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Manufacturing Processes for Plastic Bottle Caps


A bottle cap is used to seal gap of a bottle. Usually brand name of company which invents bottle come on the top of bottle. Bottle caps were initially intended to be squeezed over and around the highest point of a bottle to snatch a little rib on the bottleneck. The innovation of bottle cap identifies with a container top completely made of an engineered plastic material. More especially, it identifies with a jug top included an inward plug part made of an adaptable plastic material and an external top part made of a plastic material more inflexible than that of the internal plug part. A bottle cap can be either of plastic or metal like steel. Mostly plastic caps are used for plastic bottles whereas steel caps are used for glass ones. Many alter demonstrating container tops have been utilized for bundling drinks and different fluids. Normal alter showing jug tops are metal contort off tops having a severable metal ring which breaks after turning the tops to stay on the jug neck as an alter demonstrating band when the top has been evacuated. These sorts of tops outcome in a sharp edge staying on the top bit which has been evacuated and on the alter demonstrating band which stays on the holder. These sharp edges are innately perilous to the customer using the bundles. What’s more, bend off tops require more costly and entangled application hardware than completes a straightforward push-on conclusion. There are many types of bottle caps. If talking about bottle caps there are many types of bottle caps like crown cork, Flip-top, screw cap, glass stoppers, cork stopper and sports cap etc.


The material regularly used to make container tops is Polyethylene. Most tops, you can feel them as somewhat hardened, are made of HDPE, High Density Polyethylene. Most normal case of this is the basic refreshments, for example, Coke bottles.

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A few tops, for example, 20L water compartment, are made of LDPE, Low Density Polyethylene. Typically, this is claiming LDPE is milder, and these tops are torn to open such holders. HDPE is relatively a lot harder and sturdy, so those tops can be utilized on various occasions, shutting and reviving astute.



The present development identifies with an infusion formed polymeric family container top made of a PP synthesis. PP is a thermoplastic polymer produced using 1-propene monomers, which are gotten from raw petroleum, and has a liquefying purpose of ˜160° C. Appropriate monetarily accessible PPs include: grade PP 575-S from SABIC-KSA (Saudi Basic Industries Corporation, Kingdom of Saudi Arabia), Riyadh, Saudi Arabia; the homo-polymer European Maplin HP501L and the Maplin PP Random Copolymer RP340N, both from LyondellBasell Polymers, Houston, USA.

Said PP arrangement involves particulate CaCO3 (calcium carbonate). CaCO3 is found normally in different rocks and minerals, for example, aragonite, calcite, vat rite, chalk, limestone, marble and travertine. The PP structure involves from 5% to 14% CaCO3, more ideally the PP piece contains from 8% to 11% CaCO3, by weight of the last organization. Said particulate CaCO3 has a molecule size of 2 to 4 μm. Molecule size is regularly spoken to by the term d50. A d50 of 2 μm methods half of the particles have a width of under 2 μm. Utilizing a molecule size of over 4 μm is unwanted because bigger molecule sizes may result in the inception of breaks in PP parts. An appropriate industrially accessible CaCO3 source as a filler for the present innovation incorporates the granulated CaCO3 item Omyalene 102 M from Omya AG, Oftringen, Switzerland, which involves 84% CaCO3, 15% PP and ˜1% stearic corrosive.

Said PP creation likewise contains at any rate one added substance. Said PP structure contains from 0% to 6% added substance, more ideally from 0% to 3% added substance, by weight of the last organization. Added substances might be chosen from the gathering comprising of: sway modifiers; dispersants; fillers; filler coatings; frothing specialists; handling operators; ointments; particles; colours and colorants; UV channels; hostile to static operators; and blends thereof. At the point when particles are utilized as added substances, said particles are not the same as particulate CaCO3 as characterized previously. Added substances utilized in the PP organization as indicated by the present creation are customary added substances for example present in an ordinary PP bearer blend. Particles might be utilized for example Expancel microspheres from Akzo Nobel, Essen, Germany, as well as frothing specialists for example Hydrocerol from Clariant, Frankfurt-Höchst, Germany. Moreover, various fillers might be used notwithstanding CaCO3, for instance kaolin, carbon dark, mica, silica, diatomite, Nano-molecule muds, cellulose fiber, wood fiber, powdrous wood or china grass, rice spelt, starch and powder. With the expansion of such added substances the procedure may accomplish further advantages, for example, expanded uprooting of PP pitch, expanded process duration decrease, no yellowing reactions, and better part honesty.

