 57 viii CHAPTER 1 INTRODUCTION The .American. public: is increasingly' concerned. with environmental issues, which will dominate the national agenda in the United States throughout the coming years.(18) One of these issues is municipal solid waste, of which two hundred million tons is generated each year. Each day, the average American person generates about 4 pounds of solid waste. This is nearly double the rate 30 years ago. The largest contributor to the nation‘s municipal solid waste is expendable packaging. Plastics :uu particular constitute about one-third of all municipal solid waste. Plastic packaging, including cushioning materials which represent about 7.9% of all plastics packaging produced in U.S. ( in dollar value ), accounts for about 6 percent by weight of all municipal solid waste. The plastic content of solid waste is small on weight basis but is nevertheless significant on a volume basis. Paper and paperboard constitutes 35.6% of the total volume of municipal solid wastes ( Figure l ). Figure 1 : Weight Percent of Materials in Solid Waste Stream Miscellaneous Inorganics 1.8% Paper and Paperboard Yard Wastes 35.6% 20.1% Metals 8.9% 8.4% Source : FRANKLIN ASSOCIATES, LTD., 1988 The solid waste problem can be solved if the government, packagers, suppliers all ‘work 'together aggressively ‘to educate consumers the realistic solutions that will address the solid. waste problem. Unless make up function of landfills becomes clearly understood, well—intentioned efforts are likely to aggravate this problem. Landfilling, incineration, recycling, and source reduction will all be necessary to address the solid waste issue(7). The Environmental Protection Agency ( EPA ) has developed a hierarchy as described in Table l to address the problems associated with solid waste. TABLE 1 : Hierarchy for Solving Solid Waste Problems 1 Source Reduction 2 Recycling or Composting 3 Incineration 4 Landfilling Landfilling is an engineered method of disposing of solid wastes on land in a manner that minimizes environmental hazards. At a site that is carefully selected, designed and prepared, the wastes are spread in thin layers, compacted to smallest practical volume and covered with earth. The critical factors which must be considered in landfill design are leachate, gas production, odor, noise, aesthetics, air pollution, dust, fires and birds. Landfilling remains the most frequently used and economical means of safe disposal in United States. .However ix:.is estimated that one-fourth of the nations major cities will run out of such disposal sites by 1993 (11) (23). One-third of the existing landfills will be full, and.tflu2 new landfills are becoming increasingly difficult to site (15). Incineration is a means of disposing of refuse by high temperature oxidation. The residue left over will vary widely depending on the composition of the wastes. For example, waste paper yields ash which is as little as 1% of the mass of waste. Incineration reduces the volume of garbage to be landfilled by 90% and it also transforms waSte to usable energy, but the cost associated is as much as twice that of landfilling. The 10% remaining ash, containing heavy metals which must be disposed off as hazardous waste, does not eliminate the need for landfills. It is second in tonnage among community disposal methods with landfill predominating by a large factor. There is also concern about the incineration of plastics that emit gaseous pollutants like HCl, HF or CO.(10) Recycling is the other process that the public can directly contribute to the solid waste problem. It is the most attractive approach for a number of reasons. It saves energy expended for retrieval and the type of material recycled. It also conserves valuable raw material resources. For example recycled plastics and paper can be more economical alternatives than the corresponding virgin material. However they suffer some degradation during reprocessing, but they are nevertheless useful and viable alternatives. The three major factors that influence recycling are collection, separation, and cleaning. The public can provide mechanisms to address the first two issues. The fourth criteria to accomplish successful recycling is listed below, (1) continuing source of scrap (2) variable recycling and reprocessing technology (3) good economics (4) application and market for products derived from the recycled waste. Cushioning is a prime application for recycled materials. This however would not be suitable for consumer packages such as the primary food container where direct food contact with recycled material will not be approved by the Food and Drug Administration. Traditional approaches euui add-on solution (xf waste management alone cannot easily solve the solid waste problems. .All waste management practices have associated economic and environmental costs, and can simply shift pollution problems from one environmental medium to another. Creative, new approaches are needed at the source of garbage problems. It is source reduction which :us the most significant anui important practice t1) reduce solid waste stream by designing, manufacturing, purchasing or using materials and packages to reduce their amount or toxicity before they enter the municipal solid waste stream. In addition they should not increase the net amount or toxicity of wastes generated throughout the life of material.