16-Closure-of-Metal- Containers.pdf

16-Closure-of-Metal-Containers.pdf

1. USDA
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Module 16. Closures for Metal
Containers
Thermal Processing for Meat and Poultry
Products Training
1

2. T HERM AL PROCESSI NG
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Container Integrity
Primary Intent Of Part 9 CFR 431.2
To prevent product adulteration due to
leakage during cooling and handling after
retorting.
2

3. Sanitary (Open Top) Can
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4. T HERM AL PROCESSI NG
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Can Manufacturing Plate
Tin coated steel plate
Tin free steel plate
Temper indicates the hardness of the metal
plate; T1 = very soft, T5 = very hard
Base weight = plate thickness/.00011
Plate characteristics affect double seam
characteristics
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Doubl~Snl'l
Factory Finished Can
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6. Metal Cans
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3-PIECE SOLDERED 3 -PIECE WELDED 2 PIECE DRAWN 6

7. Seams
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8. Half-Size Seam Table Tray
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9. End (Lid) Curl
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10. T HERM AL PROCESSI NG
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Double Seam
Formed by joining body of can with end
Body flange interlocked with end curl
Formed in two operations
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11. T HERM AL PROCESSI NG
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Double Seamer Head
First Operation Roll
Second Operation
Roll
Seaming Chuck
Can
Base Plate
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12. T HERM AL PROCESSI NG
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First Operation
Contoured groove of seaming roll
(narrow/deep) forms the seam profile
End curl is interlocked with body flange
Faulty first operation will result in a faulty
finished seam
12

13. ,·
se.quenoe
10f op.
onto a cah body.
ls Operation
em,mgRoU
+
First Operation
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13

14. ., ,'
. 2. After Stan ,Of 1st Operati.on Se . . ~
• ■ ' ' ' • ' ~ ' •
'. .
''
be Operation . n
Se,aming Roll Chndc · ~ .. ·
t
' ''•
,· ',
- ' ' ■ : •• ,,.
' ' ' ,.
' ■ I •' ., '••, I , •
,
1,. "'. ': " ~ • :··,· ... ,.· '.,· ■ '
Double seam1,hg rs pe:rtormed in, two operations, ;· .;.:. ·: ·: . · . ::.-... :·-/ ·:.:· ... :: · ·~· .··~-· ... •·~· ~~ , _____ ,
The iirst operatinn roll cur1s the end hook .. ;·, · ::· ~· · ·. ·_:;· ··
around the lnsiae of the body hoo to, p.rovide
.an inte, ·1ock. ·, ... _ ·. . _. .. · : ..
' ' '
■,-·· ' ■ ' '•:•.• . .. • 1' ,'
' ', ' . ~ ,• '
','
',■ I '
First Operation
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14

15. Complete First Operation
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Body Hook (BH)
approximate parallel to
Cover Hook (CH)
BH tucked down in CH
radius
CH rounded and
adjacent to or touching
can body wall
Wrinkle created in CH
at end of hook
15

16. 4, Finished Double ~earn : . -,.
2nd Operation ···' .. Seaming
~eamln~ Roll i . Chuck
' . '
Second Operation:
(Seaming Roll Contour Shallow & Flat)
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Flattens and
tightens the hooks
Irons out CH wrinkle
Seaming compound
forced into voids of
seam
16

17. Second Operation
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17

18. t
BOD
HOO
WIDTH
THICK ES
OVE
LA
C
Double Seam Measurements
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18

19. T HERM AL PROCESSI NG
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Double Seam Measurements
The most critical measurements to a can’s
double seam are:
Overlap
Tightness
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20. T HERM AL PROCESSI NG
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Overlap
The degree of interlock between the
body hook and cover hook
Formula when using a micrometer
BODY HOOK + COVER HOOK + END
THICKNESS (.010 IN.) − SEAM
WIDTH
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21. T HERM AL PROCESSI NG
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Tightness
Degree of cover hook wrinkle after double
seaming
Tightness rating indicates relative freedom
from wrinkles
21

22. Canco 4-head Double Seamer (Can Spin Type)
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22

23. Seaming Rolls and Chuck
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24. T HERM AL PROCESSI NG
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Juncture Area
Location where double seam crosses welded
side seam
24

25. Juncture Area
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Droop at Crossover
3-piece soldered can
25

26. Juncture Area
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27. T HERM AL PROCESSI NG
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Can Seam Defects
27

28. 0






Can Seam Defects: First Operation Too Loose
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Formation of cover hook
and overlap may be
affected
Possible cause—
improper setting of first
operation seaming roll,
worn seaming roll, wrong
groove profile
28

29. ■
H RT 0. · V LAP
fl ST
s co
Can Seam Defects: Loose First/Normal Second Operation
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30. T HERM AL PROCESSI NG
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Can Seam Defects: First Operation Too Tight
Results in flattened seam
bottom, sharp seam and
poor cover hook
One possible cause—tight
setting of first operation
seaming roll, worn seaming
roll, groove profile too
narrow
30