The PP organization in its strong structure and with normal divider thickness T has a flexural modulus, estimated by ASTM D790-07, of in any event 95% of the flexural modulus estimated on a reference PP piece considerably free of CaCO3 and having normal divider thickness of at any rate T+10%. ATSM represents American Society for Testing and Materials, which is presently known as ATSM International. The flexural modulus can be estimated utilizing ASTM D790-07, which is a standard test technique for flexural properties of unreinforced and strengthened plastics and electrical protecting materials by three-point twisting.

Normal divider thicknesses of container tops can be estimated with a calliper gadget. FIG. 4 demonstrates the normal divider thickness of a container top, wherein the mass of the top is appeared as a cross-brought forth parcel (F), which has a normal divider thickness (T). In an epitome, the jug top has a normal divider thickness T of at any rate 10% lower than the normal divider thickness of a reference polypropylene jug top generously free of CaCO3. More ideally the normal divider thickness T is diminished by at any rate 20%. In an exemplification, the jug top has a normal divider thickness T of ideally from 0.5 mm to 10 mm, more ideally 0.5 mm to 1.5 mm.

In an epitome, the polypropylene piece in its strong structure has a pressure strength, estimated by ASTM D2659, of at any rate 10% higher than pressure soundness of a reference PP synthesis significantly free of CaCO3. The pressure soundness can be estimated utilizing ASTM D2659, which is a standard test strategy for section pulverize properties of blown thermoplastic holders.



Now that all the parts are made, the nozzle and cap need to be put together. First, the inner race is put inside the outer race, only off to one side as far as possible. This makes a space between them on the opposite side large enough to put them together. The required material is put in, then the races are moved so that they are both cantered, and the material distributed evenly around the cap. At this point, the cage is installed to hold both apart from each other. Plastic cages are usually just snapped in, while steel cages usually must be put in and riveted together. Now that the assembly is done, it is coated with a rust preventative and packaged for shipping.


In simple terms, the jig is a tool that guides the cutting tool. The most common type of jig is the drill jig, which guides the drill bit for creating holes at desired locations. Using drill jigs increases production rate drastically by eliminating the time spent using a square scriber, height gauge, centre punch, etc. The picture below shows the functionality of a simple drill jig. Like drill jigs, welding jigs and wood working jigs are also used in industry quite extensively. Wood working jigs are useful for creating intricate wooden profiles.


The fixture is a tool which holds the work piece with the machine bed precisely at the desired location. The fixture also reduces the non-productive loading, unloading, and fixing time of the work piece. For example, you need to use a milling machine for giving a chamfer at the corner of rectangular work pieces. You can use a vice to hold it in the desired position, but in that case every new work piece will take lots of time for fixing it. On the other hand, if you can make a milling fixture like the one shown below and bolt the fixture to the milling machine bed, then you need not waste much time for fixing the work pieces every time. You just place the work piece and it will automatically aligned to the required angle, and straight away you run the machining operation, no need to measure the angle, and no need to be worried about the accuracy.



Well known broadly useful liner less fixing component which can be utilized on most all jugs. The plan regularly includes a .045″ shaped inward rib which when connected with typical application torque packs to roughly one-portion of its thickness while fixing against the jug lip. The liner makes a watertight seal with a jug having a base .065″ wide fixing surface which is free of scratches, burrs or anomalies. This style liner less instrument is accessible in mainstream apportioning tops. The Jigs and fixture are used in the procedure of manufacturing of plastic bottle nozzle cap as well. Almost all the parts of the bottle cap are machined.


To conclude, the process of manufacturing of plastic bottle nozzle is easy. The amount of the work depends upon the size of the cap. It has made the work a lot more easier and with new innovations and inventions, these will continue to do so in the coming future.


  • Grussen, J., 1978. Screw-type bottle cap having improved sealing properties. U.S. Patent 4,090,631.
  • Grussen, J., SOMEPLA SA, 1975. Tamper-proof and loss-proof screw-type bottle cap. U.S. Patent 3,904,062.
  • Story, D., Story and Douglas, 2000. Injector bottle cap assembly. U.S. Patent 6,165,523.
  • Whitley, K.W., Becton Dickinson and Co, 2003. Cap assembly for a roller bottle. U.S. Patent Application 29/167,769.
  • Maas, W.J. and Hurkmans, P.L., AFA Products Inc, 1993. Quick-locking child resistant bottle cap assembly. U.S. Patent 5,238,152.

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