(l8) (24) The political leaders at all levels have already been actively involved imlea mirage of pmoposed packaging bans. The Environmental Protection Agency ( EPA ) has provided the outlining of hierarchy for integrated waste management to be considered at seminars, workshops and research projects. The proposed recyclable Materials Science and Technology Development Act has required the Department of Commerce to recommend the measures for ensuring the development of technologies for recycling nondurable consumer product packaging and the expansion of markets for recycled products. Over 20 states had procurement guidelines for the acquisition of recycled materials. Nine of these states had deposit laws and waste management laws to assist their activities. Many environmentally conscious packaging materials and manufacturing methods have been developed in the past few years to respond to this crisis. In 1990 Astro-Valcour had successfully eliminated the CFCs and HFCs from the manufacturing process by replacing it.rmhfli a hydrocarbon— based blowing agent. Most of the polystyrene industries are also eliminating the use of Chlorofluorocarbons as a blowing agent. Man-made Chlorofluorocarbons (CFCs) are believed to have been a major cause in destroying the ozone layer which shields earth.:fimmn harmful ultraviolet radiation. NASA satellites have found an ozone hole which covers an area of 5.5 million square mile at the South Pole. Plastic cushioning materials have also been scrutinized by environmentalists and city engineers. They have negative images to the consumers with regard to their long-term life in landfill sites and their volume used in packaging has essentially doubled in the past 10 years. Consequently, many manufacturers have shown their significant interests in new cellulose-based cushioning materials (17) like curled wood shavings, popcorn, zigzag shredded kraft paper, honeycomb or Quadrapak ( an innovative structural kraft paper) that were supposed to be more environmentally friendly since they can biodegrade. Berry Hill, a small mail order firm in St. Thomas, Ontario, uses about 100 pounds of fresh popped corn daily for packing and shipping of farm equipment.(2) In the Packaging Magazine issue, November, 1990, Melissa Larson. described tflma environmental concerns cu? standard plastic loose-fill materials and an interest in alternative materials (16). Based on this, a survey was done to request cushion performance data front a list of manufacturers provided in the article. The purpose of this study was to evaluate cellulose- based cushioning materials to the polymer cushion materials by comparing the environmental performance measured as the ratio of weight and volume of the cushioning material to the weight of product, required to provide the same level of protection to the product. Specifically, the objectives of this study were 1 To quantify the cushioning performance of the "environmentally conscious " materials like popcorn, zigzag shredded paper and Honeycomb. 2 To provide a means of comparing the percent utilization of cushioning materials of various kinds to provide the same level of protection to the product. CHAPTER 2 MATERIALS AND METHODS 2.1 Materials Seven different commercially available types of polymer cushioning materials were chosen to be evaluated and compared with three "environmentally conscious" materials. The cushions selected auui the appropriate manufacturers are listed in Table 2. All materials evaluated in this study are described in alphabetical order in section 2.1.1 to 2.1.11 2.1.1 Arcel 310 :n; is ARCO Chemical's moldable Polyethylene copolymer which falls between EPS and EPE in performance but exceeds both materials in toughness. It has good multiple impact performance, better tensile and puncture resistance than any other moldable resilient foam available in [HS'today. The price is in the $2.50 per pound range. 