31. C
L 5· l u
~
LJ 0


Can Seam Defects: Tight
First/Loose Second Operation
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32. Can Seam Defects: Short Cover Hook
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A short cover hook may
result in short overlap:
Possible Causes:
Loose first operation roll
Excessive lifter pressure
Excessive countersink
depth
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33. T HERM AL PROCESSI NG
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Long Cover Hook -May Result In Reduced
Overlap (Possible Cause):
A long cover hook may
result in reduced
overlap:
Possible Cause:
First operation
seaming roll set too
tight.
33

34. LO G R D
00
Mushroomed Flange
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35. M I





Can Seam Defects: Loose Second Operation Seam
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Possible Causes:
Folds of metal may not
be pressed together
tightly enough
Cause may be
improper setting of or
worn second operation
seaming roll
35

36. Loose Seam
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36

37. Can Seam Defects: Broken Chuck
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Possible Causes:
Portion of chuck lip
missing
Loose seam at that
point
Several possible
causes of chuck
damage
37

38. T HERM AL PROCESSI NG
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Excessively Tight Second Operation
May cause
reduction of overlap,
sharp seam and/or
compound to
squeeze out of the
seam.
38

39. T HERM AL PROCESSI NG
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Insufficient Overlap Possible Causes
Irregular can body flange
Irregular end curl
Poor closing machine adjustment
39

40. EXC SS E
COU T SI K
DE H





Excessive Countersink Depth
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Results in shortened
cover hook and
overlap
Excessive baseplate
pressure or chuck
set too deep are
possible causes
40

41. Seam Bumps
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Most often on 2-piece
or welded side seam
cans
Localized increase in
packer’s end seam
thickness
Distorted body hook
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42. T HERM AL PROCESSI NG
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Seam Bumps
Possible Causes:
Excessively tight finished seam
Long body hooks
Excessive sealing compound (gasket) in the
end curl
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43. Al-SES AM




False Seam
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Seam which is entirely
unlocked
Not always detected by
visual examination
Revealed by teardown
examination
43

44. False Seam
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45. Damaged Flange and End Curl
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Damaged flange
Damaged end curl
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46. Knock Down Flange
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47. DOOP









Droop
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Smooth projection of
the double seam below
the bottom of normal
seam
Possible causes:
excessive body hook,
loose first operation,
product trapped in the
seam, too much gasket
material in end curl
47

48. “VEE” & SHARP SEAM
“Vee”, Lip, or Spur
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49. Cocked Body
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Can body blank out
of square causing
unevenness at lap
Can manufacturing
defect
49

50. Sharp Seam
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Sharp edge at the top
inside portion of seam
More easily felt with finger
nail than seen
50

51. Cut Over
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Seam that is sharp
enough to fracture
the metal at the top
inside portion of
seam
Several possible
causes
51

52. .!Inspect for
metal bact.ure,
- • %, p ate reduction
------metal fracture·
Cutover and Fracture
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52

53. AD H AD OR
NO Ml
Sl
---------
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Deadhead (Spinner)
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Incomplete seam
caused by chuck
spinning in countersink
Caused by grease/oil on
chuck, insufficient pin—
gage setting, no second
operation, insufficient
base plate pressure
53

54. Double Seam Skip
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55. Can Body Buckling
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Buckled or twisted
condition under finished
double seam
Possible causes:
excessive base plate
pressure, chuck set too
low
55

56. Misassembly
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Referred to as
misplaced cover
Can body and end
improperly aligned in
closing machine
56

57. JUMPED SEAM
AAEA ADJACENT
0 lAP I MP'R E.SSION
CAN BODY SIDE
SEAM LAP IMPRESSION




Jumped Seam Or “Jump-over”
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Seam not rolled tight
enough next to
juncture
Caused by jumping
of seaming rolls after
passing over top of
juncture area
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58. Cut Seam
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Outer layer of double
seam fractured
Possible causes:
damaged chuck,
excessive seaming
compound (gasket)
material in end curl
58

59. Fractured Embossed Code
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Results when metal of can has been cut through
at the code mark.
59