10 11 wamouamm AHONV momvlavleoomv ooovubmhnAHomv ooownbms Aaowv Hmamlmmmeromv mmmvravleoowv .ocH .mmflupmzocH xommroom coaumuomuoo HMOHEch zoo coaumuomuoo Ham poamom coaumuomuoo ufl< ooamom muoo neooxocom amcoflumcuoucH coflumuomuoo HmoHEono zoo xmmmuomso ommumuoaoz cwmmmaom ommom dmosaom snooaom xoawmumcH QEooxmcom omm amoumaom Momma pmmum mcouxum>aom manmocmmxm magnum Hfla mm \ coasz \ mm cuoo oommom Emow womaumus>aom Momma pmmum Emom wcmaxnumwaom oooerNmIAoowv >CMQEOU Hmofleoco comm ooo sound Emom maflnuflcoH>uo< ocwnxum ooosuammrloomv scadEoo Hmousoao ooua mmmv xmoua ammo mamassumsaom omocmdxm ooouufimmeromv >cmmEoo Hmoaewco comm cam Hmoud qu>Homoo mcmaanum>aom pmpcmmxm .oc wconamama wowsuommscmz osmcmomua coaumofluflmmmao HMflHmumz >osum menu CH omumsam>m mamaumumz macanmso " m magma 12 2.1.2 Arpak 4322 It is ARCO Chemical's Expanded Polyethylene bead. The properties are similar to Dow Chemical's Ethafoam 220. It is a low density semirigid, closed-cell polyethylene homopolymer whidh is soft, nonabrasive, provides good multiple impact cushioning, has good vibration—damping characteristics, high mechanical strength, and good chemical resistance. The raw material cost is in the $2.25 per pound range.(4) 2.1.3 Arsan 600 It is ARCO Chemical's Styrene Acrylonitrile copolymer foam which is an attempt to take the best properties from EPS and EPE, and combine them into a moldable, lightweight, semi- rigid, closed cell, high resilient styrene copolymer resin. The resin relies (n1 a fluorocarbon blowing agent to pre— expand and fuse the material during its molding phase. It provides good impact protection, good insulation, and good vibration damping characteristics. Its advantage over EPS is the ability to withstand repeated drops. The cost of resin is in the $2.00 - $2.50 per pound range. These properties make it suitable for application where multiple impact, low l3 fragility, high static loading and.luufl1 value items are involved.(5) 2.1.4 Ethafoam 220 This is time trademark for Iknv Chemical's Polyethylene foam. The general characteristic is the same as Arcel 310 tough, closed cell materials which are energy absorbent, resilient, lightweight, moisture and chemical resistant and easy tx> fabricate. Potential disadvantages (n5 PE foam include : it. is more expensive than :most (other' common cushioning materials on volume basis, slightly abrasive for some highly polished or very sensitive painted surfaces. Ethafoam has been in use for the past two decades. It is extruded in planks which are fabricated to provide required cushions. It is economical as a cushioning material for sensitive products when shipping volumes are small and molded cushion per product costs are expensive.(l3) 2.1.5 Honeycomb It was developed by the Structural Mechanical Research Laboratories at the University of Texas, Austin during 1953 to 1959. They had investigated many kinds of cmshioning 14 materials to determine the best available material for single drop aerial delivery and Honeycomb was determined to be the most suitable for this particular use. The structure of Honeycomb is a sandwich construction, consisting of oval cells, glued between two thin, high strength facings. The loads are transferred from the face, to the core, to the second face. It can be best understood by comparing it t1) the I-beam structure, resisting shear loads and increasing structural rigidity by spreading the opposite faces apart. Unlike: the I-beam, .however, ‘the honeycomb core gives the continuous support to the facing because of its network configuration.(14) The entire structure is made of unbleached Kraft paper. The oval core is made from kraft paper with 33 pound basis weight and the face panel from 69 pound basis weight. It is available in different size of core cells and thicknesses. In 1986, the cushion curves were experimentally developed by Singh (22), to evaluate the effect of core size, the cushion thickness and drop height on shock transmission. 15 The Honeycomb used in this study has a 7/16 inch core size and 115 2 inches thick. The density, impact velocity, moisture content anui temperature are luunni to affect the dynamics stress and strain curve of Honeycomb.(8) 2.1.6 Instaflex It is a semi—rigid, CFC free Foam-in—Place developed by Sealed Air Corporation. The material is produced on site by pumping Polyurethane resin and Polymeric Isocyanate through the heated line to the dispenser at which the two chemicals are ndxed.tx> the proper ratio. .As the liquid mixture is dispensed out, :U: quickIy expands and solidifies to form.a. custom fit cushioning foam. Water vapor and Carbondioxide are emitted during the raising period that might cause concern to the operator. Adequate air circulation is therefore required in the operation place. Foam—in-Place has some significant handling and storage advantages because the cushioning is produced when it is needed. It also provides an increased flexibility to pack a wide variety of product shapes, sizes and weights. It can be stored. in liquid form, reducing' the storage space and l6 inventory cost. However, its density is not uniform as it varies depending (M1 the shape and region dispensed. The molds used are made generally from wood and therefore are very economical as compared to EPS or EPE. It is biostable, difficult to degrade and can 1x3 landfilled without contributing to air and water pollution. Another way to dispose is as a fuel for waste-to-energy incinerators.(19) 2.1.7 Pelaspan Mold-a-pac The EPS loosefill is used to pmotect the product and fill voids. It is cost—effective protection for lightweight products. On the volume basis, it is the least expensive and the lightest of all plastic cushioning. However, it is messy and not designed to protect heavy products. Some will settle during transit due to vibration and may cause the product to shift and result in damage during subsequent handling.(1) This Dow Chemical's bonded EPS loosefill can solve some problems of ordinary EPS loosefill. It comes in s-shape configuration. Each piece is coated with adhesive as it is dispensed from the overhead hopper into the container and 17 plastic film is used to separate the loosefill from the product. It is uniform, has consistent density, forms a resilient cushion to better hold the product. It is a light weight cushioning with the density of only 0.26 pound per cubic feet, providing a clean and custom-designed appearance. It has a lower material cost than many other cushioning materials. It is typically used for a wide range of products where shipping volume are small and increased flexibility is required. It is used by several small mail order houses to ship a wide variety of products.(12) 2.1.8 Polycap Plus PD230 In 1960, Sealed Air Corporation invented an air cellular material for cushioning and surface protection, a significant breakthrough in packaging science. It was produced by encapsulating bubbles of air between two sheets of plastic film. It is typically flexible, soft, lightweight, transparent, water—resistant anui heat-sealable. It is available in barrier and non-barrier types, determined by the size of the air bubble and the thickness of film. Since the air is the most important factor for this cushioning, the size of the bubbles, the thickness and the type of the film, 18 and the number of wraps determine the level of protection. It is recommended only for short and predictable shipping cycles.(9) Small air bubble wrap is used for protecting surfaces and wrapping small intricate items. Larger air bubble wrap is used to provide cushioning and void filling. Unlike most ordinary polyethylene Air bubble wrap, Polycap Plus PD230 is coextruded film of PE—Nylon-PE which is resistant to the air to escape, and holds the air much longer under high pressure. The bubble cell evaluated had a 1 inch diameter and is 0.5 inch thick.(20) 2.1.9 Popcorn Due to its biodegradable nature, popcorn cushioning has found an increased interest over foam peanuts. Popcorn is a special kind of flint corn. Popping occurs at about 350° F which is equivalent to a stream pressure of 135 psi inside the kernel. The water in the kernel is superheated and then converts to steam, which provides the driving forces for expanding the ‘thermoplastic endospernl after' the kernel ruptures. Expansion volume is tflua most critical quality 19 factor of popcorn. Most commercial popcorn has a 30-40 fold expansion. There are two processes in popping, Wet Popping The corn is popped in vegetable oil. Dry popping Using the radiant heat at 4109F- 430°F to pop the corn in large scale operations. Popped corn rapidly absorbs air moisture and becomes tough at a moisture level above 3%RH. It is totally biodegradable and can also be used in composting facilities. However, it is also a source for insects, ants, and rodents that will result in impregnating the package and damaging the product. A major safety concern is consumption of this industrial popcorn by infants resulting in fatal accidents. Industrial corn may have been treated to provide resistance to humidity and abrasion. These coatings or treatments are usually unsafe for human consumption.(3) 2.1.10 Quadrapak It is formed from unbleached kraft paper which is slit, folded and compressed into a zigzag shape. With this shape, 20 it retains a memory of its original shape, and after packing the material slowly springs back and interlocks like a nest. It is usually used as void filler which prevents the product from migrating to the package wall. It is manufactured using up to 50% to 60% post-consumer recycled kraft paper which makes this material easily degradable. It can also be collected to be reused or recycled.