60. Swollen Can
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Possible Causes:
Under-processing
Post process leakage
Hydrogen swell
Incipient spoilage
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61. Panelling
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Caused by inadequate
pressure control during
cooling in the retort
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62. Corrosion
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63. Internal Can Corrosion (Pinhole Development)
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64. Damaged Coating
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65. Open Weld At Side Seam
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66. Dents
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67. T HERM AL PROCESSI NG
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Evaluating Double Seam Integrity
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68. T HERM AL PROCESSI NG
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Evaluation of Double Seam Integrity
Inspections must be performed by a trained
technician
Inspections must include visual and teardown
examinations
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69. T HERM AL PROCESSI NG
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Good Seam Formation
Cannot be judged purely by mechanical
means or measurement
Requires experience and skill which cannot
be quickly imparted
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70. T HERM AL PROCESSI NG
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Visual Inspection Requirements
9 CFR 431.2(b)(1)
At intervals of sufficient frequency, the
container closure inspector must visually
examine either the top seam of a can
randomly selected from each seaming head
or the closure of any other type of container
being used.
Measurements/recordings should be made at
intervals not to exceed 30 minutes.
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71. Visual Can Inspection
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72. T HERM AL PROCESSI NG
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Visual Inspection Requirements
For double-seam cans, each can should be
examined for gross defects such as cutover or
sharpness, skidding (deadheading), false
seam, droop at the crossover or lap, and
condition of the inside of countersink wall for
evidence of broken chuck.
Must record the observations made and any
corrective action taken.
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73. Visual Can Inspection
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74. T HERM AL PROCESSI NG
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Visual Inspection Requirements
Additional visual closure inspections must be
made immediately following a jam in a closing
machine, after closing machine adjustment, or
after start-up of a machine following a
prolonged shutdown.
All pertinent observations must be recorded.
When irregularities are found, the corrective
action must be recorded.
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75. T HERM AL PROCESSI NG
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Visual Inspection Requirements
Regular observations must be maintained
during production runs for gross closure defects.
Any such defects must be recorded and
corrective action taken.
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76. T HERM AL PROCESSI NG
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Visual Inspection Requirements
Immediate Corrective Action Required When:
• Sharp cut-overs/fractures
• Heavy cut-over at crossover
• Severe droop at cross-over
• VEES or LIPS
• False seam
• Distorted seam
• Skidding or deadheading
• Fractured code
76

77. T HERM AL PROCESSI NG
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Teardown Examination for Double-seam Cans
9 CFR 431.2(b)(2)
Must be performed by a qualified individual
Must be performed at intervals of sufficient
frequency on enough containers from each
seaming head to ensure maintenance of
seam integrity
77

78. T HERM AL PROCESSI NG
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Teardown Examinations
Should Perform Teardown Examinations:
At the beginning of production
Immediately after severe jam
After adjustment or changes to seaming
machine
78

79. Teardown Examinations
T HERM AL PROCESSI NG
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79

80. T HERM AL PROCESSI NG
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Micrometer Measurement System
Three measurements made 120° apart
excluding the side seam juncture
Body hook, cover hook, width, thickness,
juncture rating (USDA) and tightness are
required
80

81. Marking Seam for External Measurements
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82. Can Seam Micrometer
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83. T HERM AL PROCESSI NG
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Teardown Measurement Procedure
External measurements (seam width, thickness
and countersink)
followed by
Internal measurements (body and cover hooks,
tightness, pressure ridge and juncture rating
83

84. Cover Hook Wrinkle
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84

85. TIGHTNESS (WRINKLE) RATING IN%
100 90 70 60 50
I
40 30 20 10 0
---
FORMER #0
WRINKLE
#1 #2 LESSTHA 50%WRINKLE""#3
Cover Hook Wrinkle Rating
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85

86. Pressure Ridge
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86

87. T HERM AL PROCESSI NG
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Optical Measurement System
Cuts should be from at least 2 different
locations
Body hook, overlap, thickness, tightness, and
juncture rating are required
87

88. Seam Saw
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88

89. Cutting Cross Section of Double
End Seam With Seam Saw
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90. Seam Projector
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90

91. MEASURING DOUBLE SEAM ON SEAMPROJECTOR
Measuring Double Seam on Seam Projector
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92. T HERM AL PROCESSI NG
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Interpretation of Inspection Results
Resample if results are unsatisfactory, then
assess severity of defect
Timeliness of corrective action depends upon
severity of defect
92

93. T HERM AL PROCESSI NG
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Teardown Inspection Results
If critical factor measurements are beyond
adjustment tolerance limits, immediate
adjustments must be made.
93

94. T HERM AL PROCESSI NG
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Teardown Inspection Results
Shut the line down immediately and adjust
double seamer if:
Cut overs
False seams
Severe droops
Skidding/deadheading
Fractured embossed code
94

95. Records
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Can Seam Evaluation:
All visual
examinations and
measurements must
be recorded
Must record defects
and steps to correct
problems
95

96. T HERM AL PROCESSI NG
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Evidence of Container Defects
Needed for Regulatory Action
Plants Need Documentation when:
Seam defects occur
Product contains viable microorganisms or is
spoiled
Deviations from Part 431
96

97. T HERM AL PROCESSI NG
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Regulations and Guidelines
9 CFR 431.2—LACF Regulations
Reference Manual—Guide to Inspection of
LACF Manufacturers, Part 3, Container
Integrity
97

98. Questions
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Questions?
98