(21) 21 2.2 Methods Three different methods are used to determine the shock absorbing characteristic (M5 the cushions according to the shape and structure of material. ASTM D 1596-78a, ( Standard Test Method for Shock Absorbing Characteristics of Package Cushioning Materials ) is applied to materials like Ethafoam 220, Arpak 4322, Arsan 600, Arcel 310, and Honeycomb. ASTM 4168-88 ( Standard Test Methods for Transmitted Shock Characteristics of Foam-in-Place Cushioning Materials ) is applied tx: materials like Instaflex, Pelaspan Mold-a-pac, Popcorn and Quadrapak. Table 3 lists the cushioning materials and published cushion performance data used in this study. Cushion curves were developed for Popcorn and Quadrapak. The material was filled in 12"x12"x12" RSC corrugated box with the 8"x8"x8" wooden test block placed in the center of the corrugated.lxnn The cushioning material was 2 inches thick distributed around the wooden test block. The ballast weights were placed inside the test block. A piezoelectric accelerometer with an output characteristic of 10 mV/g's was 22 Table 3: Reference Documents for Cushion Curve Data Ethafoam 220 Instaflex Pelaspan Mold-a-pac Polycap Plus Material Reference document for cushion curves Arcel 310 ARCO Chemical's Document ACC-P127—908. Arpak 4322 ARCO Chemical's Document ACC-P106-8610. Arsan 600 ARCO Chemical's Document ACC-P108-8610. Dow Chemical,"Product and Design Data for Ethafoam brand polyethylene foam". Sealed Air Corporation, "Technical data report of Instaflex", 1988. Dow Chemical, "Combining the economies of loose fill with the protection of engineered, molded cushions", 1987. Sealed Air Corporation, "Technical data report of Polycap Plus PD230", 1990. 23 mounted on the top of platen of ballast weight. The accelerometer responds to the shock incurred by dropping the whole box on the shock table and recording the acceleration in accordance with ASTM 4168. Data were collected for three drop heights of 24 inches, 30 inches and 36 inches. Using the cushion curves which represent the shock absorbing characteristic of the material, the Cushion Weight to Product Weight Ratio and the Cushion Volume to Product Weight Ratio are determined by the following equation Cushion Weight to Product Weight Ratio h h. n X 100 ( 2‘1 ) Weight of Product =. t x D x JQQ ( 2—2 ) 6 x 1728 Cushion Thickness ( inches ) where t D == Cushion Density ( lb./ ft3.) o = Static Loading ( lb./in2.) 24 therefore, Minimum Cushion Weight to Product Weight Ratio (%) =t_x_D_x_l_QQ 0' x 1728 max Maximum Cushion Weight to Product Weight Ratio (%) =txDx1§2§2 0'. x 1728 min ( 2-3 ) ( 2-4 ) Similarly, the Cushion Volume to Product Weight is expressed by; Cushion Volume to Product Weight Ratio =W Product weight r x ' kn Area x Static Loading = I. 11113). 0 (1b.) Minimum Volume to Product Weight Ratio Maximum Volume to Product Weight Ratio L Omin ( 2-5 ) ( 2-6 ) ( 2-7 ) ( 2-8 ) ( 2-9 ) 25 Figure 2 : Minimum and Maximum Static Stresses were Obtained From Each Cushion Curve. (G'S) Peak Deceleration l I I Static Stress (psi ) Minimum Static stress Maximum Static stress CHAPTER 3 DATA AND RESULTS The experimental data for the shock transmission values for Popcorn, Honeycomb and Quadrapak are shown in Table A1 through Table A3 in Appendix A. The cushion curves for these materials are provided in Figure B5, B9 and B10 in Appendix B. The Cushion Weight to Product Weight Ratios were calculated for all the materials as described by equation (2-3). Table 4 describes these computed values for the cushioning materials for multiple ( 2-5 average ) impacts from a drop height of 24 inches. The values are presented for various levels of protection from 20 9'8 up to 150 g's with an increment of 10 9'8. Similarly, Table 5 and 6 present the data for drop height of 30 inches and 36 inches respectively. All materials in this study were evaluated for a thickness of 2 inches. 26 27 Hwo =mH\> QEoomwcom xmmmupmso swoonom omm om omosaom omanmnoaoz cadmmaom xoaumumcH oam Hmoud com :mmum mmme gamma CNN Emoumnum omH ONH om or ow om oe muommefl mum mmmum>m :fl Davao: mono monocfl em Eoum Amy cofiuomuoum mo Hw>ma cm>flm m now A w v onumm oedema uosooum on Dreams coanmso omuflsvmm " v magma 28 unmade mono was» Eouu muomdefi mrm How amfluoume umnu uou camp on ma muocu momma ¢\z « <\z ¢\z ¢\z <\Z ¢\Z ¢\Z ¢\Z <\z aawo ama\h QEoomwco: xmamuomso :uoodom omm om omosaom omdumnoaoz cmdmmaom xwaumumcH cam Honda 000 gamma mmmv xmdu< 0mm smoumnum omH ova omH ONH oaa OOH om ow on om om ow om om w Davao: mono mucosa om Eoum muommefl muN mmmuo>m CH va cofluowgoum mo Ho>wa cm>fla m now A w v oflumm unmfloz uospoum on unmflmz coazmsu Umuflsqmm " m magma 29 ucmflon mono many Eouu muomoefl mum wow amfiuoume page you mump on ma muonu momma ¢\z « ¢\z ¢\z m\z ¢\z <\z ”:2 <\z <\Z <\z <\z <\z <\z <\z «\z HHwO:mH\> DEOOchom xmdmuomso enougom omdumnoaoz cmdmmamm xoaumumcH OHm Hoou< 000 ammufi Name xmdua ONN Emoumnum omH ova oma ONH OHH OOH om om or om om ov om om w unmade mono monocfl mm Eoum muomdefl mum ommuo>m cfl Amy cofluomuoum mo Hm>oa co>fim m now A w v oflumm unmfloz poopoum on ucmflmz coflnmso Umuflsqom " m magma 30 The calculated data for Cushion Volume to Product Weight Ratio were determined using equation ( 2-9 ). The Cushion Volume to Product Weight Ratio values are presented in cu.in./lb . Table 7 describes the calculated values for the different cushioning materials for nmltiple impacts ( 2-5 average ) from a drop height of 24 inches. Table 8 and 9 present the data for drop heights of 30 and 36 inches respectively. Previous studies (M1 product fragility have described that the most fragile and delicate products have to be protected below 40 g's. These usually are precision aligned test instruments or electronic equipment. Most mechanical and electrical products have a fragility between 40 and 85 9'5 Rugged industrial machinery and appliances have a fragility higher than 85 g's. Cushioning materials, that can provide lower shock transmission values in G's with smaller values of Cushion Weight to Product Weight Ratio will be the more environmentally sensitive solutions. 31 ewaaoo :mH\b nEoomocom xmmmuomso cuoOQom omm om dmosaom omdumnpaoz cmdmmaom xoaumumcH cam Hmoufi _oom ammud mmmq gamma omm smoumnum oea OOH or ow om oe om A wuomQEw mum mmmum>m Cw ADV unmade Qoup monocfl vm Eoum cofiuomuowm mo Hw>ma cm>flm w you .QH\.cfl.:o v oflomm unmfloz uozooum on megao> coflnmso nonfizqmm " s magma 32 unmade mono mach Eouu muomoefl mum wow Hmauoume own» now when on ma ouocu memos «\z « ¢\z <\z ¢\z <\z ¢\z ¢\z <\z «\Z <\z «\z <\Z <\z Haoo :wa\b QEoomwcom xmamuomso cuoooom omm om omosaom omdumroaoz chmmHom xoaumumcH cam Hmoum oom ammum Name Amuse omm smoumsum omH ova OMH OHH ooa om om or om om ov om om muommefi mum mmmum>m Ca A .QH\.cfl.so V oflumm unmfim3.uooooum on oesao> coanmso pouflsqmm unmflms mono monocfl om Eoum on cofluoououm mo Hm>oa cm>flm m wow H m magma 33 unmade mono mflnu Eoum muomdefi mum mom Hmfluoume umcu How mumo on ma ouosu memos ¢\z « <\z <\z 4:2 <\Z ¢\z <\Z «\z 4:2 A12 4:2 <\z 4:2 4:2 NN.N ,._H.,....H.w. a. H. 5......” <\z A .. ¢.\.z H”,_H.A.N\7~..m_.w. aawo =OH\> nEooNocom xmamuomoo cucumom 0mm om amosaom omdnmuoaoz cmdmmawm xoaumumcH cam Hwoue oom ammum mmms xmau< omm snowmaum OOH OMH ONH OOH om ow Ob OO om Ov om ON muommefl mum ommum>m CH A ucmfloz mono monocfl mm Eoum va cofluomuoum mo Hm>wa cm>flm m How .QH\.cfl.so v OHDMm usmfloz uospoum on oesao> coflnmzo omuflsqmm " m OHQMB 34 The " Environmental Cushion Curves " are a plot of the percent Cushion Weight to Product Weight Ratio for a given level of protection. These plots describe the performance of different cushioning materials for a given thickness. Materials that show good shock attenuation have lower ordinate values. Naterials that will be used in smaller quantities fem ea given level of protection will have lower abscissa values. The ideal cushioning material that will address both protection and environmental concerns will be the closest to the origin. Figure 3, 4, and 5 are the Environmental Cushion Curves comparing the different materials based on Percent Cushion Weight to Product Weight Ratio for drop heights of 24, 30, and 36 inches respectively. Figure 6, 7, and 8 are the Environmental Cushion Curves comparing the different materials based on Cushion Volume to Product Weight Ratio ( cu.in./lb. ) for drop heights of 24, 30, and 36 inches respectively. Based on these curves, Arsan 600 and Instaflex show the best performance since they provide maximum protection for the least amount of cushion material used both by weight and 135 QEoo>ocox xmdmupmso CLOQom 0mm om amusAom :QOmem xmawmumcH OHM Hmou< OOO ammu< mmmv xmdu< omw emoumzum va oflumm unmflmz poseoum ou unmamz coflamso son. A V 22.85 OAS «AU «Au OAS .3 _ a q . . ON m . m 5:58. $.55... 1 ON 1 £8.26 1 8 “M .A . Om % l m . 8 w .. 3630 m 1 ON n A m - OO m. . .d . s m 9:83:01 m 1 8w W. 1 OF? 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A V seesaw m.m m6 md mN m... m.O 3 q . .l a a q . . . ON W LOO m 10¢ r on 503.0.“ .. ....... now . E m §§§3§3§§§ L W 5.515.555: 0 {sis/2. .A 8 M (f. .1 m loo m ._ m. U 1A5? 1 O: Seeded . nONF infip . a. A . m . . h . P . . p . no N ousmflm 41 volume. Pelaspan shows very good performance when comparing Percent Weight Ratios but deteriorates when evaluated on the volume basis. All polymer based cushion materials like Arcel 310, Arpak 4322, Ethafoam 220, Polycap, show good protection capabilities between 40 g‘s anui 100 g's using much lesser material by weight and. voluma: as compared tn) Popcorn, Honeycomb and Quadrapak. All materials were evaluated for a cushion thickness of 2 inches. From the cushion curves of Popcorn ( Appendix B ) it is clear that a 2 inches thick popcorn cushion can barely protect a product for 100 g's for multiple impacts. Based on free fall shock equations we know that the shock transmitted through a cushion is inversely related to the square root of the thickness. Most 2 inch thick polymer cushions evaluated like Arcel 310, Arpak 4322, Ethafoam 220,etc. show protection below 50 g's. It is clear that for popcorn to provide protection levels of 50 g's, we would need = [ 100 + 50 12 x 2 = 8 inch thick cushion. 42 .A popcorn cushion would therefore occupy four times the thickness of these polymer cushions. This not only results in poor performance in terms of source reduction but results in a poor economic solution based on larger size boxes, poor loading efficiencies in trailers, increased transport costs, increased disposal concerns. A.similar trend is seen with Honeycomb and Quadrapak. However, Popcorn, Honeycomb, euui Quadrapak show mmch better protection performance for the single impacts as seen in Appendix B. CHAPTER 4 CONCLUSION For multiple impact, Honeycomb, Popcorn, and Quadrapak show poor environmental performance by using more weight and more volume than the polymer cushions when compared at moderate levels <1f protection ( 40—85 g's ). Figure 3 through 8 are means of comparing the environmental performance of each cushions. If the fragility and expected drop height were known, the Cushion Weight to Product Weight Ratio and Cushion Volume to Product Ratio can be determined. For example, a given product of 10 pounds with a fragility of 60 g's and 24 inches expected drop height, using Figure 3, Arsan 600, Arcel 310, Ethafoam 220 and Arpak 4322 provide the lightest weight of cushion respectively. Popcorn and Honeycomb barely protect at 100 g's. Quadrapak is the only " environmentally conscious " cushion that provides protection but the weight is almost 3 to 4 times more than those polymer cushions indicated above. Similarly, from 43 44 Figure 6, Quadrapak needs 3 tx: 4 times larger volume than those polymer cushions. Popcorn and Honeycomb are interesting alternatives only for rugged products which need the cushion as a void filler. Specifically this study concludes the following 1 Biodegradable material like Popcorn, Honeycomb, and Quadrapak demonstrate shock isolation properties for single impact. However, they show poor protection properties for multiple impacts. 2 Expanded polyethylene based cushions show the best performance for protection and the least amount of materials used. 3 Biodegradable cushion alternatives evaluated show poor environmental performance, since as much as three to four times material is required as compared to polymer cushions for a given level of protection. APPENDICES Table Static Stress Impact number 24"drop ht. A 1 (psi) OOOOO *4 H FJFA H N R)borv N 00000 00000 KOKDkDKDkO mmmmm wwwww H HitJIA H H hiiJiA H UIUIUIU'IU'I (1)0)me 45 APPENDIX A Shock Transmission Data For Honeycomb, with 7/16" cell size and 2 inches thick U'IthOJNH LDQWNI-J 01.5me UItHWNH U'ItbCONI-J U'libUONH G 200. 200. 200. 200. 200. 00000 150. 140. 135. 135. 135. 00000 110. 90. 95. 95. 95. O 0000 75.0 70.0 62.0 120.0 190.0 70.0 58.0 60.0 100.0 200.0 50.0 50.0 90.0 160.0 200.0 30"drop ht. G 36"drop ht. G 46 Table A 2 : Shock Transmission Data For Popcorn, 2 inches thick Static Stress Impact number 24"drop ht. 30"drop ht. 36"drop ht. ( psi ) G G G 0.1 1 84.4 99.0 112.5 2 112.5 125.4 148.8 3 131.2 151.2 181.6 4 140.6 171.2 209.8 5 147.7 181.1 226.3 0.32 1 66.2 65.6 85.0 2 112.5 116.6 141.8 3 132.4 128.9 157.6 4 144.1 133.6 171.1 5 154.1 139.5 177.0 0.51 1 50.4 55.1 63.3 2 77.9 84.4 107.2 3 94.9 100.8 124.8 4 103.1 113.7 145.3 5 109.6 118.9 162.3 0.77 1 46.3 49.2 45.7 2 75.0 83.8 79.7 3 100.8 99.6 101.4 4 127.4 124.1 117.2 5 141.3 131.7 128.3 0.94 1 52.7 60.9 90.0 2 100.2 124.8 213.3 3 140.7 187.9 318.7 4 189.8 237.9 - 5 219.1 272.5 - 1.3 1 41.0 65.6 - 2 100.0 155.1 - 3 147.1 233.2 - 4 191.6 305.9 - 5 217.5 347.7 - 1.66 1 48.9 63.9 - 2 123.0 159.3 - 3 207.4 249.0 — 4 276.6 333.9 - 5 336.3 400.0 - 47 Table A 3 : Shock Transmission Data For Quadrapak, 2 inches thick Static Stress Impact number 24"drop ht. 30"drop ht. 36"drop ht. ( psi ) G G G 0.1 1 58.8 46.9 50.4 2 61.8 55.4 70.9 3 64.1 59.0 80.5 4 65.3 63.4 85.6 5 70.9 65.8 89.1 0.266 1 37.0 47.8 44.1 2 49.0 62.6 57.2 3 56.1 71.2 66.8 4 62.0 76.2 74.8 5 64.3 80.7 79.4 0.344 1 34.6 47.8 42.5 2 46.6 61.4 61.3 3 57.4 73.9 75.4 4 60.8 82.3 82.6 5 67.2 83.9 91.7 0.5 1 37.9 49.3 45.5 2 65.5 67.0 60.6 3 68.7 83.2 72.4 4 79.6 93.1 78.5 5 78.2 118.4 92.9 0.85 1 34.9 54.4 54.1 2 54.2 94.7 85.5 3 66.7 102.4 108.7 4 80.8 104.8 128.4 5 100.5 153.1 158.4 APPENDIX B Figure Bl : Arcel 310's Cushion Curve Density = 1.5 PCF average 2-5 impacts Deceleration, G's 24" drop height Deceleration, G's 30" drop height Deceleration, G's 36" drop height $8??? 1.0 1.5 2.0 “Big :5 "' 1.0 1.6 2.0 , Jr" . ~15 t‘w~ . ' an 15 29 Static stress,psi {1% $8“ Ft: 1 Kc. LP ‘1 L ,1) 4‘ 4 L x r Figure 82 Arpak 4322's Cushion Curve Density = 2.2 PCF average 2-5 impacts Deceleration (G's) 24" drop height I Static stress, psi Deceleration (0'3) 30" drop height 0.5 1.0 _ 1.6 _ 3.0 Static stress, psi Deceleration (G's) 36" drop height 0.5 1.5 8.0 Static stress. psi 50 Figure BB Arsan 600 's Cushion Curve Density = 1.0 PCF average 2 — 5 impacts Oaxmmmmsh 24" drop height 05 19 _1s 20 25 an Static Stress, psi. mummwun 30" drop height 0.5 1.0 . u _ Static Stress, p51 mummmun 36" drop height 0.5 2.5 3.0 1.5 Static Stress, psi Figure B4 : 51 Cushion Curve For Ethafoam 270 Density = 2.2 PCF average 2-5 impacts 24" drop height 30" drop height 36" drop height H.— 88 888 N 0 Average deceleration (G’s) O 0.5 1.0 1.5 2.0 2.5 Staticloading(psi) lv 0 Average deceleration (G’s) 0.5 1.0 1.3 2.0 2.5 Static loading (psi) O—‘H 8'53 888 Average deceleration (G’s) N c> O 0.5 1.0 1.5 2.0 2.5 Staticloading(psi) Figure BS : Cushion Curve For Honeycomb Cell size = 7/16" 2' thick 24" drop height First Impact 24" drop height average 2-5 Impacts Peak Deceleration ( G's ) Peak Deceleration ( G's ) 52 Static Stress (psi) 180- 160'- I IN 0.0 Static Stress (psi) 53 Figure B6 : 1m Cushion Curve For Instaflex ” average 2 - 5 impacts .. m u b n c u .3 u 4.) ‘0 u 31 3 a 24" drop height 8 a Q m o ,3 01 a4 or as 13 11 Static stress, psi 1» n a. n U) - n o " n c O a "-1 p ‘0 m u u o H n o 30" drop height E; fl 0 0 on oz t4 0‘ 01 1s 1: Static stress, psi 10 m A. n U) - m 0 " n 8 so -r-| u a ‘3 o n r—l . o N 36" drop height 0 8 m on 02 to an 01 1! 11 Static stress, psi 54 Figure B7 : Cushion Curve For -100 Pelaspan MOld-a-pac 6 average 2-5 impact 'E 80 i 60 .3 9 ‘ ‘\“~E-——-———u-—-—"1t g 40 \ 2” J —4 a! 20 24" drop height 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 Snchoaduui) 100 9 so 5 ”i 60 .1 g . \\N~‘_T __._.——-2n 4O A;_4n '1 d‘.’ 20 30" drop height 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 Studded“) 100 ‘3- so E i E 60 D H g 40 \ z” 1: *4 a: 20 36" drop height 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 StaticLouNpti} Figure BB Cushion Curve For Polycap Plus PD230 average 2 - 5 impacts 24" drop height 30" drop height to 1m 250 E3 zoo g 2Laym '5 .5. 150 $ /- 0 g 1” —_T’ 313193/ so :13. uwmj 0 , 0.” 0.05 0.10 0.15 0.20 015 on 0.05 0.10 Static Loading (psi) no T? a. 3w 5. .51." .. o mym/ /7 7: zoo .g / g we 7. \ / 3 .. " / 9r ' o 55 0.10 0.15 an Static Loading (psi) 0.25 0.35 0.10 56 Figure B9 : Popcorn's Cushion Curve 2" thick Deceleration (G's) First Impact 24", 30" and 36" drop height 0.0 290 250 210 Deceleration (G's) 170 average 2-5 Impacts 24", 30" and 36" drop height 50 p—n 0.2 0.4 0 6 Static Loading (psi) : 36" 30" . 2r L i f F 0 0 l is 5 1 $kammmde) 57 Figure BIO Quadrapak's Cushion Curve " 2 —5 impacts 2. 2" thick 2: .i. 70" “i ‘71 “d ..\ , “a “a a. 61" ‘11-: $91 a- Deceleration (G's) 24" drop height 574. l i .1 .4 Static Loading (psi) ’10 125 110 4 ”-1! c Deceleration (G's) 30" drop height n4 U 1 n u ‘l 1 T a 1 0.3 0.5 0? 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Anonymous, " Popcorn Lands A New Part ", Fortune, August 13, 1990. Anonymous, " Popped Fresh Daily ", INC. Magazine, March 1990, P.92. ARCO Chemical's Document ACC-PlO6-8610," Arpak 4322 ". ARCO Chemical's Document ACC—PlO8-8610," Arsan 600 ". ARCO Chemical's Document ACC-P127-908," Arcel 310 ". Ashton, Robin; Erickson, Greg; Larson, Melissa, " Packaging and the solid waste problem ", Packaging Magazine, Vol.34, August 1989, P.32—86. Asvanit, Punnapa," On Effect of Moisture Content on the Shock Transmission Properties of Honeycomb Cushioning ",Master's Thesis, School of Packaging, Michigan State University, 1988. Auguston, Karen A., " Playing the Protective Packaging Game ", Modern Materials Handling, Vol.44, April 1989, P.64-66. Bakker, Marilyn," The Wiley Encyclopedia of Packaging Technology", John Wiley & Sons, 1986. Bergstrom, Robin P., " Why Plastics Won't Go Away ", Production, Vol.102, October 1990, P.69—71. 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